Russellstoll MaxGard® Interconnection Systems 30-400/600 Amp Plugs, Connectors, Receptacles, Inlets and Interlocked Receptacles Ordering Information I I ^"^^"^"^ Receptacle with Angle Receptacle with Angle Adapter** Receptacle Only Receptacle with Angle Enclosure Adapter & Junction Box" Cat. No. Cat. No. Cat. No. Cat. No. * T » V * T » T DF3107FROEO DF3107FRABO DF3107FRAOO DF3107FROOO DF3207FROEO DF3207FRABO DF3207FRAOO DF3207FROOO DF3307FROEO DF3307FRABO DF3307FRAOO DF3307FROOO DF3404FROEO DF3404FRABO DF3404FRAOO DF3404FROOO DF3504FROEO DF3504FRABO DF3504FRAOO DF3504FROOO DF6207FROEO DF6207FRABO DF6207FRAOO DF6207FROOO DF6307FROEO DF6307FRABO DF6307FRAOO DF6307FROOO DF6404FROEO DF6404FRABO DF6404FRAOO DF6404FROOO DF6504FROEO DF6504FRABO DF6504FRAOO DF6504FROOO DF1207FROEO DF1207FRABO DF1207FRAOO DF1207FROOO DF1307FRABO DF1307FRAOO DF1307FROOO DF1307FROEO DF1404FRABO DF1404FRAOO DF1404FROOQ DF1404FROEO DF1504FRAOO DF1504FROOO DF1504FROEO DF1504FRABO DF2304FRABO DF2304FRAOO DF23i04FROOb — DF2404FRABO DF2404FRAOO DF2404FROOO — DF2504FRABO DF2504FRAOO DF2504FROOO DF4304FRABO DF4304FRAOO DF4304FROOO — DF4404FRABO DF4404FRAOO DF4404FROOO — DF4504FRABO DF4504FRAOO DF4504FROOO * Disconnect Service Ratings Available (Consult Factory) Maximum Terminal Wire Size: ** If receptacle is desired with a Straight Adapter instead of standard Angle Adapter, substitute "S" for the "A" in the catalog number. Rating Max. Conductor Size AWG Entrance Dia. Boldface figures are for voltage assignment; for different ratings see following pages. 30 #8 AWG - 7 Strand or Flexible Conduit .187" Receptacles furnished with flap cap also have screw thread to accept male collar on plug. 60 #4 AWG - 7 Strand or Flexible Conduit .302" Catalog numbers shown are for flap cap receptacles, change "DF" to "DS" for 100 #0 AWG -19 Strand or Flexible .386" ordering screw cap. 200 #4/0 AWG -19 Strand or Flexible .625" T Control contacts for pljgs/receptacles: Use "K" where noted. 400 500MCM-37 Strand or Flexible .937" Ex: DS3104MROOK 4 "F" Flap Cap style shown. "S" Screw Cover option also available. Conduit entry furnished at location l" unless otherwise specified. ex:"DF __"vs. "DS 30 Amp 1"NPT 200 Amp 3" NPT e 60 Amp 11/2" NPT 400 Amp 4" NPT 100 Amp 2" NPT For adapters, junction boxes and accessories, See pg. 29. ThomasiBetts 17 © 2001 Thomas & Belts Corporation. Specifications are subject to change without notice. WWW.tnb.COm Russellstoll Application Guide This catalog has been divided into sections based on standard application groups. Each application group has been color- coded for your convenience. Below is a description of each of the six general categories Russellstoll products fall in. Applications are not limited to those listed below. Heavy Industrial / Marine Applications: Outdoor, Severe or High Abuse Environments • Agriculture • Industrial hook-ups • Irrigation & wastewater equipment |£ • Shdre to ship power connections • Portable power connections • Industrial and shipyard welding stations • Aerospace manufacturing and • Power distribution centers • Portable generator sets airports • Job site power: For telephone power • Mills & process plants • Lift stations and communications equipment Washdown & Light Marine Applications: Watertight / Waterproof Bottling and beverage plants Food processing plants Pulp & paper factories Pharmaceutical manufacturing Barge and workboat applications Outdoor construction sites Industrial and Commercial Applications » Entertainment (lighting & sound • Computer related equipment Construction sites systems) • Welding installations Facilities electrical power • Machinery L Control