Switch-Rated Electrical Plugs, Receptacles & Connectors for the Power Generation Industry meltric.com
Benefit from Meltric’s DecontactorTM Series Switch-Rated Plugs, Receptacles, and Electrical Connectors Safety and Code Compliance Meltric’s DECONTACTORTM Series products combine the safety and function of a switch with the convenience of a plug & receptacle. They are UL & CSA rated for ‘motor circuit’ and ‘branch circuit’ switching and are approved NEC ‘line of sight’ disconnects. Key features, including silver-nickel butt style contacts, enclosed arc chambers, dead front construction and high short circuit ratings, ensure user safety and eliminate the potential for exposure to arc flash or live parts, greatly simplifying compliance with NFPA 70E. Portable Equipment Connection Wastewater Mixer Connection Portable Oil Filter Pump and Cordset Switch ratings comply with NEC ‘line of sight’disconnect requirements Short circuit ratings up to 100kA help ensure user safety in overload conditions Dead front construction prevents unintended access to live parts Enclosed arc chambers prevent arc flash exposure 2 Common Meltric Applications at Power Generation Facilities Welding Machines Downtime Portable Power Critical Motors Distribution Hoist Connections Modular Conveyors
Throughout Your Plant Performance with Cost Savings Meltric’s DECONTACTORTM Series plugs and receptacles help power plants enhance safety and performance while also reducing equipment and labor costs. Their switch ratings eliminate the expense of interlocks and auxiliary disconnect switches, and their flexible mounting configurations simplify installation. Decontactors unique combination of safety features and plug & play simplicity allows technicians to quickly and easily make and break electrical connections during equipment change-outs. The electrical work can be performed efficiently back at the shop. Welding Machine Process Pump Connections Power Receptacles Switch ratings eliminate the need for expensive interlocks and auxiliary disconnects Solid silver-nickel contacts are backed by a 5 year warranty Plug & play simplicity helps reduce equipment change-out time by up to 50% Optional pilot contacts allow control and power circuits in one connection 3 Meltric Installed Base Includes Nuclear, Hydro, SWITCH-RATED Fossil Fuel and ‘Waste to Energy’Plants Heat Lamps & Pumps Fans & Cordsets Portable Lighting Mobile Facilities Portable Generators
Application Spotlights DecontactorTM Series Switch-Rated Plugs & Receptacles Welding Machine Connections Decontactors provide an ‘inline switch’ when used on extension cords Ensure User Safety Significant safety and cost advantages make Decontactors the ideal choice for connecting power to welding machines and other equip- ment. With their switch ratings, 65kA or greater short circuit ratings, enclosed arc chambers and dead front construction, they not only allow users to safely make and break resistive and inductive loads under full load, but also eliminate the potential for arc flash expo- sure and provide protection in dangerous over- load situations. The need for the expensive interlocks required with other plug & recepta- cles and the common problem of defeating the Decontactors allow welders to safely connect and disconnect welding machines even under overload conditions. interlock with extension cords are eliminated. 4 Meltric DSN30 Meltric DSN30 Mobile Facilities Power Supply 30A, TYPE 4X 30A, TYPE 4X 10 HP, 480VAC 10 HP, 480VAC LISTED 22Y3 LISTED 49B6 08L10 08L10 63-38043 63-34043 SWITCH RATED INLET/PLUG SWITCH RATED RECEPTACLE/CONNECTOR MOTOR CIRCUIT DISCONNECT SWITCH MOTOR CIRCUIT DISCONNECT SWITCH BRANCH CIRCUIT DISCONNECT SWITCH BRANCH CIRCUIT DISCONNECT SWITCH Typical Plug and Receptacle Label showing the Decontactors UL & CSA switch ratings Easily Meet NEC Code Requirements The NEC requires motors to have readily accessible ‘line of sight’ disconnects. Meltric Decontactors are UL and CSA listed for ‘Motor Circuit’ and ‘Branch Circuit’ Disconnect Switching, and are approved NEC ‘line of sight’ disconnect switches. With models rated up to 60 hp and 200A, and with configurations available for wall mounted, equipment mounted, and in-line connections, Decontactors provide the most convenient and cost effective means of meeting code require- ments for local disconnects. Decontactors provide convenient power supply connections and local disconnects for mobile facilities.
