Meltric DS Decontactor Series Operating Instructions

DS & DSN
DECONTACTORS
Meltric Corporation
4640 Ironwood Drive
Franklin, WI 53132
(800)433-7642
www.meltric.com

GENERAL

DS and DSN Decontactor™ 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, even in overload situations and are an
approved 'line of sight' disconnect switch. Please fol-
low the instructions below to ensure the proper instal-
lation and use of the product.

RATINGS

Meltric's Decontactor™ Series Switch Rated plugs &
receptacles are UL & CSA listed in accordance with
UL Subject 2682, UL 1682 and CSA 22.2 182.1. All
are listed as 'Branch Circuit Disconnect Switches'
and most are also horsepower rated and listed as
'Motor Circuit Disconnect Switches'. The amperage,
voltage, horsepower, switch and environmental rat-
ings are indicated on the product labels.
All Decontactors are rated to make and withstand
short circuit currents of 65kA or more. These ratings
are indicated in Table 1 along with the fusing upon
which they are based.
Table 1 - Short Circit Make & Withstand Ratings
Device Rating Fuse
DSN20 - 20A 100 kA @ 480 VAC
DSN30 - 30A 100 kA @ 600 VAC
DSN60 - 60A 100 kA @ 600 VAC
DS100 - 20A 100 kA @ 600 VAC
DS30 - 30A 100 kA @ 600 VAC
DS60 - 60A 100 kA @ 600 VAC
DS100C - 100A 100 kA @ 600 VAC
DS100 - 100A 65 kA @ 600 VAC
DS200 - 200A 65 kA @ 600 VAC
* Rating applies with fusing up to this amperage. Ratings
are based on tests performed with Ferraz Shawmut non-time
delay current limiting fuses.

INSTALLATION

Decontactors should be installed by qualified electri-
cians in accordance with all applicable local and
national electrical codes. Before starting, verify that
the power is off, that the product ratings are appropri-
ate for the application, and that the conductors meet
code requirements and are within the capacities of
the terminals noted in Table 2.
Table 2 - Wiring Terminal Capacity
Device
DSN20 - 20A
DSN30 - 30A
DSN60 - 60A
DS20
DS30
DS60
DS100C - 100A
DS100 - 100A
DS200 - 200A
Capacity is based on THHN wire sizes
1
Auxiliary contacts are optional and may not be on all products.
2
Auxiliary contacts are prewired at the factory.
3
4/0 AWG if part number includes the 'A06' suffix.
4
General Notes & Precautions
INSDS/DSN 072408 E
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 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.
Table 3 - Wire Strip Length – Dimensions A
Device
DSN20 Phase
DSN30 Phase
DSN60 Phase
DS20
DS30
DS60
DS100C Phase
DS100
DS200
4. Wiring terminals are spring assisted to prevent
loosening due to stand settlement, vibration and
Type*
thermal cycling. They should not be over-tightened.
RK1 35A
Appropriate tools and tightening torques are indi-
cated in Table 4.
RK1 125A
RK1 110A
Table 4 - Terminal Screw Tightening Torques
RK1 80A
RK1 125A
RK1 250A
Device/Contact in-lbs N-m
RK1 250A
DSN20 Phase
RK5 100A
DSN30 Phase
RK5 200A
DSN60 Phase
DS20
DS30
DS60
DS100C Phase
DS100
DS200
(in AWG)
1
Main Contacts Aux. Contacts
Minimum Maximum Maximum
20 12
14 8
12 4
- 20A 14 8
- 30A 12 4
- 60A 6 2
6 2
4 2/0
4 3/0
4
Receptacle Plug / Inlet
Inches mm Inches
1/2 13 5/8
7/16 10 3/4
Auxil. 1/2 12 3/4
9/16 14 7/8
Auxil. 1/2 13 5/8
Phase 7/16 10 3/4
Auxil. 1/2 12 3/4
Phase 9/16 14 7/8
Auxil. 1/2 13 5/8
Phase 15/16 24 15/16
15/16 24 15/16
Phase 1 3/16 30 1 3/16
Phase 1 3/16 30 1 3/16
Torque Required Screwdriver
or Allen Wrench
7 0.8 3 mm or 1/8" precision tip
13 1.5 4 mm or 3/16" precision tip
Auxil. 13 1.5 4 mm or 3/16" precision tip
16 1.8 5 mm or 3/16" precision tip
Auxil. 7 .8 3 mm or 1/8" precision tip
Phase 13 1.5 4 mm or 3/16" precision tip
Auxil. 13 1.5 4 mm or 3/16" precision tip
Phase 16 1.8 5 mm or 3/16" precision tip
Auxil. 7 0.8 3 mm or 1/8" precision tip
Phase 35 4.0 4 mm hex head
35 4.0 4 mm hex head
Phase 80 9.0 4 mm hex head
Phase 130 15.0 5 mm hex head
5. The DS9 and DS2 are rated as general purpose
switches, but are not horsepower rated. If these
devices are installed in motor power supply
applications, warning labels may be required to
advise users not to disconnect the device under
load. Labels are provided in the package, but
should only be used when required.
2

Assembly for In-Line Connections

n/a
8
When Decontactors are used as in-line connectors,
12
finger drawplates (or a drawbar mechanism for the
8
DS9 & DS2) should be installed on both the recepta-
12
cle and plug in order for the user to more easily
14
3 provide the leverage required to connect the device.
14
3
14
3
14
3
Bushing
Strain
Relief
Handle
Compression
Nut
Adjust the bushing diameter to fit the cable by remov-
ing 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
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 terminals and tighten the terminal
mm
screws with the appropriate tool to the torque indicated
16
in Table 4.
19
19
Verify that the cable sheath extends beyond the strain
22
relief and into the handle. Assemble the receptacle
16
(or inlet), the color coded gasket, the finger draw-
19
plate, and the thin black drawplate gasket to the han-
19
dle with the four self-tapping screws provided. Adjust
22
the cable location so that it will not be under tension
16
inside the handle and tighten the compression nut to
24
secure the cable.
24
30

Assembly for Mounted Receptacles (or Inlets)

30
In applications where DS or 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.
Finger Drawplate Gasket
Finger Drawplate
Color-Coded Receptacle
Gasket (or Inlet)