Meltric DS37c - Manual

GENERAL
DS and DSN Multipin products are used for power
and control. They can carry loads as well as low level
signals and information. DS and DSN Multipin devices
comply with applicable IEC standards.
Please follow the instructions below to ensure the
proper installation, operation and maintenance of this
product.
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.
INSTALLATION
DS and DSN Multipins 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 1.
General Notes & Precautions
1. Self-tapping screws are provided for use with
some polymeric accessories. High torque may be
required to drive them in. NOTICE: 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. 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.
Crimped/Soldered Terminal Wire Connections:
For 18-16 AWG Wires, the Ferrule is required:
1. Strip each conductor to 25/64-inches (10-mm).
2. Insert Ferrule into contact.
3. Insert stripped wire end into Ferrule.
(Perform either step 4 or 5)
4. For Crimping the Contacts, use either North
American Contact Crimping Tool 4CN30 (using
crimping slot 12-10) or Crimp contact with
European Contact Crimping Tool 61-CA500
(using 4 MM slot).
5.
NOTICE: Soldering of the wire into the contact
must be performed with the contact out
of the Interior Insulator to prevent damage
to the insulator.
• Using tin solder and a 50W soldering iron, heat
the terminal for approximately 30 seconds.
While heating, apply the soldering wire into the
hole at the bottom of the terminal and let it
penetrate by capillary action. Let it cool down
without any mechanical stress.
6. Slide the Heat Shrink Insulation Sleeve over the
contact until it butts up against the contact
shoulder. NOTICE: Sleeve must be applied to
maintain creepage and clearance distance.
Please see picture.
7. With a Heat Gun that has a temperature range
of 600°F to 950°F, apply heat evenly 360°
around the sleeve until it shrinks around the
contact and wire.
For 14 AWG Wires (Max), the Ferrule is not required:
1. Strip each conductor to 25/64-inches (10-mm).
2. Insert wire into contact.
(Perform either step 3 or 4)
3. For Crimping the Contacts, use either North
American Contact Crimping Tool 4CN30 (using
crimping slot 8) or Crimp contact with European
Contact Crimping Tool 61-CA500 (using 4 MM slot).
4.
NOTICE: Soldering of the wire into the contact,
must be performed with the contact out of the
Interior Insulator to prevent damage to the insulator.
• Using tin solder and a 50W soldering iron, heat
the terminal for approximately 30 seconds.
While heating, apply the soldering wire into the
hole at the bottom of the terminal and let it
penetrate by capillary action. Let it cool down
without any mechanical stress.
5. Slide the Heat Shrink Insulation Sleeve over the
contact until it butts up against the contact
shoulder. NOTICE: Sleeve must be applied to
maintain creepage and clearance distance.
Please see picture.
6. With a Heat Gun that has a temperature range
of 600°F to 950°F, apply heat evenly 360°
around the sleeve until it shrinks around the
contact and wire.
Assembly of Contacts
Once wired, the contacts must be inserted into the
rear of their respective insulating block. The rear side
of the inlet/plug or receptacle/connector is
considered as the flat surface of the 4-bolt hole
mounting surface.
Assembly Disassembly
1. NOTICE: Before insertion of a contact into an
insulator, please review the insulator’s contact
numbering scheme so the ground and each
contact (phase) is placed into the proper hole.
2. Push the wired contact into the insulating block
until it stops and snaps into place.
3. Ensure its correct mounting by slightly pulling on
the contact.
4. The male contacts are solid for their entire
length and are inserted with the contact tip first
into the rear of the inlet/plug.
5. The female contacts consist of a flexible braid
and spring and are inserted with the contact tip
first into the rear of the lidded receptacle/connector.
6. Insert the Provided Hole Plugs into the unused
holes in the front of each insulating block.
NOTICE: If a new Receptacle or Inlet is to mate
with a previously installed device, pay particular
attention to the number of contacts and
numbered position in the Receptacle or Inlet.
Continuity will not be obtained unless the male
and female contacts are appropriately mated.
Disassembly of Contacts
1. To remove the contact from the insulating
block, the provided Multi-Contact Removal Tool
9-LD12-37 must be used. From the front side of
the insulating block, slide the contact removal
tool over the contact.
