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TABLE 2
200 AMPERE
Cable Diameter
Cable Diameter
Catalog No.
Catalog No.
Accommodated
(.75" Dia.
Accommodated
(.56" Dia.
(Inches)
(Inches)
Wire Well)
Wire Well)
AP20315
.875 to 1.375
AP203111
1.375 to 1.875
AP20317
1.375 to 1.875
AP203112
1.875 to 2.500
AP20318
AP204111
1.875 to 2.500
1.375 to 1.875
AP20415
.875 to 1.375
AP204112
1.875 to 2.500
AP20417
1.375 to 1.875
AP204113
2.500 to 3.000
AP20418
1.875 to 2.500
AP203210
.875 to 1.375
AP20325
.875 to 1.375
AP203211
1.375 to 1.875
AP20327
AP203212
1.875 to 2.500
1.375 to 1.875
AP20328
1.875 to 2.500
AP204211
1.375 to 1.875
AP20425
.875 to 1.375
AP204212
1.875 to 2.500
AP20427
1.375 to 1.875
AP20428
1.875 to 2.500
TABLE 3
400 AMPERE
Cable Diameter
Catalog No.
Cable Diameter
Catalog No.
Accommodated
Accommodated
(1.25" Dia.
(.84" Dia.
(Inches)
Wire Well)
(Inches)
Wire Well)
AP40317
AP403110
1.375 to 1.875
2.500 to 3.000
AP40318
1.875 to 2.500
AP403112
3.000 to 3.800
AP40417
1.375 to 1.875
AP404110
2.500 to 3.000
AP40418
1.875 to 2.500
AP404112
3.000 to 3.800
AP40327
1.375 to 1.875
AP403210
2.500 to 3.000
AP40328
1.875 to 2.500
AP403212
3.000 to 3.800
AP404210
AP40427
1.375 to 1.875
2.500 to 3.000
AP40428
1.875 to 2.500
AP404212
3.000 to 3.800
3. Loosen hex head bolts on cable clamps and slide gland
nut over cable. Slide slip washer over cable with bevel
towards the gland nut.
4. Slide sealing bushing (selected from bushings packed
with unit) that has smallest inside diameter that will pass
over the cable. Slide over cable with large end towards
gland nut. Slide handle body over cable.
5. Strip outer cable jacket and then conductor insulation to
the dimensions shown in figure 4. These dimensions
will allow the conductor cable to bottom in the contact
wire well and the cable insulation to extend into the
insulator tube.
CAUTION
DO NOT cut into the individual conductor insulation
when removing the outer cable jacket. DO NOT
damage the conductor when removing its insulation.
400 AMP
200 AMP
Grounding Conductor
Grounding Conductor
* Strip 3/4" for Use with Style 1 Cable Connector.
Strip 1 9/16" for Use with Style 2 Cable Connector.
Figure 4. Conductor Insulation
6. Connect the conductors (except the grounding
conductor) into each contact wire well by either
crimp (preferred) or solder method, following the
established system wiring pattern. Grounding
conductors are not crimped or soldered but held
securely with two pressure connector screws; torque
screws to 50-100 in.-lb.
IF 854 • 04/12
Copyright
Crimp Connection:
Proper crimp termination may require the use of a wire well
reducer to ensure a complete metal fill in the crimped joint.
Tables 4 and 5 list the various wire well reducers and
crimping dies to be used with each wire well contact and
conductor size.
Figure 5. Wire Well Reducer
Select the proper wire well reducer and insert into the
contact wire well, (See Figure 5). Insert the conductor and
crimp the connection in two places using a Thomas & Betts
hex crimp die recommended in Tables 4 and 5. Crimp near
bottom of wire well first making sure that the reducer is fully
inserted in wire well. Refer to Figure 6.
Second Crimp
Cable
First Crimp
Figure 6. Crimp Connection
Inspect the crimp connection. The contact must securely
grip the conductor without any cracks or tears in the wire
well. Remove any flash raised by crimping.
*Note: Dimensions given are to center line of crimp.
TABLE 4
200 AMPERE CONTACTS
Conductor
Cable
Contact
Construction
Size
I.D.
AWG/MCM
Class
Strands
Dia.
G
133
0.377
0.56
1
H
259
0.378
I
210
0.367
133
0.423
1/0
G
0.56
259
0.424
H
266
0.441
I
2/0
G
133
0.474
0.56
H
259
0.477
I
342
0.500
3/0
H
259
0.536
0.56
H
427
0.535
I
418
0.549
0.75
4/0
H
259
0.601
H
427
0.602
I
532
0.613
G
0.653
0.75
250
259
H
0.653
427
I
0.682
637
©
2012, Cooper Industries, Inc.