Downtime Critical Equipment Meltric’s Switch-rated plugs and receptacles utilize motor starter contact technology, allowing users to safely make and break motor loads up to 60 hp Simplify Motor Change-outs Motors that are prewired with a Decontactor plug or inlet can be electrically connected simply by plugging them in. Safety features allow technicians to perform motor change-outs in the field, eliminating the need to wait for an electrician. Using Meltric Decontactors to connect motors instead of hardwiring can help reduce motor change-out and downtime costs by 50%. Correct motor rotation can be ensured by pre-testing motors at a test bench with receptacles that match the polarization in the field. 5 Roof Area Electrical Connections (Above Turbines) Decontactor receptacle – dead front prevents unintended exposure to live parts Ensure Arc Flash Protection Decontactors provide arc flash protection by eliminating the potential for exposure to live parts and arcing. The contacts are completely enclosed during load-making and breaking, ensuring that any associated arcing is safely isolated in internal arc chambers. The plug can only be removed if the device has been switched ‘off’ and the plug contacts are dead. The safety shutter on the receptacle automatically closes while the plug is being removed, maintaining a dead front and preventing access to live parts after the plug is removed. Thus, at no time during the operation of the device will the user have Decontactors allow quick disconnection of electrical cables located above gas turbines. Costs associated with maintenance of unintended access to live contacts or arcing. gas turbines (including roof removal) are reduced.
Application Spotlights DecontactorTM Series Switch-Rated Plugs & Receptacles Portable Lighting Connections MATERIAL CONTACT RESISTANCE New Oxidized SILVER-NICKEL 23 60 BRASS 370 1400 Meltric’s silver nickel contacts are 20X more conductive than brass Withstand Harsh Environments In addition to their superior electrical properties, Decontactors spring-loaded, silver-nickel butt style contacts are more durable and withstand harsh environments better than the brass contacts used on pin & sleeve devices. Decontactor contacts close with a self-cleaning wiping action, their heavy duty coil springs maintain optimal contact pressure and the silver-nickel material offers excellent wear resistance, providing more reliable performance in dirty environments. Unlike brass, silver-nickel maintains its electrical properties after oxidation and withstands many Meltric plugs and receptacles ensure worker safety when connecting heat lamps or other lighting loads, even in damp conditions. common corrosive environments. 6 Pump Connections Decontactor inlets/plugs include lockout/tagout provisions. Receptacles are available with an optional lockout pawl. Simplify NFPA 70E Compliance The NFPA 70E ‘Standard for Electrical Safety in the Workplace’ requires the establishment of an electrically safe work condition before work tasks can be performed. Meltric Decontactors make this simple. Dead front construction eliminates potential exposure to arcing and unintended access to live parts, and the removal of the plug from the receptacle provides verification of de-energization. Thus, electrical connections can be made and broken without the need to establish flash hazard boundaries, perform voltage testing, or ‘suit-up’ Float pumps or dewatering pumps can be safely and quickly disconnected and reconnected with Decontactors. to meet NFPA 70E’s PPE requirements for energized electrical work.