2. Push until the contact pops out the back side of
the insulating block.
3.
NOTICE: Each contact is designed to be
removed from the insulating block a maximum
of 3 times. New contacts should be used if
contacts are removed more than 3 times.
Voltage Labels
Always have a qualified electrician complete
the installation and apply one of the supplied
voltage labels that best describe the voltage
application level.
WARNING: For safety reasons, it is always recom-
mended to use a ground wire. Please reference
your local codes for specific electrical requirements.
Assembly for In-Line Connections
When DS and DSN Multipins are used as in-line con-
nectors, 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.
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 25/64” and
twist the strands of each conductor together.
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.
Table 1 - Wiring Terminal Capacity 1 (in AWG)
Main Contacts
Device Minimum Maximum
DSN24c 18 14
DSN37c 18 14
DS24c 18 14
DS37c 18 14
1 Capacity is based on THHN wire sizes
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 and 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. For DS
receptacles, mount device so one latch is 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 25/64”, and twist
the strands of each conductor together.
Assemble the receptacle (or inlet) and the color-cod-
ed 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 2.
NOTICE: In order to maintain the NEMA 4X or IP 66
& 67 protection provided by DSN 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.
They 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.
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.
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 (about
30°) until it releases from the receptacle as shown in
figure 4 . Close and latch the lid on the receptacle.
Connection and Disconnection of
Stainless Steel DS
Operation of the stainless steel DS is similar to the
standard DS/DSN operation with the following two
exceptions:
1. The stainless steel DS utilizes two pawls to
latch the plug to the receptacle. Thus to
disconnect the plug from the receptacle both
pawls must be depressed.
2. The stainless steel DS24c plug casing does not
have a red dot that can be used for proper
alignment before insertion. Instead, the thicker
groove in the plug casing should be aligned with
the thicker protruding screw in the receptacle
and the thinner groove should be aligned with
the thin protruding screw.
3. The stainless steel DSN37c casings do not
utilize red dots for alignment. For proper
alignment before insertion, align the arrow on
the plug with the “off” position on the receptacle.
ACHIEVING RATED WATERTIGHTNESS
Rated ingress protection applies to the device when
the plug and receptacle are mated and latched togeth-
er. It also applies to the receptacle when the lid is
latched closed.
NOTICE: Meltric threaded handles come with tapered
style threads. The use of fitting seal tape is recom-
mended to maintain watertightness of all NPT fittings
and joints.
Lockout Provisions
Poly DS and DSN receptacles may be purchased with
optional lockout provisions. To lockout the
receptacle, close and latch the lid and then attach
the locking device through the optional hole provid-
ed 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
insertion of a plug. Lockout of the receptacle 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.
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.
Receptacle contacts may be inspected by a qualified
electrician. This should only be done with the power
off. If any significant pitting of the contacts or other
serious damage is observed, the device should be
replaced.
Deposits of dust or similar foreign materials can be
rubbed off the contacts with a clean cloth. Meltric
recommends regular cleaning of contacts in low
voltage applications. If a cleaning spray is used, it
should be a fast evaporating, non-conductive type
that doesn’t leave a residue and is compatible with
plastics.
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 intermatablility with similarly rated products
manufactured by other members.
www.becma.ch
INSDSDSNMULTI G
Table 2 - Custom Mounting Dimensions
‘A’ ‘B’ C
Model Inches mm Inches mm Inches mm
DSN24c 2.25 57 1.89 48 .19 5
DSN37c 2.50 64 2.17 55 .19 5
DS24c 2.25 57 1.89 48 .19 5
DS37c 2.50 64 2.17 55 .19 5
OPERATING INSTRUCTIONS
DS & DSN
MULTIPIN
Meltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : [email protected]
INSDSDSNMULTI G
A manufacturer of products using Marechal technology
meltric .com
Compression
Nut
Handle
Strain
Relief
Color-Coded
Gasket
Receptacle
(or Inlet)
Bushing
Finger Drawplate Gasket
Finger Drawplate
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
WARNING
DANGER
CAUTION
NOTICE
C B
B
A
WARNING
DANGER
CAUTION
NOTICE
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO