Meltric DXN Series - Manual

terminals and tighten the terminal screws to the
torque indicated in Table 4, with a hand screwdriver.
Assemble the receptacle (or inlet) and the color-
coded gasket to the box with appropriate
hardware. NOTICE: Over-tightening the screws
may cause cracking in polymeric components.
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.
In cases where custom mounting is being per-
formed to an appropriate hazardous duty box or
panel, the clearance and mounting holes should
be drilled as indicated in the following diagram.
Hole Pattern for Custom Mounting
NOTICE: In order to maintain IP66/67 protection
in custom installations, watertight seals must 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 can be drilled and threaded to
accommodate #8-32 x 5/8” mounting screws.
The hole depth must be 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.
They can only be used in conjunction with mating
receptacles or plugs manufactured by Meltric or
another licensed producer of products bearing the
technology trademark.
Meltric plugs & receptacles are designed with
different keying arrangements, so that only plugs
and receptacles with compatible contact configura-
tions 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 1 so that the red arrow on the
outside of the casing lines up with the red arrow
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 2
until it becomes securely latched in place. The
connection is now made. For in-line connectors,
squeeze the drawplates on both sides of the
device together until the plug latches in place.
NOTICE: When making a connection, ensure
that the plug latch is secured behind the catch on
the blue pawl. A properly connected plug cannot
be pulled out of the receptacle.
Disconnection
To break the connection, simply depress the pawl
as shown in figure 3 . 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(CCW) (about 30°) until it releases from
the receptacle as shown in figure 4 . Close and
latch the lid on the receptacle.
Achieving Watertightness Ratings
DXN’s have an IP66/IP67 rating for protection
against ingress of water, dust and other matter.
IP 66 provides total protection against dust and
water jets. IP 67 adds protection for temporary
immersion in shallow water.
These ratings apply when the plug and receptacle
are mated. They also apply to the receptacle
alone, provided that its lid is latched in the closed
position. Optional plug caps are available for providing
IP66/IP67 protection on unmated plugs.
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.
Lockout Provisions
All DXN plugs are provided with lockout
provisions. To lockout the plug, insert the
locking device through the hole provided in the
casing. This will prevent the plug from being
able to be inserted into a receptacle.
Some 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 latch. This will prevent
the lid from being opened.
NOTICE: Attaching the receptacle locking device
with the lid open will not prevent the insertion of a
plug. Lockout is only accomplished 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.
Any replacement of DXN components must be
performed under the control of the manufacturer:
Meltric Corporation.
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
sup ported 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 male 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.
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
other kind of 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 technology trademark. The
use of Meltric products in conjunction with mating
devices that are not marked with the
technology trademark shall void all
warranties on the product.
Meltric Corporation is a member of the international
association, BECMA: the Butt-contact Electrical
Connectors Manufacturers Association.
GENERAL
Meltric’s DXN Series plugs & receptacles are
designed and rated for use in hazardous environments
where explosive gases or dusts may be present.
The DXN receptacle has a dead front, which iso-
lates the supply contacts and prevents user expo-
sure to live parts. The receptacle’s safety shutter
blocks access to the contacts and can only be
opened by DXN plugs with compatible ratings and
contact configurations.
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 main-
tenance of the Meltric devices. Before installation,
disconnect all sources of power to the circuit to
eliminate the risk of electrical shock.
RATINGS & CERTIFICATIONS
To ensure the safe use of this product,
the installer must verify that the product is
properly rated for the application.
The amperage and voltage ratings are indicated
on the device labels. Some DXN 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 1.
Hazardous Duty Ratings
DXN plugs & receptacles have both ATEX and
CSA ratings for use in hazardous environments.
ATEX – Class 1 Zone 1 AEx ed IIC T6
This rating certifies the product for use in surface
(non-underground) applications where a high
level of protection is required and where the
presence of an explosive atmosphere of any type
of gas or dust is likely to occur. The associated
maximum surface temperature of the product is
85°C (185°F), at an ambient temperature of 40°C
(104°F).
CSA – Class 1 Division 2 Group A, B, C, D
Class 2 Division 2 Group E, F, G
This rating certifies the product for use in applica-
tions where flammable gases, such as acetylene,
hydrogen, ethylene or propane, or dusts, such as
magnesium, coal or grain, may be present under
abnormal conditions.
I INSTALLATION
DXN’s must be used in conjunction with
other appropriately rated hazardous duty
products and must be installed by qualified
electricians in accordance with all applicable
local and national electrical codes.
