GENERAL
DB 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.
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
DB devices are UL & CSA listed as switch rated
plugs and receptacles in accordance with UL Subject
2682, UL 1682 and CSA 22.2 No. 182.1. They are
listed as ‘Branch Circuit Disconnect Switches’ and
are also horsepower rated and listed as ‘Motor Circuit
Disconnect Switches’. The amperage, voltage, horse-
power, switch and environmental ratings are indicat-
ed on the product labels.
All DB plugs and receptacles are rated to make and
withstand short circuit currents of 100 kA or more.
These ratings are indicated in Table 1 along with the
fusing upon which they are based. Some DB devic-
es 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 Circit Make & Withstand Ratings
Device
Rating Fuse
Type*
DB30 – 30A
100 kA @ 600 VAC
RK1 125A
DB60 – 60A
100 kA @ 600 VAC
RK1 250A
DB100 – 100A
100 kA @ 600 VAC
RK1 250A**
*
Rating applies with fusing up to this amperage. Ratings
are based on tests performed with Ferraz Shawmut non-time
delay current limiting fuses.
**
The fusing used limits the 100kA rating to 60hp @ 600V, 40hp
@ 480V, 20hp @ 240V & 208V. The device is rated for 10kA
for all hp ratings where the 100kA rating does not apply.
Table 2 - Auxiliary Contact Ratings
Device
120VAC 240VAC 480VAC 600VAC
DB30, DB60
6A
3A
1.5A
1.2A
INSTALLATION
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CAUTION
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MELTRIC products should be installed by
qualified electricians 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
Minimum Maximum
Maximum
DB30 – 30A
14
8
14
DB60 – 60A
8
3
14
DB100 – 100A
1/0
3
2/0
14
1
Capacity is based on THHN wire sizes
2
Auxiliary contacts are optional and may not be on all products.
3
Terminal can retain down to a 6 AWG conductor. For 100A applications,
conductors smaller than 1/0 AWG may result in a temperature rise greater
than the 30°C max. allowed in our UL and CSA certification.
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 secure cord gripping.
Table 4 - Wire Strip Length – Dimensions A
Device
Phase & Neutral
Ground
Inches
mm
Inches
mm
DB30 – 30A
3/4
19
1/2
12
DB60 – 60A 13/16
20
5/8
15
DB100 – 100A 1 3/8
35
1 3/16
30
4. Wiring terminals are spring assisted to prevent
loosening due to wire strand settlement, vibration
and thermal cycling.
NOTICE:
Back out the termi-
nal screws on the receptacle (or inlet) far enough
(but not completely) to allow the conductors to
pass. Then insert the conductors fully into the
proper terminal. The terminal screws should not
be over-tightened. Appropriate tools and tighten-
ing torques are indicated in Table 5.
Table 5 - Terminal Screw Tightening Torques
Device
Torque
Required Screwdriver
Flathead type
in-lbs N-m
DB30 – 30A
15
1.7
3 mm or 1/8" tip
DB60 – 60A 23.9
2.7
5 mm or 3/16" tip
DB100 – 100A 39.8
4.5
6 mm or 1/4" tip
Assembly for Mounted Receptacles (or Inlets)
WARNING
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Do not overtighten terminal or self-tapping
screws. Tighten screws to the proper torque
to ensure a secure connection.
In applications where DB receptacles (or inlets) are
mounted to wall boxes, panels or other equipment,
optimal operation is achieved when the device is
installed with the viewing window at the top.
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, and twist the strands of each
conductor together.
NOTICE:
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 ter-
minals and hand tighten the terminal screws to the
torque indicated in Table 5.
Assemble the receptacle (or inlet) and the color-cod-
ed gasket to the box using the appropriate hardware.
Assemble the mating plug (or receptacle) to the cord
end as indicated in the assembly instructions above
for in-line connections.
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.
Assembly for Plugs (or Connectors)
Compression
Nut
Handle
Strain
Relief
Receptacle
(or Inlet)
Bushing
Gasket
When assembling male inlets (or female recept-
acles) to handles with integral multi-layer bushing
cord grips, adjust the bushing diameter to fit the
cable by removing 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 4
and twist the strands of each conductor together.
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
Do not overtighten terminal or self-tapping
screws. Tighten screws to the proper torque
to ensure a secure connection.
NOTICE:
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 screws with the appropriate tool to the torque
indicated in Table 5.
Verify that the cable sheath 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.
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.
A
B
B
4 x 0.196
(#9 or 5mm)
MELTRIC Corporation / 4765 W. Oakwood Park Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 433 2701 / e-mail : [email protected]
INSDB J
meltric
.com
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DB SERIES
ENGLISH OPERATING INSTRUCTIONS
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