Circuit and Industrial / Interlock Applications Automotive/Industrial Interlock plugs under full load. 1 Shipyard maintenance power systems were designed for the , Automatic press 1 Battery chargers needs of the manufacturing ,, , 1 Automated welder applications industry. These devices are used ' HeavY dutV Portable welding where safety requirements mandate Portable systems • Food processing a mechanically interlocked system Machine tool control or Servo systems 1 Temporary power connections for connection and removal of Hazardous Location Applications: Class I, Div. 1 / Class II, Div. 1 • Aerospace • Petroleum • Food processing • Steel mills and mining • Chemical • Waste treatment Computer Systems: Data Center and OEM Products Raised Floor Applications • Main Power Connections • Critical power for test, instrumentation, telephone and medical equipment ThomasiBetts © 2001 Thomas & Belts Corporation. Specifications are subject to change without notice. WWW.tnb.COm Russellstoll MaxGard Interconnection Systems 30-400/600 Amp Plugs, Connectors, Receptacles, Inlets and Interlocked Receptacles Engineering Specifications Pin & Sleeve Plugs, Receptacles & Systems 2.7 Interior Type - Interiors must be male (pin type) or 1.0 Scope female (sleeve type). Pins and sleeves shall also be self-aligning and self-wiping/self-cleaning. 1.1 This document covers multi-contact: pin & sleeve, industrial grade, arc-quenching, circuit interrupting 2.8 Control Contacts - All devices must have an option rated electrical plugs, motor plugs, connectors, for two control contacts which shall be make-last and receptacles, mechanically interlocked receptacles break-first for use in electrical interlocks and/or control and assorted accessories. Usable in dry, damp, wet, circuits. See table below. marine and/or hazardous locations for electrical power 2.9 Conductor Terminals - Pin and sleeve connections circuits. Devices are to be rated 30, 60, 100, 200 and/ shall employ solderless pressure type screw terminals or 400 amperes at 600 VAC, 50-400 Hz and 250 VDC and be sized to accept stranded or solid copper maximum. Devices are also rated for continuous use conductors in AWG sizes (max. O.D.'s as noted). The in temperatures from -40 degrees C to + 130 degrees screw terminals shall also have socket heads to insure C. These devices must provide internal environmental proper torquing of wires. seals for marine and extreme wet applications and 2.1 0 Environmental Seals - Each device must have an can be electrically interlocked. environmental seal or "0" ring around all interiors and 1.2 The devices described shall be Thomas & Betts/ around each pin and sleeve to prevent water and Russellstoll MaxGard catalog numbers as specified. contaminants from entering the wiring compartment'. This provides waterproof capability, even when not 2.0 Product Classifications (Features) mated. 2.11 Hazardous Location - All standard plugs 30, 60 and 2.1 Gated Dead Front - All receptacles and connectors 100 amp shall be UL and CSA listed for hazardous must have a rotating disk on the face of the interior location Class I Division 1, Groups C & D; Class II which provides live contact isolation and Division 1, Groups F & G. A hazardous location environmental separation. circuit-breaker protected interlock shall also be 2.2 Delayed Action Arc Containment - All devices upon applicable to the same environments and possess all disconnect under load shall have provision so the arc the same product features as outlined above. is contained and extinguished within the insulation Enclosures shall meet NEMA 8 hazardous outdoor cavity making it