Marechal Electric MELTRIC DS20 Operating Instructions

ENGLISH OPERATING INSTRUCTIONS
DS/DSN
©2023 MELTRIC Corporation. All rights reserved.
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
meltric.com
MODE D'EMPLOI
INSTRUCCIONES

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
DANGER
instructions must be followed to ensure the safe and proper installation, operation and
maintenance of the MELTRIC devices. Before installation, disconnect all sources of
CAUTION
power to the circuit to eliminate the risk of electrical shock.
NOTICE

RATINGS

ADVERTENCIA
DS and DSN Series Switch Rated plugs & receptacles are UL & CSA listed in
DANGER
accordance with UL 1682, Subject 2682 and CSA 22.2 182.1. All are listed as 'Branch
Circuit Disconnect Switches', are horsepower rated, and listed as 'Motor Circuit
CAUTION
Disconnect Switches'. The amperage, voltage, horsepower, switch, and environmental
ratings are indicated on the product labels.
AVISO
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 Table 2.
Table 1 - Short Circuit Make & Withstand Ratings
Device
DSN20
DSN30
DSN60
DSN100
DSN150
DS20 –
DS30 –
DS60 –
DS100C
DS100 –
DS200 –
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
DSN20
DSN30, DSN60
DSN150, DS100, DS200
DS20, DS30
DS60, DSN100,
DS100C, 2 Aux
DS60, DS100C, 3 & 4 Aux

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
WARNING
the application, and that the conductors meet code requirements and are within the
DANGER
capacities of the terminals noted in Table 3.
CAUTION
Table 3 - Wiring Terminal Capacity
NOTICE
ADVERTENCIA
DANGER
Device
CAUTION
DSN20
AVISO
DSN30
DSN60
DSN100
DSN150
4
DS20
DS30
DS60
DS100C
DS100
DS200
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
The DSN150 is intended to be wired with 2/0 conductors rated 75°C or higher
4
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
DSN20 Phase
DSN30 Phase
Auxil.
DSN60 Phase
Auxil.
DSN100 Phase
DSN150 Phase
DS20 Phase
Auxil.
DS30 Phase
Auxil.
DS60 Phase
DS100C Phase
DS100 Phase
DS200 Phase
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.
4. Factory installed auxiliary wires should be stripped as necessary to make a
connection.
Table 5 - Terminal Screw Tightening Torques
Device/Contact
DSN20 Phase
DSN30 Phase
Auxil.
DSN60 Phase
Auxil.
DSN100 Phase
DSN150 Phase
DS20 Phase
Auxil.
DS30 Phase
Auxil.
DS60 Phase
DS100C Phase
DS100 Phase
DS200 Phase
5. 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.
6. Some auxiliary contacts are factory prewired. Proper lugs should be used and lugs
should be crimped with the proper tool.
7. NOTICE: MELTRIC
fitting seal tape is recommended to maintain watertightness of all NPT fittings, joints.
To maintain environmental protection use listed cord grips.
Bushing
Strain
Relief
Compression
Nut
Assembly for In-Line Connections
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
WARNING
on both the receptacle and plug in order for the user to more easily provide the leverage
DANGER
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
CAUTION
standard.
NOTICE
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
ADVERTENCIA
relief, then insert the assembly into the handle and loosely install the compression nut.
DANGER
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
CAUTION
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
AVISO
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, 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.
Mount with the latching pawl at
the top to counteract the weight
and strain of the plug & cable.
Mount the receptacle
at a downward angle
whenever possible.
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
Type 3R
rated devices
180°
Type 3R
rated devices
Hole Pattern for Custom Mounting
C
Model
DSN20
DSN30
DSN60
DSN100
DSN150
DS20
DS30
DS60 & DS100C
DS100
DS200
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
gasket compression.

