GENERAL
DS and DSN Multipin products are used for power
and control. They can carry loads as well as low level
signals and information. DS and DSN Multipin devices
comply with applicable IEC standards.
Please follow the instructions below to ensure the
proper installation, operation and maintenance of this
product.
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.
INSTALLATION
DS and DSN Multipins 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 1.
General Notes & Precautions
1. Self-tapping screws are provided for use with
some polymeric accessories. High torque may be
required to drive them in.
NOTICE:
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.
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.
Crimped/Soldered Terminal Wire Connections:
For 16 AWG Wires, the Ferrule is required:
1. Strip each conductor to 25/64-inches (10-mm).
2. Insert Ferrule into contact.
3. Insert stripped wire end into Ferrule.
(Perform either step 4 or 5)
4. For Crimping the Contacts, use either North
American Contact Crimping Tool 4CN30 (using
crimping slot 12-10) or Crimp contact with
European Contact Crimping Tool 61-CA500
(using 4 MM slot).
5.
NOTICE:
Soldering of the wire into the contact
must be performed with the contact out
of the Interior Insulator to prevent damage
to the insulator.
• Using tin solder and a 50W soldering iron, heat
the terminal for approximately 30 seconds.
While heating, apply the soldering wire into the
hole at the bottom of the terminal and let it
penetrate by capillary action. Let it cool down
without any mechanical stress.
6. Slide the Heat Shrink Insulation Sleeve over the
contact until it butts up against the contact
shoulder.
NOTICE:
Sleeve must be applied to
maintain creepage and clearance distance.
Please see picture.
7. With a Heat Gun that has a temperature range
of 600°F to 950°F, apply heat evenly 360°
around the sleeve until it shrinks around the
contact and wire.
For 14 AWG Wires (Max), the Ferrule is not required:
1. Strip each conductor to 25/64-inches (10-mm).
2. Insert wire into contact.
(Perform either step 3 or 4)
3. For Crimping the Contacts, use either North
American Contact Crimping Tool 4CN30 (using
crimping slot 8) or Crimp contact with European
Contact Crimping Tool 61-CA500 (using 4 MM slot).
4.
NOTICE:
Soldering of the wire into the contact,
must be performed with the contact out of the
Interior Insulator to prevent damage to the insulator.
• Using tin solder and a 50W soldering iron, heat
the terminal for approximately 30 seconds.
While heating, apply the soldering wire into the
hole at the bottom of the terminal and let it
penetrate by capillary action. Let it cool down
without any mechanical stress.
5. Slide the Heat Shrink Insulation Sleeve over the
contact until it butts up against the contact
shoulder.
NOTICE:
Sleeve must be applied to
maintain creepage and clearance distance.
Please see picture.
6. With a Heat Gun that has a temperature range
of 600°F to 950°F, apply heat evenly 360°
around the sleeve until it shrinks around the
contact and wire.
Assembly of Contacts
Once wired, the contacts must be inserted into the
rear of their respective insulating block. The rear side
of the inlet/plug or receptacle/connector is
considered as the flat surface of the 4-bolt hole
mounting surface.
Assembly
Disassembly
1.
NOTICE:
Before insertion of a contact into an
insulator, please review the insulator’s contact
numbering scheme so the ground and each
contact (phase) is placed into the proper hole.
2. Push the wired contact into the insulating block
until it stops and snaps into place.
3. Ensure its correct mounting by slightly pulling on
the contact.
4. The male contacts are solid for their entire
length and are inserted with the contact tip first
into the rear of the inlet/plug.
5. The female contacts consist of a flexible braid
and spring and are inserted with the contact tip
first into the rear of the lidded receptacle/connector.
6. Insert the Provided Hole Plugs into the unused
holes in the front of each insulating block.
NOTICE:
If a new Receptacle or Inlet is to mate
with a previously installed device, pay particular
attention to the number of contacts and
numbered position in the Receptacle or Inlet.
Continuity will not be obtained unless the male
and female contacts are appropriately mated.
Disassembly of Contacts
1. To remove the contact from the insulating
block, the provided Multi-Contact Removal Tool
9-LD12-37 must be used. From the front side of
the insulating block, slide the contact removal
tool over the contact.
2. Push until the contact pops out the back side of
the insulating block.
3.
NOTICE:
Each contact is designed to be
removed from the insulating block a maximum
of 3 times. New contacts should be used if
contacts are removed more than 3 times.
Voltage Labels
Always have a qualified electrician complete
the installation and apply one of the supplied
voltage labels that best describe the voltage
application level.
WARNING:
For safety reasons, it is always recom-
mended to use a ground wire. Please reference
your local codes for specific electrical requirements.
Assembly for In-Line Connections
When DS and DSN Multipins are used as in-line con-
nectors, finger drawplates should be installed on both
the receptacle and plug in order for the user to more
easily provide the leverage required to connect the
device.
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 25/64” and
twist the strands of each conductor together.
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.
Table 1 - Wiring Terminal Capacity
1
(in AWG)
Main Contacts
Device
Minimum
Maximum
DSN24c
16
14
DSN37c
16 14
DS24c
16 14
DS37c
16 14
1
Capacity is based on THHN wire sizes
MELTRIC Corporation / 4765 W Oakwood Park Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 433 2701 / e-mail : [email protected]
INSDSDSNMULTI H
A manufacturer of products using Marechal technology
meltric
.com
Compression
Nut
Handle
Strain
Relief
Color-Coded
Gasket
Receptacle
(or Inlet)
Bushing
Finger Drawplate Gasket
Finger Drawplate
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
WARNING
DANGER
CAUTION
NOTICE
ENGLISH OPERATING INSTRUCTIONS
DS & DSN
MULTIPIN