impossible to withdraw a live plug. duty classifications and shall meet shipboard use above deck in accordance with the Department of 2.3 Flap Cover or Screw Cover Option - Flap cover Transportation. (USCG "Green Water") option must provide weathertight capability by utilizing a spring actuated self closing flap. Watertight 2.12 Lockout Devices - Plug connection lockout is capability shall be obtained by using a gasketed crew achieved by a padlock through plug sleeve housing cap. hole provided for this purpose. On Hazardous Location/Explosion Proof Interlock Receptacles, 2.4 Polarization - All devices shall be factory polarized lockout shall additionally be achieved by separate for amperage, voltage, frequency and phase; thus lockout accessory available from the factory. On providing a single voltage rating, single interface standard Interlocks, lockout accessory/construction is system. available from the factory. 2.5 Grounding - The grounding of the device shall be 2.13 Horsepower Ratings - Horsepower ratings shall be accomplished through a separate center ground in accordance with NEC Article 430 conditions, (earth) make-first and break-last pole on all devices depending on applicable voltage up to 600 VAC. See for complete system grounding. Chart Next Page. 2.6 Pole Capabilities - All devices shall accommodate up to four power pins plus a separate center ground pin and they shall be integral with the connector bodies (5 pins total). Rating for Pilot/Control Contacts* Contact Rating Code Designation A-600, Table 119. 1 - U.L. 508 Heavy Pilot Duty Load (720 VA/600 VAC) Maximum Thermal Maximum Current, Ampere Continuous Current Amps 120V 240V 480V 600V Max Volt Ampere Make Break Make Break Make Break Make Break Make Break 1 0 60 6 30 3 1 5 1.5 1 2 1.2 7200 720 ThomasiBetts 14 © 2001 Thomas & Betts Corporation. Specifications are subject to change without notice. WWW.tnb.COITl Russellstoll MaxGard Interconnection Systems 30-400/600 Amp Plugs, Connectors, Receptacles, Inlets and Interlocked Receptacles Engineering Specifications (Continued)________________________ Maximum Horsepower Ratings* 4.0 Design and Construction Requirements Service Connection Use: Not for normal disconnect 4.1 Circuit Interrupting Rating - All devices 30, 60, 100 service, but plug may be withdrawn if necessary within and 200 amperes shall be tested to be interrupted at these maximum HP ratings. 150% of rated current. Additionally, all devices shall Plug and Full Load - Motor Rated HP be designed and tested to interrupt 100% of rated Receptacle 120 240 480 600 current. Amp Rating Volts Volts Volts Volts 4.2 Wiring - All devices shall be wired from the rear Single-phase 30 2 3 7.5 1 0 requiring no disassembly of the pins and/or sleeves 60 3 1 0 20 20 from the insulated body. 100 7.5 1 5 30 30 5.0 Applicable Documents (Compliances) 200 1 5 30 40 40 5.1 Underwriters Laboratories (UL) - The devices Three-phase 30 3 7.5 1 5 20 specified herein shall be listed in applicable sections of UL Standards 1010, 231 , 168 2 an d 1686, File Nos. 60 7.5 1 5 30 30 E2630, E57324, E68085, E123752. 100 1 0 20 40 40 200 20 40 50 50 5.2 Canadian Standard Association (CSA) - The devices specified shall be listed in the applicable * Use of a horsepower rated switch for motor disconnection (under load) is sections of CSA C22.2-182.1, File Number LR14096. recommended per NEC 430. 