Portable Power Distribution NEMA 4X rated DSN Decontactor Protect Against the Elements Meltric’s DECONTACTORTM Series plugs and receptacles are available with ingress protection ratings up to NEMA 4X and IP66/67. DS and DSN series Decontactors achieve their ratings simply by mating the plug with the receptacle. There is no need to turn or tighten additional fittings as is required to enable protection on many other plug & receptacles. The ratings can also be maintained when the plug & receptacle are disconnected: by closing and latching the lid on the receptacle, or by installing an optional cap on the plug. A mobile diesel generator supplies power via Meltric plugs & receptacles during outage conditions. 7 Retrofit Applications Adapter plates are available in a variety of sizes and configurations. Minimize Upgrade Costs With Meltric Decontactors, power generation facilities can upgrade existing pin & sleeve con- nections to improve safety and comply with NEC and NFPA 70E requirements easily and with minimal expense. Their switch ratings eliminate the need for expensive interlocks and auxiliary disconnect switches, and available adapter plates allow Decontactor receptacles or inlets to be easily installed on existing junction boxes, eliminating the need for costly rewiring. Meltric offers standard Adapter plates made it simple for this power plant to convert their existing pin and sleeve receptacles to Decontactors. adapter plates to fit hundreds of other manufacturers boxes and can quickly custom make others as required.
Product Specifications Meltric DecontactorTM Series Plugs & Receptacles – 20 to 200A • Allow easy NEC, NFPA 70E OFF Button and CSA Z462 code compliance Press to deenergize. Provides DSN pictured • Functions as a ‘line of push button circuit disconnection. sight’disconnect switch • Safely makes and breaks Dead Front/Safety Shutter resistive or inductive loads Assures safety by preventing user access to live parts. Lockout-Tagout Provisions Allows plug to be easily locked out and tagged. Spring-Assisted Screw Terminals Optional padlock pawl allows lockout/tagout of the receptacle. Patented design assures “Tighten and Forget” confidence. Silver-Nickel Contacts Spring-Loaded Butt Style Contacts Silver-Nickel material provides superior Ensures consistent contact force over conductivity, durability and corrosion thousands of operations. resistance. Durable Casings Lid Offers great resistance to impact Provides additional protection and harsh environmental conditions. from harsh environments. DSN 20-60A DS 20-200A DB 30-100A • Compact, lightweight design • Rugged construction • High horsepower capacity • Type 4X, IP66+IP67 • Type 3R (4X optional) • IP67 • Up to 4 auxiliary contacts • Up to 6 auxiliary contacts • Up to 4 auxiliary contacts 8 • Fiberglass reinforced • Fiberglass reinforced • Zinc aluminum alloy casing Polyester casings Polyester or Metal casings • 100kA short circuit rated+ • 100kA short circuit rated+ • 65kA short circuit rated + + Testing was performed with RK1 current limiting fuses sized at 400% of the highest full load motor ampacity associated with the devices hp ratings, except for DB100 which was tested with 250A fuses. Non-horsepower rated DS100 and DS200 devices were tested with RK5 time delay fuses sized at 100% of the devices rated ampacity. Tested to a Higher Standard Meltric Decontactors are the world’s only UL and CSA Switch-rated plugs and receptacles. Not only do they meet performance test requirements for UL 1682/CSA C22.2 No. 182.1 (to which competitive pin and sleeve devices are listed), but Decontactors also meet the performance test requirements in UL Subject 2682 “Switch-Rated Plugs and Receptacles.” Based on their evaluation against