Meltric DX Series - Manual

GENERAL
Meltric’s DX Series plugs & receptacles are designed
for industrial use according to IEC/EN 60309-1. They
are designed for applications where rugged metal
construction is required and when there is a need for
amperages up to 100A. Follow the instructions below
to ensure the proper installation and use of this product.
There are inherent
dangers associated
with electrical products. Failure to follow safety pre-
cautions 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 & CERTIFICATIONS
To ensure the safe use of this product,
the installer must verify that the product
is properly rated for the application.
The amperage, voltage, temperature, and environ-
mental ratings are indicated on the product label.
Meltric’s DX Series plugs and receptacles are
ATEX-rated in accordance with the European ATEX
Directive (94/9/EC).
The ATEX 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 is likely to occur (Zone 1 and
Zone 21 environments). It’s suitable for installation in
areas that may contain flammable gases, vapors, mists,
or dusts, including subdivision C gases. The prod-
uct possesses explosion protection and is provided
with ‘e’ increased safety in the conductor termination
area and ‘d’ explosion proof chambers for making
and breaking electrical current that can withstand the
pressure of internal ignition. It also can prevent arcs,
flame or other ignition events from being communi-
cated to the surrounding atmosphere. The maximum
allowable surface temperature of the product is 85°C
(185°F) at 40°C (104°F) ambient.
INSTALLATION
DX Series devices must be used in conjunction
with other appropriately rated hazardous duty
products and must be installed by qualified electri-
cians and in accordance with all applicable local and
national electrical codes.
Before installing, verify that (1) the power is off, (2)
the product ratings are appropriate for the application,
and (3) the conductors meet the requirements of the
National Electric Code and are within the capacities of
the DX terminals noted in Table 1.
General Installation Notes & Precautions
1. Wire strip lengths are indicated in Table 2. 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.
2. Wiring terminals are spring assisted to prevent
loosening due to wire strand settlement, vibration
and thermal cycling. NOTICE: They should not
be overtightened. Appropriate tools and tightening
torques are indicated in Table 3. Wiring must be
made according to applicable national installation
standards. Follow all conductor coding and terminal
marking standards. Back out terminal screws far
enough (but not completely) to allow a complete
insertion of conductors. All metal parts
must be connected to Earth ground.
1 Other sizes can be used with the help of wiring ferrules.
3. Only handles with supplied cord grips may be
used in order to maintain proper ATEX ratings.
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.
Insert cable through handle (connector) or remove
plug interior molding from the front and insert cable
through plug body (plug/inlet). Strip the cable sheath
as required to provide a workable wire length while
being aware that the strain relief must clamp on the
cable sheath. Strip the individual wires to the lengths
indicated in Table 2 and twist the strands of each
conductor together. 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
3. Verify that the cable jacket will extend beyond the
strain relief and into the handle. Assemble the recep-
tacle (or connector) to the handle. Adjust the cable
location so that it will not be under tension inside the
handle and tighten the compression nut to secure the
cable. After assembly, the cable sheath must extend
into the handle. Assemble handle with supplied
screws and gasket (connector) or assemble interior
molding into plug casing (plug) and tighten cord grip
(cable gland). Cord grip cable tightening ranges are
indicated in Table 4. While clamping or anchoring,
the conductors inside the handle must not be tight.
NOTICE: For a proper clamping the use of PVC
cables is not recommended.
Assembly for Mounted Receptacles (or Inlets)
In applications where DX receptacles 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. (However, if the receptacle
is mounted to the Meltric surface box accessory, the
pawl latch will be on the bottom due to the vertical
orientation of the box/receptacle.)
NOTICE: if the DX device is mounted to a wall box,
make sure that hole plugs are securely tightened in
any unused connection holes.
All wires brought into a Meltric wall box or hazardous
duty box/panel must be connected in accordance with
all approved local and national electrical codes based
on the rating of the hazardous location environment.
The individual wire insulators should be stripped off
base on the dimensions given in Table 2. Then, twist
the strands of each conductor together. Back out the
terminal screws on the receptacle (or inlet) far enough
to allow the conductors to pass and insert the con-
ductors fully into their respective terminals. Tighten
the terminal screws with a hand screwdriver to the
torque indicated in Table 3. Assemble the receptacle
(or inlet) on adapter or wall box, using gaskets and
screws provided. When not in use, ensure that the
protective cap or lid supplied is properly secured to
prevent environmental contamination. Assemble the
mating plug (or inlet) to the cord end as indicated in
the assembly instructions for in-line connections. In
cases where custom mounting is being performed to an
appropriate hazardous duty box or panel, the clearance
and mounting holes should be drilled as indicated in
the next section, Hole Pattern for Custom Mounting.
