Meltric DXN Series User Manual

Operating instructions

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.

Capacity is based on certification testing. Wire size should

be determined in accordance with the electrical code.

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

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

N/A

DXN30

DXN60

Table 2 - Wiring Terminal Capacity

- AWG

Main Contacts

Aux. Contacts

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

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