Meltric DS Decontactors - Manual

GENERAL
DS and DSN Decontactor™ Series products are
designed to provide the safety and functionality of a
switch with the convenience of a plug & receptacle.
They can safely be used to make and break electrical
connections, even in overload situations and are an
approved ‘line of sight’ disconnect switch.
There are inherent dangers
associated with electrical
products. Failure to follow safety precautions can
result in serious injury or death. These instructions must
be followed to ensure the safe and proper installation,
operation and maintenance of the Meltric devices.
Before installation, disconnect all sources of power
to the circuit to eliminate the risk of electrical shock.
RATINGS
Meltric’s Decontactor™ Series Switch Rated plugs &
receptacles are UL & CSA listed in accordance with
UL Subject 2682, UL 1682 and CSA 22.2 182.1. All
are listed as ‘Branch Circuit Disconnect Switches’ and
most are also horsepower rated and listed as ‘Motor
Circuit Disconnect Switches’. The amperage, voltage,
horsepower, switch and environmental ratings are
indicated on the product labels.
All Decontactors are rated to make and withstand
short circuit currents of 65kA or more with appropriate
fusing as indicated in Table 1. Some DS and DSN
devices are provided with optional auxiliary contacts
that make after and break before the phase contacts.
The ratings for auxiliary contacts are shown in Table 2.
INSTALLATION
Decontactors should be installed by qualified
electricians in accordance with all applicable
local and national electrical codes.
Before starting, verify that the power is off, that the
product ratings are appropriate for the application, and
that the conductors meet code requirements and are
within the capacities of the terminals noted in Table 3.
General Notes & Precautions
1. Self-tapping screws are provided for use with
some polymeric accessories. High torque may
be required to drive them in. Once they are
seated, care should be taken in order to avoid
over-tightening them against the plastic material.
2. Various handles and cord grip options may be
used. These instructions are based on handles
provided with integral multi-layer bushing cord grips.
3. Wire strip lengths are indicated in Table 4. Strip
lengths for cable sheathing will depend on the
specific application. When used with handles, the
cable sheathing should extend into the handle to
ensure secure cord gripping.
4. Factory installed auxiliary wires should be
stripped as necessary to make a connection.
5. Wiring terminals are spring assisted to prevent
loosening due to wire strand settlement, vibration
and thermal cycling. NOTICE: Do not over-
tighten the terminal screws. Appropriate tools
and tightening torques are indicated in Table 5.
6. Some auxiliary contacts are factory prewired.
Proper lugs should be used and lugs should be
crimped with the proper tool.
7. The DS100 and DS200 are rated as general
purpose switches, but are not horsepower rated.
WARNING! If these devices are installed in
motor power supply applications, warning
labels may be required to advise users not to
disconnect the device under load. Labels are
provided in the package, but should only be
used when required.
8. NOTICE: Meltric threaded handles come with
tapered style threads. The use of fitting seal
tape is recommended to maintain watertightness
of all NPT fittings and joints.
Assembly for In-Line Connections
Do not overtighten terminal or self-tapping
screws. Tighten screws to the proper torque to
ensure a secure connection.
When most Decontactors are used as in-line connectors,
finger drawplates should be installed on both the
receptacle and plug in order for the user to more easily
provide the leverage required to connect the device.
On the larger sized devices, (DS100 & DS200) the
finger drawplates are not needed because an easy
closing mechanism is provided as standard.
Adjust the bushing diameter to fit the cable by removing
inner sections of it as required. Insert the bushing into
the strain relief, then insert the assembly into the
handle and loosely install the compression nut. Insert
the cable through the handle, the thin black drawplate
gasket and finger drawplate (if applicable) and the
color coded gasket. Strip the cable sheath to provide
a workable wire length, being mindful that the sheath
must extend into the handle to achieve a secure cord
grip. Then strip the individual wires to the lengths
indicated in Table 4 and twist the strands of each
conductor together.
Back out the terminal screws on the receptacle (or
inlet) far enough (but not completely) to allow the
conductors to pass, insert the conductors fully into
the proper terminals and tighten the screws with the
appropriate tool to the torque indicated in Table 4.
