Meltric DB Decontactors - Manual

GENERAL
DB 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
DB Decontactors are UL & CSA listed as switch rated
plugs and receptacles in accordance with UL Subject
2682, UL 1682 and CSA 22.2 No. 182.1. DB
Decontactors are listed as ‘Branch Circuit Disconnect
Switches’ and are also horsepower rated and listed
as ‘Motor Circuit Disconnect Switches’. The amperage,
voltage, horsepower, switch and environmental rat-
ings are indicated on the product labels.
All DB Decontactors are rated to make and withstand
short circuit currents of 100 kA or more. These ratings
are indicated in Table 1 along with the fusing upon
which they are based. Some DB 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. Wiring terminals are spring assisted to prevent
loosening due to wire strand settlement, vibration
and thermal cycling. NOTICE: Back out the terminal
screws on the receptacle (or inlet) far enough (but
not completely) to allow the conductors to pass.
Then insert the conductors fully into the proper
terminal. The terminal screws should not be
over-tightened. Appropriate tools and tightening
torques are indicated in Table 5.
Assembly for Mounted Receptacles (or Inlets)
Do not overtighten terminal or self-tapping
screws. Tighten screws to the proper torque to
ensure a secure connection.
In applications where DB receptacles (or inlets) are
mounted to wall boxes, panels or other equipment,
optimal operation is achieved when the device is
installed with the viewing window at the top.
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 indicat-
ed in Table 4, and twist the strands of each conductor
together. NOTICE: 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 using the appropriate hardware.
Assemble the mating plug (or receptacle) to the cord
end as indicated in the assembly instructions above
for in-line connections.
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 Plugs (or Connectors)
When assembling male inlets (or female receptacles)
to handles with integral multi-layer bushing cord
grips, 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.
Do not overtighten terminal or self-tapping
screws. Tighten screws to the proper torque to
ensure a secure connection.
NOTICE: 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 tighten the
terminal screws with the appropriate tool to the torque
indicated in Table 5.
Verify that the cable sheath 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.
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.
Table 1 - Short Circit Make & Withstand Ratings
Device Rating Fuse Type*
DB30 - 30A 100kA @ 600 VAC RK1 125A
DB60 - 60A 100kA @ 600 VAC RK1 250A
DB100 - 100A 100kA @ 600 VAC RK1 250A**
* Rating applies with fusing up to this amperage. Ratings
are based on tests performed with Ferraz Shawmut non-time
delay current limiting fuses.
** The fusing used limits the 100kA rating to 60hp @ 600V,
40hp @ 480V, 20hp @ 240V & 208V. The device is rated for
10kA for all hp ratings where the 100kA rating does not apply.
Table 3 - Wiring Terminal Capacity 1 (in AWG)
Main Contacts Aux. Contacts 2
Device Minimum Maximum Maximum
DB30 - 30A 14 8 14
DB60 - 60A 8 3 14
DB100 - 100A 1/0 2/0 14
1 Capacity is based on THHN wire sizes
2 Auxiliary contacts are optional and may not be on all products.
Compression
Nut
Handle
Strain
Relief
Receptacle
(or Inlet)
Bushing
Gasket
Table 5 - Terminal Screw Tightening Torques
Torque Required Screwdriver
Device in-lbs N-m Flathead type
DB30 - 30A 13 1.4 3 mm or 1/8” precision tip
DB60 - 60A 20 2.37 5 mm or 3/16” precision tip
DB100 -100A 35 4.0 6 mm or 1/4” precision tip
Table 4 - Wire Strip Length – Dimensions A
Phase & Neutral Ground
Device Inches mm Inches mm
DB30 - 30A 3/4 19 1/2 12
DB60 - 60A 13/16 20 5/8 15
DB100 - 100A 1 3/8 35 1 3/16 30
A
B
B
4 x 0.196
(#9 or 5mm)
Table 2 - Auxiliary Contact Ratings
Device 120VAC 240VAC 480VAC 600VAC
DB30, DB60 6A 3A 1.5A 1.2A
Meltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : [email protected]
INSDB G
A manufacturer of products using Marechal technology
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NOTICE: In order to maintain the IP protection
provided by DB models in custom installations,
watertight 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
manufactured 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
First remove the lid on the receptacle by turning the
locking ring fully counterclockwise. The lid can then
be removed. For convenience it remains attached to
the receptacle by a wire.
To insert the plug into a receptacle, the arrow on the
plug casing is aligned with the left end of the viewing
window on the receptacle, Figure 1 . Push the plug
partially into the receptacle until it hits a stop then
rotate slightly clockwise. The plug is now in the rest
position with circuit open.
Push the plug straight into the receptacle until it is
held in place by the locking ring Figure 2 . The
electrical connection is now made as indicated by the
red color in the viewing window. IP67 watertightness
is achieved by fully rotating the locking ring in the
clockwise direction until the protruding lockout tab
completely clears the window shroud.
Disconnection
To break the connection, turn the locking ring fully
counterclockwise. This will break the circuit and eject
the plug straight out to the rest or off position. The
plug contacts are deenergized at this point. To
remove the plug, rotate it counterclockwise (about
10°) until it can be withdrawn from the receptacle,
Figure 3 . Insert the lid and rotate the locking ring
fully clockwise to provide IP67 protection to the
receptacle, Figure 4 . To attempt another
engagement after disconnection, the plug
must be returned to its rest position.
Achieving Ratings & Watertightness
Rated ingress protection is achieved when the plug
and receptacle are mated and the locking ring is fully
rotated in the clockwise direction. It can also be
achieved by the receptacle when the lid is inserted
and the locking ring is fully rotated in the clockwise
direction.
NOTICE: Proper steps must be taken to maintain
watertightness at NPT fittings on the plug handles
or at the junction box. Use of a sealer tape is
recommended.
Lockout Provisions
All DB plugs and receptacles are provided with
lockout provisions.
Plug Lockout
To prevent the DB plug from being inserted into any
DB receptacle place a padlock or a safety lockout
through the hole provided.
Receptacle Lockout
Insert the lid and fully rotate the locking ring clock-
wise. A padlock or safety lockout can then be inserted
in the hole on the locking ring.
Locking Plug and Receptacle in Closed Position
Deenergize electrical power to the receptacle
prior to punching out the knockout hole on the
receptacle locking ring.
To lock the plug and receptacle in the closed position
a knock-out hole located on the receptacle locking
ring must first be opened with the help of a 1/4”
punch. When the plug and receptacle are engaged
and the locking ring is fully rotated then the lockout
hole will have cleared the window shroud and a
padlock or safety lockout can be inserted.
Locking Plug and Receptacle in the Open or
Parked Position
When the plug is in the rest or off position the lockout
holes on the locking ring and plug can be aligned.
Insert a safety lockout device through both holes to
lock the unit in the parked position.
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.
Use a clean cloth to rub off deposits of dust or similar
foreign materials on the contacts and the plug interi-
ors. 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.
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
consequential 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
technology 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 inter-
matablility with similarly rated products manufactured
by other members.
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3
2
1
2
4
5
6
3
4
Table 6 - Custom Mounting Dimensions
‘A’ ‘B’
Model Inches mm Inches mm
DB30 2.17 55 2.17 55
DB60 2.68 68 2.59 66
DB100 3.35 85 3.2 81
Lockout
Holes
Locking
Ring
Lockout
Hole
INSDB G
DB
DECONTACTORS
OPERATING INSTRUCTIONS
WARNING
WARNING
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