5.3 International Electro-Technical Commission (IEC) - 2.14 Disconnect (Non-Interrupting) Current Ratings - The 30, 60 and 100 ampere devices specified shall Devices may be used at up to 150% of rated current have been tested and comply with IEC 309-1. within applicable NEC wiring guidelines. When used 5.4 Federal Department of Transportation - at 150% ratings, device shall not make or break Refrigerated National Shipboard location devices shall current loads while in service. UL approved 45 amp meet and comply with Federal Register volume 47, (30) and 150 amp (100) polarizations are available; for number 68, subpart 111.79. other ratings and special polarizations, consult 5.5 Standards - The devices specified shall comply with factory. Military Standards MIL-STD-105 and 1344; ASTM Standards D570 and D2565: NEMA Standard PR4- 1983; and OSHA regulations when installed in 3.0 Materials Requirements accordance with the National Electrical Code (NEC). 3.1 Housings - Plug, motor plug, receptacles, connectors and interlock housings, associated covers 5.6 NEMA 250 Enclosures Standard and caps, screw collars, and clamp holders shall be made of copper-free cast aluminum (max. .004% NEMA-1 - General Purpose for indoor use; guards copper). against contact with equipment. 3.2 Finish - All external surfaces except those that NEMA-3R - Outdoor use primarily to protect against provide means of grounding shall be epoxy powder rain, sleet, wind-blown dust and damage from coated to resist corrosion. external ice formation. 3.3 Hardware - All hardware, external and springs, shall NEMA-4 - Indoor or outdoor use to protect against be stainless steel. Cable clamps shall be stainless windblown dust and rain; splashing and hose directed steel or epoxy powder coated copper-free cast water. aluminum. NEMA-4X - Watertight, dust-tight corrosion-resistant 3.4 Insulators - All device body insulators shall be for indoor or outdoor applications. molded from glass-reinforced high strength thermoset polyester, minimum of UL94V0 flammability rated. NEMA-6 - Watertight, casual/temporary immersion. 3.5 Contacts - Contacts base material shall be made of NEMA-7 - Class I (Hazardous) for indoor use in Class a conductive copper alloy, (brass CDA485) to prevent I areas, per NEC. dezincification. Accessory material of the contacts NEMA-8 - Class I (Hazardous) for indoor use in Class shall be made of a compatible corrosion resistant I, oil-immersed equipment. material. NEMA-9 - Class II (Hazardous) for indoor use in Class 3.6 Environmental Seals - Environmental gaskets and II areas, per NEC. "0" rings shall be made of neoprene material. NEMA-12 - Industrial use, dust-tight for indoor use to protect against dust, failing dirt and dripping non- corrosive liquids. ThomasiBetts © 2001 Thomas & Belts Corporation. Specifications are subject to change without notice. WWW.tnb.COm 15 Russellstoll MaxGard® Interconnection Systems 30-400/600 Amp Plugs, Connectors, Receptacles, Inlets and Interlocked Receptacles Ordering Information PH . All available voltage PgD = QQJ polarizations m on pg. 20. f \ ,PT Maximum rjr^ir^ r 600 VAC 250 VDC, Load 1 Breaking f I __ _ Male PI Female Connector* Male Inlet1 ug** Standard Ratings Std. Std. Poles Bushing Bushing Wires Voltage Cat. No. I.D.** Cat. No. I.D.** Cat. No. P 30 Amp / 45* T * T *T 2P3W 125 DS3107MPOOO W DF3107FPOOO W DS3107MROOO 2P3W 250 DS3207MPOOO 7/8" DF3207FPOOO W DS3207MROOO 3P4W V' :gI|Iif : 125/250 DS3307MPOOO 1" DF3307FPOOO 1" OS3307MROOO 3P4W : : 30480 DS3404MPOOO • r DF3404FPOOO 1" DS3404MROOO 4P5W 30Y 277/480 DS3504MPOOO w DF3504FPOOO W DS3504MROOO 60 Amp / 90* 2P3W 250 DS6207MPOOO 13V DF6207FPOOO 1W DS6207MROOO 3P4W illiif. 