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Thermoplastic DuraGard
®
30, 50 & 60 Amp Circuit Interrupting Receptacles, Plugs & Connectors
WARNING
Risk of electrical shock. De-energize all power prior to
installation or repair.
APPLICATION
Thermoplastic DuraGard® plugs, receptacles and connectors are
ideal for washdown duty, harsh environments and wet locations.
They can be found in a broad range of industrial uses, from
chemical and food processing to data processing and mining; in
marine applications both shipboard and dockside.
Pin and sleeve contact design allows DuraGard
tailored to specic industrial applications and special purpose work
in accordance with the National Electrical Code and local codes.
The devices are rated and polarized for specic voltages and
amperages, preventing dangerous mismating of devices of different
ratings.
®
devices to be
PREPARATION
1. Recommended Tools
Torque Wrench Screw Drivers
Ohmmeter Wire Strippers
Allen Wrench 3/16" Dia. Drive Pin (opt.)
2. Select cable size from table according to ampere rating of device.
Ampere Rating
Cable Size Awg.
Cord Type
3. Establish a wiring pattern so the same colored wire is put in
the same terminal on all plugs, receptacles and connectors
in the system. DuraGard® devices are polarized so the
plug will enter the receptacle or connector only one way.
4. Interior markings for wiring as follows:
5. Proceded to Receptacle Installation or Plug and Connector
Installation as applicable.
30
50, 2P3W
8
6
S, SJ
S, SJ
2p 3w 3p 4w
X/L1,Y/L2,G/ X/L1,Y/L2,Z/L3,G/
50, 3P4W
6
SC, SCE, SCT, PPE,
G, G-GC, W
SC, SCE, SCT, PPE,
G, G-GC, W
60
6
WARNING
Equipment connected to circuits having different voltages,
frequencies or types of current (AC or DC) must not have
interchangeable attachment plugs per NEC Section 406.3(F).
CAUTION
Use only copper or copper clad aluminum wire with box
mounted outlet or inlet. Use of other wire may result in the
connector failing in service.
Receptacle Installation
1 5 4 3
6. Turn power OFF.
7. Securely mount junction box #1 (purchased separately) and
install service supply. Pull cable into junction box #1 leaving
enough cable to connect to receptacle #2. Slide gasket #6
over supply cable from box.
NOTE: Receptacle #2 is pre-assembled with 3, 4 and 5.
8. Strip cable jacket 1 inch to 2-5/8 inches.
Strip conductors 1/2 inch (30 & 50A) or 3/4 inch (60A).
NOTE:
TA01986 N Page 1 of 2
For male receptacles (reverse service) items #3B are pins.
6 2 7
3A 3B
9. Loosen pressure screws #3A in sleeves. Insert stripped end
of each conductor in sleeve #3B or pin #3B in accordance
with wiring pattern established in Preparation Step #3.
10. Tighten pressure screws #3A to 20 in-lbs (30 & 50A) or
25 in-lbs (60A) of torque.
11. Assemble gasket #6 and receptacle #2 to junction box #1
with 4 screws #7.
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Plug and Connector Installation
8
8A
8B
*NOTE: Hand assemble both cable clamp yokes (#8B), and
both machine screws and nuts (supplied loose) onto cable
gland nut #8 as shown. Alternately tighten screws to rmly
grip cable & bushing to 10-15 in-lbs. Use of power tools is
NOT recommended unless veried torque limit <15 in-lbs.
6. Turn power OFF.
7. Strip cable jacket 1 to 2 inches (30 & 50A) or 2-5/8 inches
(60A). Strip conductors 1/2 inch (30 & 50A) or 3/4 inch (60A).
8. Disassemble device removing gland nut #8, glide washer #7,
bushing #6, liner #5, collar nut #4 (furnished with plug only)
and interior #2 from housing #1.
NOTE: Connector interior is separated from housing by inserting
a small screwdriver or drive pin in current sleeve from the front
and tapping the pin lightly.
9. Loosen screws #8B (2). Slide gland nut #8, glide washer #7,
bushing #6, (conical face towards device) liner #5, and collar
nut #4 over supply cable.
NOTE: For female plugs (reverse service) item 2B are sleeves.
10.
Loosen pressure screws #2A in pins or #2A in sleeves. Insert
stripped end of each conductor in pin #2B or sleeve #2B in
accordance with wiring pattern established in Preparation Step #3.
11. Tighten pressure screws #2A to 20 in-lbs (30 & 50A) or 25
in-lbs (60A) of torque.
7
6
5
3
2 1
2A 2B
4
12. Reassemble interior #2 in housing #1 by lining up 2 tabs in
housing with 2 notches on interior.
a. Plug interiors can be rotated to "seat" by grasping pins while
slowly turning housings. Interior must seat at against housing
inner ring (liner #5 with housing #1).
b. Connector interiors are assembled by lining up ground sleeve
with interior ground carrier sleeve. Push rmly until entire
interior is seated.
NOTE: O-rings on plug & connector interiors are lubricated at
factory for sealing and ease of assembly. If additional lubricant is
required, apply a non-conductive lubricant such as GE type G661
silicone compound.
13. Slide liner #5 down cable, to seat on the interior (inside housing).
Liner can be rotated by hand (note keyways) until properly
engaged. Liner #5 seats completely inside housing #1, ush with
back end.
14.
Position bushing #6 (conical face down) into liner #5, with glide
washer ring #7 on top. Secure in place with gland nut #8. Tighten
gland nut #8 on housing #1 to 40 in-lbs or until bushing compression
rmly grips cable. Maximum compression of bushing is
approximately 10% or 90% of original I.D. Other bushing sizes are
available. Maximum torque on gland nut #8 is 80 in-lbs. Gland nut #8
has an additional thread locking screw #8A, tightened to 2 in-lbs.
See *Note for screws /clamp #8B.
NOTE: Make sure O-ring gasket #3 is on housing (for plugs only).
ELECTRICAL TESTING
Do not connect to power until the following electrical tests have
been performed.
1. Make continuity checks of wiring with ohmmeter to verify
correct phasing and grounding connections.
2. Check insulation resistance to be sure system does not
have any short circuits or unwanted grounds.
Connect all devices in the system, turn the power on and test
the system.
MAINTENANCE
Inspection of electrical equipment used in industrial and heavy use
situations must be conducted regularly to ensure proper function
and safety.
Check for the following items during inspection:
1. Unsecured contact wire terminals
2. Cracked or broken housings
3. An unfastened or loose ground conductor
4. Deteriorated or misplaced gaskets
5. Loose or missing screws
MAINTENANCE MANAGER: Please record
the following information for your records.
COMPLETE CATALOG NO.
(As shown on device label)
If any part of a new plug, receptacle or connector appears to be
missing or damaged, DISCONTINUE USE IMMEDIATELY. Call
factory for return. Use only new authorized Russellstoll factory
replacement parts for any repairs.
WARNING!
DATE OF INSTALLATION
WARRANTY: Thomas & Betts sells this product with the understanding that the user will perform all necessary tests to determine the suitability of this product for the user's intended application.
Thomas & Betts warrants that this product will be free from defects in materials and workmanship for a period of two (2) years following the date of purchase. Upon prompt notication of any
warranted defect, Thomas & Betts will, at its option, repair or replace the defective product or refund the purchase price. Proof of purchase is required. Misuse or unauthorized modication of the
product voids all warranties.
Limitations and Exclusions: THE ABOVE WARRANTY IS THE SOLE WARRANTY CONCERNING THIS PRODUCT, AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE SPECIFICALLY DISCLAIMED. LIABILITY
FOR BREACH OF THE ABOVE WARRANTY IS LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT, AND UNDER NO CIRCUMSTANCES WILL THOMAS & BETTS BE
LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES.
© 2012 Thomas & Betts. All Rights Reserved. TA01986 N Page 2 of 2
Thomas & Betts Corporation Memphis, Tennessee www.tnb.com
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