Hole Pattern for Custom Mounting
NOTICE: In order to maintain IP65 protection in cus-
tom 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. The hole depth must be sufficient to
achieve adequate gasket compression. Refer to the
following instructions and drawing for the assembly of
the plug/receptacles or inlets on ‘e’ increased safety
boxes, panels or enclosures:
Table 1 - Wiring Terminal Capacity 1 (in AWG)
Main Contacts
Device Min Max
DX20 - 20A 14 8
DX30 - 30A 14 8
DX60 - 60A 6 1
DX100 - 100A 2 2/0
1 Capacity is based on THHN wire sizes
OPERATION
To ensure a safe and reliable operation,
Meltric’s DX Series plugs & receptacles must
be used in accordance with their assigned
electrical and Ex ratings, as well as their IP
ratings according to IEC/EN 60309-1.
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 configurations and electrical
ratings will mate with each other. When not in use,
the receptacle is shielded by a protective lid to prevent
the entry of dust and moisture. This is held in the
closed position by a latch.
Connection
To connect a plug and receptacle, first depress the
pawl to release the lid on the receptacle, then orient
the plug so that the colored mark on the outside ridge
of the plug casing lines up with the Ø or unlock sym-
bol on the receptacle casing. Push the plug in par-
tially into the receptacle until it hits a stop Fig. 1. At
this point, the circuit is still open. To close the circuit,
turn the plug clockwise Fig. 2 until it hits another
stop after about 30° of rotation. Fig 3.
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, depress the pawl and rotate
the plug counterclockwise about 30° until it hits a
stop. At this point, the electrical circuit is open. To
fully remove the plug, depress the pawl and pull the
device straight out. The self-closing lids on the re-
ceptacles may need to be manually latched to ensure
optimal environmental ratings.
Achieving Rated Watertightness
Meltric’s DX Series plugs & receptacles have an IP65
rating for protection against ingress of water, dust and
other matter. IP65 provides total protection against
dust and water jets. 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 IP65 protection on unmated plugs.
LOCKOUT PROVISIONS
All DX plugs are provided with two types of lockout
provisions: hexagonal screw locking and padlocking
provisions. For hexagonal screw locking with the
plug inserted or lid closed (plug not in use), turn the
hexagonal screw with a key until it reaches the bot-
tom. Do not over tighten. For padlocking, insert the 3
hole shaft through the hole under the receptacle pawl.
Place user supplied lock or lockout hasp through one
of the holes. This system may be used to lock mated
devices together to prevent unintended disconnection
or to prevent mating of devices by locking the recep-
tacle lid closed.
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 prod-
ucts, disconnect electrical power to the receptacle to
eliminate the risk of electrical shock. Any replacement
of DX 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 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 inlet 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.
DECLARATION OF CONFORMITY
DX Series plugs/receptacles use the TM
technology. They have been designed, manufactured
and controlled in a strict respect of the relevant inter-
national and European standards, laws and directives,
and particularly of the European ATEX Directive.
They bear the CE marking whenever applicable.
They also bear the markings of their explosion-proof (Ex)
classification.
Note: The CE marking does not apply to spare parts
and components supplied separately.
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 conse-
quential damages associated with the loss of produc-
tion, 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
INSDX E
DX
OPERATING INSTRUCTIONS
INSDX E
A manufacturer of products using Marechal technology
meltric .com
2 3 1
Meltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : [email protected]
Table 2 - Wire Strip Length – Dimension A
Phase & Neutral Earth
Conductor Conductor
Device Inches mm Inches mm
DX20 20A 0.79 20 0.79 20
DX30 30A 0.79 20 0.79 20
DX60 60A 1 1/16 27 1 3/16 30
DX100 100A 1 3/8 35 1 3/16 30
Table 3 - Terminal Screw Tightening Torques
Torque Required Flat
Device/Contact Inches N-m Screwdriver
DX20 (20 A) 11 1.3 4 x 1 mm
DX30 (30 A) 11 1.3 4 x 1 mm
DX60 (60 A) 26 3 6 x 1.2 mm
DX100 (100 A) 53 6 6 x 1.2 mm
Table 4 - Cord Grip Cable Tightening Range
Suffix # Range
Inches mm
-20M 0.31 - 0.51 8 - 13 mm
-25M 0.35 - 0.63 9 - 16 mm
-32M 0.47 - 0.83 12 - 21 mm
-40M 0.63 - 1.06 16 - 27 mm
-50M 0.91 - 1.38 23 - 35 mm
-63M 1.42 - 1.89 36 - 48 mm B
C
B w
Table 5 - Custom Mounting Dimensions
A B C
Device Inches mm Inches mm Inches mm
DX20 4.3 109 3.62 92 1/4 M6
DX30 4.3 109 3.62 92 1/4 M6
DX60 6.0 153 4.76 121 5/16 M8
DX100 6.0 153 4.76 121 5/16 M8
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