this standard, Decontactors are UL and CSA listed for use in motor circuit disconnect/switching applications and in branch circuit disconnect/switching applications. Tests passed by Meltric Decontactors and by traditional pin and sleeve type Additional Tests passed exclusively by DECONTACTORTM Series plugs and plugs and receptacles (per UL 1682 and CSA 22.2 No. 182.1) receptacles per UL Subject 2682. Temperature Rise (not to exceed 30° C over ambient) 50 operations @ 6x motor FLA and .4-.5 power factor 50 operations @ 150% device rating and .7-.8 power factor 6,000 operations @ FLA and .75-.8 power factor Endurance - number of operations @ .75-.8 power factor Short circuit make and withstand @ 65kA, 600V and <.15 PF Additional Listings include: IEC/EN 60309-1, 60947-3, AS 3123 • 20A 5,000 under load 0 off load • 30 to 60A 1,000 under load 1,000 off load • 100 to 200A 250 under load 250 off load
Offering Durability, Safety & Code Compliance SAFETY & CODE COMPLIANCE: Meltric vs the Competition MOTOR HARD-WIRED TO A MOTOR CONNECTED WITH A MOTOR CONNECTED WITH A BLADED DISCONNECT SWITCH COMPETITIVE PLUG & RECEPTACLE MELTRIC DECONTACTOR Disconnect may be difficult to Cord connection allows Expensive mechanical install in “ line of sight” easy“line of sight’ location interlocks are required OR from the motor since these plugs & Dead front eliminates receptacles cannot access to live parts and safely make & break need for cumbersome PPE under load 18” Ability to safely make & The interlock must be break under load eliminates OR mounted on a fixed the need for interlocks Qualified surface-this may make Worker ‘line of sight’ location w/PPE ≥65kA short circuit make more difficult & withstand rating ensures safety during reenergization MOTOR CHANGE-OUT PROCESS MOTOR CHANGE-OUT PROCESS MOTOR CHANGE-OUT PROCESS 1. Open interlock switch 1. Switch disconnect to OFF position 1. Switch Decontactor receptacle to OFF position 2. Determine PPE requirements & obtain 2. Apply lockout/tagout 2. Mechanic removes plug from receptacle 3. Remove interlock cover 3. Perform Shock/Arc Flash Hazard Analysis 3. Apply lockout/tagout as required 4. Voltmeter test to verify deenergization 4. Obtain permit for energized electrical work 4. Mechanic removes old/installs new motor 5. Remove plug 5. Suit up with appropriate PPE 5. Mechanic inserts plug into receptacle 6. Apply lockout/tagout as required 6. Remove the disconnect switch cover 7. Remove old/install new motor 7. Voltage test to verify deenergization Meltric Makes it 8. Insert plug into receptacle 8. Disconnect motor from hard-wiring 9 Safe & Easy 9. Remove old/install new motor 10. Connect new motor to hard-wiring 11. Jog the motor to ensure proper rotation Product Selection Guide Maximum Number Maximum Casing Maximum Amperage Environmental of Contacts Horsepower Rating Model Material Rating Rating Voltage (VAC) Main Auxiliary 480VAC 600VAC DSN20 Poly 480VAC 20A 3P+N+E - Type 4X IP66/67 5 hp na SWITCH-RATED DSN30 Poly 600VAC 30A 3P+N+E 2 Type 4X IP66/67 10 hp 15 hp DSN60 Poly 600VAC 60A 3P+N+E 4 Type 4X IP66/67 20 hp 20 hp DS20 Poly 600VAC 20A 3P+N+E 2 Type 3R (4X optional) 5 hp 7.5 hp DS30 Poly 600VAC 30A 3P+N+E 4 Type 3R (4X optional) 10 hp 10 hp DS60 Poly or Metal 600VAC 60A 3P+N+E 3 Type 3R (4X optional) 20 hp 25 hp DS100C Poly or Metal 600VAC 100A 3P+N+E 3 Type 3R (4X optional) 20 hp 25 hp DS100 Poly or Metal 600VAC 100A 3P+N+E 6 Type 3R (4X optional) - DS200 Metal 480VAC 200A 3P+N+E 5 Type 3R (4X optional) - DB30 Zinc Aluminum 600VAC 30A 3P+N+E 2 IP67 10 hp 10 hp DB60 Zinc Aluminum 600VAC 60A 3P+N+E 2 IP67 30 hp 30 hp DB100 Zinc Aluminum 600VAC 100A 3P+N+E 4 IP67 60 hp 60 hp * Consult the Meltric catalog for horsepower ratings at other voltages.