OPERATION

To ensure safe and reliable operation MELTRIC
used in accordance with their specified ratings.
plugs and receptacles can only be used in conjunction with mating receptacles
MELTRIC
®
or plugs manufactured by MELTRIC or another licensed producer of products bearing
WARNING
the technology trademark. MELTRIC
DANGER
ferent keying arrangements, so that only plugs and receptacles with compatible contact
configurations and electrical ratings will mate with each other.
CAUTION
Connection
NOTICE
To connect a plug and receptacle, first depress the pawl to open the lid on the
ADVERTENCIA
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.
DANGER
Using a straight motion, push the plug partially into the receptacle until it hits a stop,
CAUTION
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
AVISO
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
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 drawbar 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.
Clamp around
latch
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 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.
WARNING
Lockout Provisions DANGER
CAUTION
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
NOTICE
being inserted into a receptacle.
ADVERTENCIA
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
DANGER
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. CAUTION
NOTICE: Attaching the receptacle locking device with the receptacle lid open will not
AVISO
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
WARNING
to periodically perform the following general inspections:
DANGER
• Check the mounting screws for tightness.
CAUTION
• Verify that the weight of the cable is supported by the strain relief mechanism
NOTICE
and not by the terminal connections.
ADVERTENCIA
• Check the IP gaskets for wear and resiliency. Replace as required.
DANGER
• Verify the continuity of the ground circuit.
CAUTION
• Check the contact surfaces for cleanliness and pitting.
AVISO
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
marked with the
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 intermatablility with similarly rated products
manufactured by Marechal Electric Group.
There are inherent dangers associated with electrical products. Failure
to follow safety precautions can result in serious injury or death. These
– 20A
– 30A
– 60A
– 100A
– 150A
20A
30A
60A
– 100A
100A
200A
120 VAC 240 VAC 480 VAC 600 VAC
– 20A
– 30A
– 60A
– 100A
– 150A
– 20A
– 30A
– 60A
– 100A
– 100A
– 200A
Receptacle
Inches
1/2
7/16
7/16
3/4
7/16
15/16
1-3/16
7/16
7/16
3/4
7/16
15/16
15/16
1-3/16
1-1/2
Torque
in-lbs
8.9-10.6
15
15
15
15
48
90
15
15
15
15
48
48
90
110-133 12.5-15.0
threaded handles come with tapered style threads. The use of
®
Handle
Type 4X
rated
devices
180°
Type 4X
rated
devices
B
Table 6 - Custom Mounting Dimensions
'A'
Inches
2.00
2.25
2.50
3.25
4.00
2.25
2.50
3.25
4.00
4.50
1
technology trademark shall void all warranties on the product.
MARECHAL
Rating Fuse
10 kA @ 600 VAC
100 kA @ 600 VAC
100 kA @ 600 VAC
100 kA @ 600 VAC
100 kA @ 600 VAC
10 kA @ 600 VAC
100 kA @ 600 VAC
100 kA @ 600 VAC
100 kA @ 600 VAC
100 kA @ 600 VAC
100 kA @ 600 VAC
65 kA @ 600 VAC
65 kA @ 600 VAC
10 kA @ 600 VAC
65 kA @ 600 VAC
0.60A 0.30A
6A 3A
1.50A 0.75A
6A 3A
6A 3A
3A 1.50A
Main Contacts
Min
14
14
14
10
4
14
14
10
10
4
4
mm
13
10
10
19
10
24
30
10
10
19
10
24
24
30
38
N-m
1.0-1.2
1.7
1.7
1.7
1.7
5.4
10.2
1.7
1.7
1.7
1.7
5.4
5.4
10.2
Finger Drawplate Gasket
Color-Coded
Gasket
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 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.
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 inlet with latch on 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.
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.
B
mm Inches
51 1.65
57 1.89
64 2.18
83 2.59
102 3.20
57 1.89
64 2.18
83 2.59
102 3.20
114 3.86
®
plugs & receptacles are designed with dif-
®
3
5
technology trademark. The devices that are not
TECHNOLOGY
®
-
1.50A
0.37A
1.50A
1.50A
0.75A
1
(in AWG)
Contacts
Max
12
8
4
2
2/0
8
4
2
2
2/0
4/0
Plug/Inlet
Inches
5/8
3/4
3/4
7/8
5/8
15/16
1-3/16
3/4
3/4
7/8
5/8
15/16
15/16
1-3/16
1-1/2
Required Screwdriver
or Allen Wrench
3 mm or 1/8" precision tip
4 mm or 3/16" precision tip
4 mm or 3/16" precision tip
5 mm or 3/16" precision tip
3 mm or 1/8" precision tip
4 mm hex head
4 mm hex head
4 mm or 3/16" precision tip
4 mm or 3/16" precision tip
5 mm or 3/16" precision tip
3 mm or 1/8" precision tip
4 mm hex head
4 mm hex head
4 mm hex head
5 mm hex head
Finger Drawplate
Receptacle
(or Inlet)
'B'
mm Inches
42 .19
48 .19
55 .19
66 .22
81 .22
48 .19
55 .19
66 .22
81 .22
98 .28
plugs and receptacles must be
6
INSDS/DSN AJ
Type*
RK1 50A
RK1 35A
RK1 125A
RK1 110A
RK1 250A
RK1 400A
RK1 225A
RK1 80A
RK1 125A
RK1 250A
RK1 250A
RK5 100A
RK1 175A
RK1 500A
RK5 200A
-
1.20A
0.30A
1.20A
1.20A
0.60A
Aux.
2
Max
3
18
14
14
3
14
3
14
14
14
3
14
3
14
3
14
3
14
mm
16
19
19
22
16
24
30
19
19
22
16
24
24
30
38
'C'
mm
5
5
5
5.5
5.5
5
5
5.5
5.5
7
2
4