Verify that the cable jacket extends beyond the strain
relief and into the handle. Assemble the receptacle
(or inlet), the color coded gasket, the finger drawplate,
and the thin black drawplate gasket to the handle with
the four self-tapping screws provided. Adjust the
cable location so that it will not be under tension
inside the handle and tighten the compression nut to
secure the cable.
Assembly for Mounted Receptacles (or Inlets)
In applications where DS or DSN receptacles (or
inlets) are mounted to wall boxes, panels or other
equipment, optimal operation is achieved when the
device is installed with the latch at the top and with
the force from the cable being exerted in a downward
direction opposite the latch.
Table 1 - Short Circit Make & Withstand Ratings
Device Rating Fuse Type*
DSN20 - 20A 100 kA @ 480 VAC RK1 35A
DSN30 - 30A 100 kA @ 600 VAC RK1 125A
DSN60 - 60A 100 kA @ 600 VAC RK1 110A
DS20 - 20A 100 kA @ 600 VAC RK1 80A
DS30 - 30A 100 kA @ 600 VAC RK1 125A
DS60 - 60A 100 kA @ 600 VAC RK1 250A
DS100C - 100A 100 kA @ 600 VAC RK1 250A
DS100 - 100A 65 kA @ 600 VAC RK5 100A
DS200 - 200A 65 kA @ 600 VAC RK5 200A
* Rating applies with fusing up to this amperage. Ratings
are based on tests performed with Ferraz Shawmut
non-time delay current limiting fuses.
Table 3 - Wiring Terminal Capacity 1 (in AWG) Cable Range OD
Main Aux.
Contacts Contacts 2
Device Min Min Max
DSN20 - 20A 14 12 n/a .375 .750 .750
DSN30 - 30A 14 8 14 .375 .750 .750
DSN60 - 60A 14 4 14 .510 1.25 1.25
DS20 - 20A 14 8 14 .300 - 1.380
DS30 - 30A 14 4 14 .510 - 1.380
DS60 - 60A 10 2 14 3 .500 - 1.812
DS100C- 100A 10 2 14 3 .500 - 1.812
DS100 - 100A 4 2/0 14 3 .700 - 1.812
DS200 - 200A 4 4/0 4 14 3 .870 - 2.400
1 Capacity is based on THHN wire sizes
2 Auxiliary contacts are optional and may not be on all products.
3 Auxiliary contacts are prewired at the factory.
4 2/0 AWG if part number does not include the ‘A06’ suffix.
Compression
Nut
Handle
Strain
Relief
Color-Coded
Gasket
Receptacle
(or Inlet)
Bushing
Finger Drawplate Gasket
Finger Drawplate
Table 5 - Terminal Screw Tightening Torques
Torque Required Screwdriver
Device/Contact in-lbs N-m or Allen Wrench
DSN20 Phase 15-20 1.7 3 mm or 1/8” precision tip
DSN30 Phase 15 1.7 4 mm or 3/16” precision tip
Auxil. 15 1.7 4 mm or 3/16” precision tip
DSN60 Phase 15 1.7 5 mm or 3/16” precision tip
Auxil. 15 1.7 3 mm or 1/8” precision tip
DS20 Phase 15 1.7 4 mm or 3/16” precision tip
Auxil. 15 1.7 4 mm or 3/16” precision tip
DS30 Phase 15 1.7 5 mm or 3/16” precision tip
Auxil. 15 1.7 3 mm or 1/8” precision tip
DS60 Phase 48 5.4 4 mm hex head
DS100C Phase 48 5.4 4 mm hex head
DS100 Phase 90 10.2 4 mm hex head
DS200 Phase 130 14.7 5 mm hex head
Table 4 - Wire Strip Length – Dimensions A
Receptacle Plug/Inlet
Device Inches mm Inches mm
DSN20 Phase 1/2 13 5/8 16
DSN30 Phase 7/16 11 3/4 19
Auxil. 1/2 13 3/4 19
DSN60 Phase 9/16 14 7/8 22
Auxil. 1/2 13 5/8 16
DS20 Phase 7/16 11 3/4 19
Auxil. 1/2 13 3/4 19
DS30 Phase 9/16 14 7/8 22
Auxil. 1/2 13 5/8 16
DS60 Phase 15/16 24 15/16 24
DS100C Phase 15/16 24 15/16 24
DS100 Phase 1 3/16 30 1 3/16 30
DS200 Phase 1 3/16 30 1 3/16 30
Table 2 - Auxiliary Contact Ratings
Device 120VAC 240VAC 480VAC 600VAC
DSN30, DSN60 6A 3A 1.5A 1.2A
DS20, DS30 6A 3A 1.5A 1.2A
DS60, DS100C 6A 3A 1.5A 1.2A
DS100, DS200 3A 1.5A .75A 0.6A
Min Max Max
Black
Casings
Blue
Casings
Insert the cable or wires through the wall box and cut
to allow adequate length, strip the cable sheath as
desired, strip the individual wires to the lengths indicated
in Table 3, and twist the strands of each conductor
together. Back out the terminal screws on the receptacle
(or inlet) far enough (but not completely) to allow the
conductors to pass, insert the conductors fully into
their respective terminals and hand tighten the terminal
screws to the torque indicated in Table 5.