Common Product Accessories Handle Options Optional Cord Grip Meltric offers handles for all applications. with Wire Mesh Poly handles feature a layered bushing and compression nut to secure the cable, PH handles are threaded to receive cord grips or conduit fittings, and PM handles have cable clamps and interior bushings. PH or PM style Finger Poly PH PM handles are recommended for cord- Draw Plates Handle Handle Handle drop applications and optional finger drawplates are recommended for easier closure of cord-to-cord connectors. Angles and Boxes Meltric offers a variety of poly and metal angles and adapters to help users locate and position their devices in the most effective orientation for the application. Meltric also offers Conduit Metal 30° 70° a range of metal junction boxes to Entry Junction Box Metal Metal support all sizes of Decontactors Angle Angle and a line of nylon conduit entry boxes for applications where non- metallic accessories are preferred. 10 Pawl Options An emergency stop pawl with a Locking device not included larger and easier to actuate stop button is available for applications where emergency disconnections may be required. Padlock pawls include a .32”diameter hole through Emergency Padlockable the pawl to allow the insertion of a Stop Pawl Pawl padlock, allowing users to lock the receptacle lid closed or lock the plug and receptacle in the connected state. Adapter Plates Meltric adapter plates allow Decontactors to be installed on existing junction boxes, providing an easy and cost effective means of upgrading from competitive devices. Standard adapter plates are available for many Appleton, Crouse-Hinds, Hubbell, Killark and Pyle National devices, and can be quickly custom made for others. See the Meltric catalog for a complete listing of options and accessories.
Other Meltric Product Lines for the Power Generation Industry PF/PFQ Series – For High Amperage Connections Mechanical Locking System PF/PFQ Series plugs & receptacles Auxiliary Pilot are engineered for applications up Contacts to 600A where routine plug insertion and high reliability are required. Solid silver contacts maximize con- ductivity and resistance to corrosion, Silver Pressure Contacts a mechanical locking feature prevents accidental disconnection, and auxiliary pilot contacts ensure disconnection of the load before the plug can be removed. Multipin Series – For Control Wire Connections Meltric’s multipin connectors are available with up to 37 contacts and NEMA 4X environmental protection. They help eliminate rewiring errors and simplify equipment change-outs by providing a convenient single connection point for applications where the monitoring of critical parameters and/or the control of secondary circuits or equipment is required. 11 DXN Series – For Hazardous Duty Connections DXN Series plugs and receptacles are CSA rated for use in Class I Zone 1, Class I Division 2 and Class II Division 2 environments. With their lightweight, yet rugged, con- struction and their ability to be used as in-line connectors, DXN’s SAFE & RELIABLE bring the convenience of plug & play simplicity to hazardous duty environments. Power Distribution Products – For Custom Power Needs Meltric’s power distribution products make it easy for plants to provide the safety of Decontactor Series Switch-rated plugs & receptacles wherever power is required. Meltric offers a number of standard panels and boxes that can be equipped to suit users needs, or will custom design a package specifically for the intended application.
Service & Support You Can Count On Outstanding Customer Service Meltric’s Customer Service group is trained to answer most technical questions on the spot and is located at our manufacturing facility to streamline the order fulfillment and communication process. The Engineering group is located at the same facility and thus can quickly provide application and custom product design support. Friendly and personal assistance is only a toll-free call away at (800) 433-7642. Short Lead-Times Plus a Same Day Shipment Option Meltric ships most of its orders for standard products within two days of order receipt and offers same day shipment on many items for a nominal priority fee, helping to ensure that your items are delivered when you need them. Larger orders and custom orders naturally take a bit longer. Five Year Warranty on Electrical Components Meltric stands behind its products with a five-year warranty on the electrical contacts and a one-year warranty on the complete product. A complete warranty statement and information on other terms and conditions is available from Customer Service. Reasonably Priced Replacement Parts With the Decontactors robust construction, the need to 1 replace worn parts is rare. However, if they are required, parts are readily available and reasonably priced. Purchasing all the individual parts costs no more than buying an assembled product. 12 Presented by Meltric and: © 2013 Meltric Corporation. All rights reserved. PWRGEN C meltric.com 4640 Ironwood Drive • Franklin, WI 53132 800.433.7642 • Fax 414.817.6161