Before starting, ensure that the power is off and
verify that the conductors meet the requirements
of the National Electric Code and are within the
capacities of the DXN terminals noted in Table 2.
1 Capacity is based on certification testing. Wire size should
be determined in accordance with the electrical code.
2 Auxiliary contacts are optional
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 poly material.
2. Wire strip lengths are indicated in Table 3.
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.
3. Wiring terminals are spring assisted to prevent
loosening due to wire strand settlement, vibration
& thermal cycling. They should not be over-tightened.
Appropriate tools and tightening torques are
indicated in Table 4. NOTICE: Do not back
terminal screws completely out.
Assembly for In-line Plugs/Connectors
Do not overtighten terminal or self-tapping
screws. Tighten screws to the proper
torque to ensure a secure connection.
When DXN’s are used as in-line connectors,
finger drawplates should be installed on both the
receptacle and plug in order to more easily provide
the leverage required to properly connect the devices.
Loosely re-assemble the compression nut, bushing
and strain relief to the threaded adapter on the
end of the handle and insert the cable through it,
the thin black drawplate gasket and finger draw-
plate (if applicable), and the color-coded gasket.
Being mindful that the strain relief must clamp
on the cable sheath, strip the cable sheath as
required to provide a workable wire length. Then
strip the individual wires to the lengths indicated in
Table 3, and twist the strands of each conductor
together.
NOTICE: Back out the terminal screws on the
receptacle (or inlet) only far enough to allow the
conductors to pass, insert the conductors fully into
their respective terminals and tighten the terminal
screws with a hand screwdriver to the torque
indicated in Table 4.
Verify that the cable jacket will extend beyond the
strain relief and into the handle. Assemble the
receptacle (or inlet), the color-coded gasket, the
finger drawplate, and the thin black finger draw-
plate gasket to the handle with the four self-tapping
screws provided. NOTICE: Over-tightening the
screws may cause cracking in polymeric
components. 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 DXN receptacles (or inlets)
are mounted to wall boxes, panels or other
equipment, optimal operation is achieved when
the device is installed with the pawl/latch at the top.
NOTICE: If the device is mounted to a wall box,
make sure that appropriate hole plugs are securely
tightened in any unused connection holes.
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
Compression
Nut
Handle
Strain
Relief
Color-Coded
Gasket
Receptacle
(or Inlet)
Bushing
Threaded
Adapter
Finger Drawplate Gasket
Finger Drawplate
DXN20 7.1 in-lbs 1/8” precision tip
DXN30 (Main Contacts) 10.6 in-lbs 3/16” precision tip
DXN30 (Aux. Contacts) 7.1 in-lbs 1/8” precision tip
DXN60 (Main Contacts) 22.0 in-lbs 3/16” precision tip
DXN60 (Aux. Contacts) 7.1 in-lbs 1/8” precision tip
Table 4 - Recommended Tightening Torques
Terminal Torque Flat Screwdriver
Inches mm
DXN20 - Main 0.50/0.50 12/12
DXN30 - Main 0.79/0.83 20/21
DXN30 - Aux. 0.67/0.67 17/17
DXN60 - Main 0.79/0.83 20/21
DXN60 - Aux 0.67/0.83 17/21
Table 3 - Wire Strip Length - A (receptacle/inlet)
Max Min Max
DXN20 10 16 N/A
DXN30 6 14 10
DXN60 4 10 10
Table 2 - Wiring Terminal Capacity 1 - AWG
Main Contacts Aux. Contacts 2
Table 1 - Auxiliary Contact Ratings
Device 120VAC 240VAC 480VAC 600VAC
DXN30,60 5A* 5A* 5A*
5A* (550V max)
DXN
OPERATING INSTRUCTIONS
Meltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : [email protected]
INSDXN J
A manufacturer of products using Marechal technology
meltric .com
1
2
3
4
DXN20: 1.656”
(42mm)
DXN30: 1.890”
(48mm)
DXN60: 2.171”
(55.2mm)
DXN20: 2.00”
(51mm)
DXN30: 2.25”
(56mm)
DXN60: 2.72”
(69mm)
DXN20: 1.656” (42 mm)
DXN30: 1.890” (48 mm)
DXN60: 2.171” (55.2 mm) 4 x Ø.196
(#9 or 5mm)
!
INSDXN J
Pawl
Latch
Receptacle Plug/Inlet