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Wiring a 3-wire deadman handle is crucial for maintaining safety and efficiency in your blasting operations. Follow these steps carefully to set up new equipment or make field repairs correctly.
Step 1: Disassemble the 3-Prong Twistlok Connector
Start by disassembling the 3-Prong Twistlok connector, which is essential for electric deadman lines. Remove the screws to separate the backing, then feed the deadman line through the opening where the crimp was removed.
Step 2: Expose the Conductor Wires
Use a razor knife to score the line about two inches from the end, taking care not to press too hard and damage the inner conductor wires. After scoring, remove the outer protective cover with wire strippers, revealing the three inner wires: green (ground), white (neutral), and black (hot). Strip about 0.5 to 0.75 inches of insulation from each wire.
Step 3: Attach the Wires to the Twistlok Plug
Connect each wire to its corresponding terminal on the Twistlok plug: green wire to the green screw terminal, black wire to the gold/bronze screw terminal, and white wire to the silver screw terminal. Ensure no exposed wires are visible outside the terminal to maintain a safe and secure connection.
Step 4: Reassemble the 3-Prong Twistlok Connector
Align the base of the Twistlok with the terminal plug, making sure all three screws are positioned correctly. Carefully tighten the screws to secure the wires without over-tightening. Slide the weatherproofing donut into place, then fit the crimp pieces that stabilize the deadman line. Finally, tighten the screws to ensure the wire is centered and secure.
Field Repairs and Rewiring Tips
When repairing a deadman line in the field, inspect the entire length of the lead for any damage. Look for exposed copper conductors or damaged sections that could compromise safety. After inspection, follow the above steps to rewire or repair the line, ensuring a secure and efficient connection.