Assemble the receptacle (or inlet) and the color-coded
gasket to the box with the appropriate hardware.
Assemble the mating plug (or receptacle) to the cord
end as indicated in the assembly instructions above
for in-line connections, except there will be no finger
drawplate or associated black gasket.
Hole Pattern for Custom Mounting
In applications where custom mounting to a panel or
box is being performed, the clearance and mounting
holes should be drilled as indicated in the following
diagram and Table 6.
NOTICE: In order to maintain the Type 4X or IP 66 &
67 protection provided in custom installations, water-
tight seals should be used under the heads of the four
mounting bolts and they must be retained by a lock
washer and nut on the inside of the box or panel.
Alternatively, four blind holes may be drilled and
threaded to accommodate the mounting screws,
provided that the hole depth is sufficient to achieve
adequate gasket compression.
OPERATION
To ensure safe and reliable operation Meltric
plugs and receptacles must be used in
accordance with their assigned ratings.
Meltric plugs and receptacles can only be used in
conjunction with mating receptacles or plugs manu-
factured by Meltric or another licensed producer of
products bearing the TM technology trademark.
Meltric plugs & receptacles are designed with different
keying arrangements, so that only plugs and receptacles
with compatible contact configurations and electrical
ratings will mate with each other.
Connection
To connect a plug and receptacle, first depress the
pawl to open the lid on the receptacle, then orient the
plug as shown in figure 1 so that the red dot on the
outside of the casing lines up with the red dot just to
the left of the latch on the receptacle casing. Push the
plug partially into the receptacle until it hits a stop,
then rotate the plug in the clockwise direction until it
hits another stop after about 30° of rotation.
At this point, the circuit is still open. Push the plug
straight into the receptacle as shown in figure 2 until
it becomes securely latched in place. The electrical
connection is now made. On in-line connectors,
squeeze the drawplates on both sides of the device
together until the plug latches in place.
On the DS100 and DS200 devices, an integral
mechanism provides easy connection of the plug to
the receptacle. With the DS100 or DS200 plug par-
tially inserted and rotated 30° so that it is positioned
for connection, place the wire clamps around the
boltheads as shown in figure 3.
To pull the plug into the receptacle, simply push the
handles back along the side of the receptacle and
then push the plug into the receptacle until the plug
is latched in place, as shown in figure 4. After
connection, the mechanism must be released to
allow disconnection of the device.
NOTICE: Additional instructions are provided for
some DS100 receptacle configurations and must be
followed in order to ensure that the closing mecha-
nism is set up to operate properly.
Disconnection
To break the connection, simply depress the pawl as
shown in figure 5 . This will break the circuit and
eject the plug straight out to the rest, or off, position.
The plug contacts are de-energized at this point. To
remove the plug, rotate it counter-clockwise (about
30°) until it releases from the receptacle as shown in
figure 6 . Close and latch the lid on the receptacle.
