MELTRIC 63-14075-375-843 Pin and Sleeve Instruction Manual

MELTRIC 63-14075-375-843 Pin and Sleeve

GENERAL

DS and DSN 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 and are an approved ‘line of sight’ disconnect switch.

WARNING

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

DS and DSN Series Switch Rated plugs & receptacles are UL & CSA listed in accordance with UL 1682, Subject 2682, and CSA 22.2 182.1. All are listed as branch Circuit Disconnect Switches’, are horsepower rated, and are listed as ‘Motor Circuit Disconnect Switches’. The amperage, voltage, horsepower, switch, and environmental ratings are indicated on the product labels. All DS/DSN devices are rated to make and withstand short circuit currents 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.

Table 1 – Short Circuit Make & Withstand Ratings

Device| Rating Fuse| **Type***

DSN20

|

–

|

20A

| 10 kA @ 600 VAC| RK1| 50A
100 kA @ 600 VAC| RK1| 35A
DSN30| –| 30A| 100 kA @ 600 VAC| RK1| 125A
DSN60| –| 60A| 100 kA @ 600 VAC| RK1| 110A

DSN150

|

–

|

150A

| 10 kA @ 600 VAC| RK1| 400A
100 kA @ 600 VAC| RK1| 225A
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
65 kA @ 600 VAC| RK1| 175A

DS200

|

–

|

200A

| 10 kA @ 600 VAC| RK1| 500A
65 kA @ 600 VAC| RK5| 200A

Over-current protection markings DS100

Suitable for use on a circuit capable of delivering, not more than 65kA RMS symmetrical amperes @ 600 VAC maximum. See table 1 for maximum fuse sizing.

Rating applies with fusing up to this amperage. Ratings are based on tests performed with Mersen RK1 non-time delay current limiting fuses and Mersen RK5 time delayed fuses.

Table 2 – Auxiliary Contact Ratings

Device| 120 VAC| 240 VAC| 480 VAC| 600 VAC
DSN20| 0.60A| 0.30A| –| –
DSN30, DSN60| 6A| 3A| 1.50A| 1.20A
DSN150, DS100, DS200| 1.50A| 0.75A| 0.37A| 0.30A
DS20, DS30| 6A| 3A| 1.50A| 1.20A
DS60, DS100C, 2 Aux| 6A| 3A| 1.50A| 1.20A
DS60, DS100C, 3 & 4Aux| 3A| 1.50A| 0.75A| 0.60A

INSTALLATION

DS/DSN should be installed by qualified personnel 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.

Table 3 – Wiring Terminal Capacity 1 **(in AWG)**

 | Main Contacts| Aux.

Contacts 2

Device| Min| Max| Max
DSN20| –| 20A| 14| 12| 183
DSN30| –| 30A| 14| 8| 14
DSN60| –| 60A| 14| 4| 14
DSN1504| –| 150A| 4| 2/0| 143
DS20| –| 20A| 14| 8| 14
DS30| –| 30A| 14| 4| 14
DS60| –| 60A| 10| 2| 143
DS100C| –| 100A| 10| 2| 143
DS100| –| 100A| 4| 2/0| 143
DS200| –| 200A| 4| 4/0| 143

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. The DSN150 is intended to be wired with 2/0 conductors rated 75°C or higher at 150 amps.

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 adequate strain relief.

Table 4 – Wire Strip Length – Dimensions A

Device| Receptacle| Plug/Inlet
Inches| mm| Inches| mm
DSN20| Phase| 1/2| 13| 5/8| 16
DSN30| Phase| 7/16| 10| 3/4| 19
Auxil.| 7/16| 10| 3/4| 19
DSN60| Phase| 3/4| 19| 7/8| 22
Auxil.| 7/16| 10| 5/8| 16
DSN150| Phase| 1-3/16| 30| 1-3/16| 30
DS20| Phase| 7/16| 10| 3/4| 19
Auxil.| 7/16| 10| 3/4| 19
DS30| Phase| 3/4| 19| 7/8| 22
Auxil.| 7/16| 10| 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| 1-1/2| 38| 1-1/2| 38

The wire strip lengths noted on Table 4 are reference strip lengths based on conductors with thinner insulation. Flexible cables with thicker insulation may need to be stripped back further. Strip the cable jacket back as necessary to ensure the conductor bottoms out in the terminal.