125/250 DS6307MPOOO w DF6307FPOOO 1W DS6307MROOO 3P4W :Kfi':W: 30480 OS6404MPOOO w DF6404FPOOO •\S/K DS6404MROOO 4P5W 30Y 277/480 DS6504MPOOO 11/2" DF6504FPOOO 11/2" DS6504MROOO 100 Amp/ 150* 2P3W 250 DS1207MPOOO 1W DF1207FPOOO 1%" DS1207MROOO 3P4W :;:;:j:;s: 125/250 DS1307MPOOO 1%" DF1307FPOOO vw DS1307MROOO ;SS; : : 3P4W : llll|P 30480 DS1404MPOOO 1%" DF1404FPOOO vw DS1404MROOO 4P5W 30Y 277/480 DS1504MPOOO 2" DF1504FPOOO 2" DS1504MROOO 200 Amp / 300* 3P4W 30277/480 DS2304MPOOO 21/4" DF2304FPOOO 21/4" DS2304MROOO : 3P4W ' '" 30480 DS2404MPOOO 21/4" DF2404FPOOO 21/4' DS2404MROOO 4P5W 30Y 277/480 DS2504MPOOO 21/2" DF2504FPOOO 21/ " DS2504MROOO 2 400 Amp / 600* 3P4W Vf|y:i30 277/480 3" DS4304MPOOO DF4304FPOOO 3" OS4304MROOO ; c 3P4W '•— "" ::' ::'" ::- 30480 3" DS4404MPOOO DF4404FPOOO 3" DS4404MROOO 4P5W 30Y 277/480 DS4504MPOOO 31/4" DF4504FPOOO 31/4" DS4504MROOO Special Disconnect Service Ratings Available (Consult Factory) Maximum Terminal Wire Size: 150% non-UL ratings {consult tech support) with separate disconnect service. Rating Max. Conductor Size AWG Entrance Dia. Standard cable bushings shown. Additional sizes available, see page 26. Always furnished with screw collar. We recommend cup cap with male inlet and male p 30 #8 AWG - 7 Strand or Flexible Conduit .187" order catalog number DS(X)CC. (X) is the amperage 3=30, 6=60,1=100, 2=200 & 4=400. 60 #4 AWG - 7 Strand or Flexible Conduit .302" Boldface figures are for voltage assignment; for different ratings see following pages. 100 #0 AWG -19 Strand or Flexible .386" Control contacts for plugs/receptacles: Use "K" where noted. 200 #4/0 AWG -19 Strand or Flexible .625" Ex: DS3104MROOK 400 500MCM-37 Strand or Flexible .937" "F" Flap Cap style shown. "S" Screw Cover option also available. ex: "DF____"vs. "DS____". Male Inlets: Mounted same as receptacle, all options 400 AMP plugs and connectors are supplied with cast aluminum handles. available. See pg. 29. ThomasiBetts 16 © 2001 Thomas & Belts Corporation. Specifications are subject to change without notice. WWW.tnb.COtTI Russellstoll MaxGard Interconnection Systems - Catalog Numbering System 30-400/600 Amp Plugs, Connectors, Receptacles, Inlets and Interlocked Receptacles Receptacles, Plugs and Connectors. D 414 R B K 0 = Standard configuration K = 2 control contacts B = Junction Box, E = Angle Enclosure 0 = Without Adapter A = Angle, S = Straight Adapter, R = Receptacle or P = Plug 1 Ex: FP = Connector M = Male Pins, F = Female Sleeves (contacts) / MR = Motor Inlet Voltage Assignment Number See page 20 (voltage selection chart) „ , (Last 3 positions above: 0 can appear in any positic Amperage Rating •- standard plugs, etc. will ha* 3 = 30A, 6 = 60A, 1 = 100A, 2 = 200A, 4 = 400A 000 suffix- "DS2404MP00 F = Flap Cover or S = Screw Cover screw collar (for plugs) D = Gated-Dead Front Interlocks (Standard or Explosion Proof) R D 414 060 K 0 = Standard Configuration S = Auxiliary Switch, Z = Shunt Trip, 0 = Standard Configuration K = 2 Control Contacts, Breaker Rating code: (Pg. 18, Breaker Rating Trip Charts) *NAO = Non-Automatic Switch Voltage Assignment Number (Pg. 20 Voltage Selection Chart) Amperage Rating 3 = 30A, 6 = 60A, 1 = 100A, 2 = 200A, 4 = 400A E = Explosion-Proof or F = Flap Cap (weathertight) or S = Screw Cap (watertight) R = Receptacle With S in position 2, position 9,1 0 and 11 must be NAO. *S = Switch or B = Circuit Breaker D = Gated-Dead Front ThomasiBetts © 2001 Thomas & Belts Corporation. Specifications are subject to change without notice. WWW.tnb.COm 19 Russellstoll MaxGard Interconnection Systems - Voltage Selection Chart 30-400/600 Amp Plugs, Connectors, Receptacles, Inlets and Interlocked Receptacles Single Polarization/Multiple Service* Assigned Voltages and Wiring Systems n r\ o o ^ 3 S^T\ 2>rh\ I LG i I» G I IWG l i LG\ f» G i (wf i i>47 iXl7 iX£