Achieving Environmental Ratings & Watertightness
For devices rated Type 4, 4X, or 3R, use only
with mating devices having identical markings
to maintain enclosure rating of the mated pair.
Rated ingress protection applies to the device when
the plug and receptacle are mated and latched
together. It also applies to the receptacle when the
lid is latched closed.
Lockout Provisions
All DS and DSN plugs are provided with lockout
provisions. To lockout the plug, insert a locking de-
vice through the hole provided in the casing. This will
prevent the plug from being inserted into a receptacle.
DS and DSN receptacles may be purchased with
optional lockout provisions and used with 5/16-inch
shank locks. To lockout the receptacle, close and
latch the lid and then attach the locking device
through the hole provided in the pawl. This will prevent
the lid from being opened for the insertion of a plug.
NOTICE: Attaching the receptacle locking device
with the receptacle lid open will not prevent the inser-
tion of a plug. Lockout of the receptacle is only ac-
complished when the lid is locked closed.
MAINTENANCE
Before inspecting, repairing, or
maintaining Meltric products,
disconnect electrical power to the receptacle to
eliminate the risk of electrical shock.
Meltric products require little on-going maintenance.
However, it is a good practice to periodically perform
the following general inspections:
• Check the mounting screws for tightness.
• Verify that the weight of the cable is supported
by the strain relief mechanism and not by the
terminal connections.
• Check the IP gaskets for wear and resiliency.
Replace as required.
• Verify the electrical continuity of the ground circuit.
• Check the contact surfaces for cleanliness and pitting.
Deposits of dust or similar foreign materials can be
rubbed off the contacts with a clean cloth. Sprays
should not be used, as they tend to collect dirt. If any
significant pitting of the contacts or other serious
damage is observed, the device should be replaced.
Receptacle contacts may be inspected by a qualified
electrician. This should only be done with the power
off. It is accomplished by depressing the numbered
ring around the circumference of the interior on two
opposite points. This will allow the shutter to be
manually turned clockwise as required to permit
access to the contacts. Once the inspection is complete,
the shutter must be rotated counter-clockwise until it
is locked in the closed position.
MANUFACTURER’S RESPONSIBILITY
Meltric’s responsibility is strictly limited to the repair
or replacement of any product that does not conform
to the warranty specified in the purchase contract.
Meltric shall not be liable for any penalties or conse-
quential damages associated with the loss of production,
work, profit or any financial loss incurred by the customer.
Meltric Corporation shall not be held liable when its
products are used in conjunction with products not
bearing the TM technology trademark. The
use of Meltric products in conjunction with mating
devices that are not marked with the TM
techno-logy trademark shall void all warranties on the
product.
Meltric Corporation is an ISO 9001 certified company. Its
products are designed, manufactured and rated in accordance
with applicable UL, CSA and IEC standards. Meltric is also a
member of BECMA, the international Butt-contact Electrical
Connectors Manufacturers’ Association. Like all members,
Meltric additionally designs and manufactures its products in
accordance with BECMA standards established to ensure in-
termatablility with similarly rated products manufactured by
other members. www.becma.ch
C
A
B
B
Table 6 - Custom Mounting Dimensions
‘A’ ‘B’ C
Model Inches mm Inches mm Inches mm
DSN20 -Recept 2.00 51 1.65 42 .19 5
DSN30 2.25 57 1.89 48 .19 5
DSN60 2.50 64 2.17 55 .19 5
DS20 2.25 57 1.89 48 .19 5
DS30 2.50 64 2.17 55 .19 5
DS60&DS100C 3.25 83 2.59 66 .22 5.5
DS100 4.00 102 3.20 81 .22 5.5
DS200 4.50 114 3.86 98 .28 7
INSDS/DSN Q
2
3 4
5 6
1
Wire clamp
around bolthead
DS/DSN
DECONTACTORS
OPERATING INSTRUCTIONS
Meltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : [email protected]
INSDS/DSN Q
A manufacturer of products using Marechal technology
meltric .com
Mount with the latching pawl at
the top to counteract the weight
and strain of the plug & cable.
Mount the receptacle
at a downward angle
whenever possible.
WARNING
WARNING