1. Factory-installed auxiliary wires should be stripped as necessary to make a connection.

Table 5 – Terminal Screw Tightening Torques

Device/Contact| Torque| Required Screwdriver or Allen Wrench
in-lbs| N- m
DSN20  Phase| 8.9-10.6| 1.0-1.2| 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
DSN150 Phase| 90| 10.2| 4 mm hex head
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| 110-133| 12.5-15.0| 5 mm hex head

1. 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.
2. Some auxiliary contacts are factory prewired. Proper lugs should be used and lugs should be crimped with the proper tool.
3. NOTICE: MELTRIC threaded handles come with tapered style threads. The use of fitting seal tape is recommended to maintain water tightness of all NPT fittings, joints. To maintain environmental protection use listed cord grips.

Assembly for In-Line Connections

WARNING: Do not overtighten terminal or self-tapping screws. Tighten screws to the proper torque to ensure a secure connection.

When most DS/DSN 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, DSN150 & DS200) the finger drawplates are not needed because an easy closing mechanism is provided as standard. For poly handles with strain relief, adjust the bushing diameter to fit the cable by removing inner sections of the bushing 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 5. 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, the 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.

Insert the cable or wires through the wall box and cut to allow adequate length, strip the cable sheath as desired, and strip the individual wires to the lengths indicated in Table 4. 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

Reverse Service Installations

For reverse service applications having inlets rigidly mounted to a wall panel or box + angle, the mating connector (receptacle + handle) may require a 180° Open Lid. Most DSN and DS Receptacles have 180° open lids as standard. They are an available option on: DS60 metal, DS100C metal, DS100 metal, DS200 & DSN150 metal.

For reverse service applications where use of a receptacle with a 180° Open Lid is not possible, install an inlet with the latch on the bottom. When facing downwards Type-3R inlets do not protect mating connectors against streaming water. Use Type-4X devices or a rain hood for additional water protection. Periodic inspection and replacement of the gaskets may be required to maintain water tightness in the pictured Type 4X installations.

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 6 – Custom Mounting Dimensions

Model| ‘A’| ‘B’| ‘C’
Inches| mm| Inches| mm| Inches| mm
DSN20| 2.00| 51| 1.65| 42| .19| 5
DSN30| 2.25| 57| 1.89| 48| .19| 5
DSN60| 2.50| 64| 2.18| 55| .19| 5
DSN150| 4.00| 102| 3.20| 81| .22| 5.5
DS20| 2.25| 57| 1.89| 48| .19| 5
DS30| 2.50| 64| 2.18| 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

NOTICE: In order to maintain the Type 4X, IP69K or IP66/67 protection provided 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 wwgasket compression.

OPERATION

To ensure safe and reliable operation MELTRIC plugs and receptacles must be used in accordance with their specified 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 MARECHAL 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. Using a straight motion, 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. On in-line connectors with drawplates, squeeze the drawplates on both sides of the device together until the plug latches in place.

On the DS100, DSN150 & DS200 devices, an integral drawbar mechanism provides an easy connection of the plug to the receptacle. With the DS100, DSN150, or DS200 plug partially inserted and rotated 30° so that it is positioned for connection, hook the clamps around the latches as shown in figure 3.

To pull the plug into the receptacle, simply push the draw bar 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. The electrical connection is now made. The drawbar mechanism must be released and unhooked to allow disconnection of the device.

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 the 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.

Lockout Provisions

All DS and DSN plugs are provided with lockout provisions. To lockout the plug, insert a locking device 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 insertion of a plug. Lockout of the receptacle is only accomplished when the lid is locked closed.

MAINTENANCE

WARNING: 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 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 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 MARECHAL technology trademark. The devices that are not marked with the MARECHAL 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 designs and manufactures its products in accordance with Marechal keying standards established to ensure interminability with similarly rated products manufactured by Marechal Electric Group.

MELTRIC Corporation

• 4765 W. Oakwood Park Drive Franklin, WI 53132
• Tel: 800 433 7642
• Fax: 414 433 2701
• e-mail: mail@meltric.com

A manufacturer of products using MARECHAL® TECHNOLOGY

©2021 MELTRIC Corporation. All rights reserved.

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