TABLE 5
Cable
Contact
Size
I.D.
AWG/MCM
Class
0.84
250
0.84
350
400
0.84
1.25
500
1.25
600
1.25
700
1.25
750
Use in Thomas & Betts Crimp Tools, Catalog #13642 (Head)
Solder Connection:
Reliable solder connections require the use of proper
soldering techniques.
Remove insulation from conductor as shown in Figure 5
and wire brush contact wire well.
Contact
Hold contact in insulated vise with wire well in upright
position. Heat and pre-tin the wire well using a 60-40 rosin
core solder. Do not fill well with solder.
NOTE: A high heat source (750° F) is required for good
soldering. Use a high current resistance type. A torch may
be used only if the surrounding conductor insulation is
Wire Well
adequately protected.
Reducer
Insert conductor into wire well as far as possible while
applying heat to the well. Add solder by melting on
conductor until well fills and a smooth concave surface of
solder forms between the cable and well lip.
Remove heat but continue to hold the conductor and
contact rigid until solder solidifies. A good solder
connection is indicated by a bright shiny solder surface.
CABLE CONNECTOR ASSEMBLY
1. Place retaining cup around rear insulator insulation
tubes.
Reducer
T & B
Required
2. Following the system wiring pattern, push each contact
Die No.
into position in the rear insulator body. Insert the green
O.D.
I.D.
0.555
0.469
54
or grounding conductor into the grounding contact wire
0.555
0.469
54
well at the same time. Securely tighten the two pressure
54
0.555
0.469
connectors screws to 50-100 in.-lbs. torque.
0.555
0.469
54
54
0.555
0.469
0.469
54
0.555
NOTE: NEC prohibits soldering of the grounding
0.555
0.500
54
conductor in the grounding contact.
0.555
0.500
54
54
none required
3. Install the contact retaining clips onto each contact
none required
54
when fully inserted into rear insulator body. See Figure 7.
none required
54
54
none required
4. Make sure that the front insulator is installed in
0.672
71H
0.745
housing then slide rear insulator/contact assembly
0.745
0.672
71H
0.745
0.672
71H
into cable connector housing making sure that
0.745
0.672
71H
polarization grooves are aligned with the polarizing
0.745
0.672
71H
71H
key inside the housing.
none required
Page 3
IF 854 • 04/12
400 AMPERE CONTACTS
Retaining Rings
Conductor
Reducer
T & B
Construction
Required
Die No.*
Strands
Dia.
O.D.
I.D.
G
259
0.653
0.83
0.735
87H
G
259
0.773
none required
87H
H
427
0.772
none required
87H
I
882
0.8
87H
none required
none required
G
259
0.825
87H
H
427
0.826
none required
87H
980
0.831
none required
87H
I
Multiple Point Contacts Bands
G
259
1.240
0.950
0.922
115H
H
427
1.240
0.950
0.923
115H
I
1,225
1.240
0.950
0.941
115H
1.240
0.950
G
427
1.013
115H
5. Install two slotted 1/4-20 hex head screws through
1.240
0.950
H
703
1.022
115H
1.240
0.950
holes in retaining cup into sleeve. Torque to 30 in. lbs.
I
1,729
1.027
115H
G
427
1.094
115H
none required
NOTE: The grounding strap from the grounding
H
703
1.106
115H
none required
I
1,729
1.194
115H
contact in Style 2 receptacles is also attached to the
none required
G
427
1.131
none required
115H
housing with one of these screws. The strap is to be
H
703
1.145
115H
none required
placed on top of the retaining cup. See Figure 8.
I
1,862
1.235
115H
none required
M
18,788
1.207
115H
none required
6. Slide handle body up cable and thread into cable
connector housing until bottomed on O-ring gasket.
#13604 (Pump)
Torque to 10 ft. lbs. minimum. Tighten set screw on
handle body flange to 25 in. lbs. torque.
Figure 8. Style 2 Grounding Strap Location
7. Slide sealing bushing and slip washer into place in
handle body. Screw gland nut onto end of handle
body tight enough to firmly squeeze bushing against
cable. While tightening the gland nut, push in on
cable to relieve strain on the wire terminals. Tighten
gland nut set screw to 25 to 35 in. lbs. torque.
8. Tighten the cable clamp hex head bolts to 25 to
35 in. lbs. torque completing reassembly of the
cable connector.
Copyright
©
2012, Cooper Industries, Inc.
Contact Retaining Clips
Rear Insulator
Figure 7. Contact Retaining Clip Locations
Ground Strap
Location
Page 4
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