Marechal Electric Meltric DR User manual

A company of MARECHAL ELECTRIC GROUP
GENERAL
Meltric’s DR, DR7c and DS7c series industrial plugs
and receptacles are designed to ensure user safety
and provide reliable connections. Please follow the
instructions below to ensure the proper installation and
use of the 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.
RATINGS
These products are manufactured and rated in
compliance with applicable UL and CSA standards.
The products ratings are indicated on the device labels.
Some DR, DR7 and DS7 devices are provided with
optional auxiliary contacts that make after and break
before the phase contacts. The ratings for auxiliary
contacts are shown in Table 1.
INSTALLATION
These products 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 2.
General Notes & Precautions
1. Self-tapping screws are provided for use with
some polymeric accessories. High torque may
be required to drive them in. 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. Wire strip lengths are indicated in Table 3. Strip
lengths for cable sheathing will depend on the
specific application. When used with handles, the
cable sheathing should extend into the handle to
ensure secure cord gripping.
4. Wiring terminals are spring assisted to prevent
loosening due to wire strand settlement, vibration
and thermal cycling. NOTICE: They should not
be over-tightened. Appropriate tools and
tightening torques are indicated in Table 4.
5. 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.
Assembly for In-Line Connections
Do not overtighten terminal or self-tapping
screws. Tighten screws to the proper torque to
ensure a secure connection.
When these products are used as in-line connectors,
finger drawplates (or a drawbar mechanism) 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 the
lengths indicated in Table 3 and twist the strands of
each conductor together.
Back out the terminal screws on the receptacle (or
inlet) far enough (but not completely) to allow the
conductors to pass, insert the conductors fully into their
respective terminals and tighten the terminal screws
with the appropriate tool to the torque
indicated in Table 4.
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. Adjust the cable
location so that it will not be under tension inside the
handle and tighten the compression nut to secure the
cable.
Assembly for Mounted Receptacles (or Inlets)
In applications where the receptacles (or inlets) are
mounted to wall boxes, panels or other equipment,
optimal operation is achieved when the device is
installed with the latch at the top.
Insert the cable or wires through the wall box and
cut to allow adequate length, strip the cable sheath
as desired, strip the individual wires to the lengths
indicated in Table 3, and twist the strands of each
conductor together. Back out the terminal screws on
the receptacle (or inlet) far enough (but not completely)
to allow the conductors to pass, insert the conductors
fully into their respective terminals and hand tighten the
terminal screws to the torque indicated in Table 4.
Assemble the receptacle (or inlet) and the color-
coded gasket to the box with the appropriate hardware.
Assemble the mating plug (or receptacle) to the cord
end as indicated in the assembly instructions above
for in-line connections, except there will be no finger
drawplate or associated black gasket.
Compression
Nut
Handle
Strain
Relief
Color-Coded
Gasket
Receptacle
(or Inlet)
Bushing
Finger Drawplate Gasket
Finger Drawplate
Table 2 - Wiring Terminal Capacity1(in AWG) Cable Range OD
Main Aux.
Contacts Contacts2
Device Min Max Max
DR30 14 8 14 .30 1.38
DR50 14 4 14 .51 1.38
DR100 10 2 143.50 1.81
DR150 4 2/0 143.50 1.81
DR250 4 4/0 143.87 2.40
DR40042 350 MCM 143 2.09 2.87
DS7c/DR7c 14 8 10 .50 1.81
1 Capacity is based on THHN wire sizes
2Auxiliary contacts are optional and may not be on all products.
3Auxiliary contacts are prewired at the factory.
4Use with 75 degree C wire.
Min Max
Blue
Casings
OPERATING INSTRUCTIONS
Meltric Corporation / 4765 W. Oakwood Park Drive Franklin, WI 53132
Tel. : [phone] / Fax : [phone] / e-mail : [email protected]
INSDR/DR7/DS7 H
A manufacturer of products using Marechal technology
meltric.com
DR/DR7C/DS7C
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Table 1 - Auxiliary Contact Ratings
Device 120VAC 240VAC 480VAC 600VAC
DR30,DR50,DR100 6A 3A 1.5A 1.2A
DR150, DR400 1.5A 0.75A .375A .30A
DR225, DR250 3A 1.5A .75A 0.6A
DS7c – – 5A (400V max)* –
DR7c – 5A* – –
* Rating is not UL or CSA listed
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Table 4 - Terminal Screw Tightening Torques
Torque Required Screwdriver
Device/Contact in-lbs N-m or Allen Wrench
DR30 Phase 15 1.7 4 mm or 3/16” precision tip
Auxil. 13 1.5 4 mm or 3/16” precision tip
DR50 Phase 15 1.7 5 mm or 3/16” precision tip
Auxil. 7 .8 3 mm or 1/8” precision tip
DR100 Phase 48 5.4 4 mm hex head
DR150 Phase 90 10.2 4 mm hex head
DR250 Phase 130 14.7 5 mm hex head
DR400 Phase 90 10.2 4 mm hex head
DS7c/DR7c Phase 16 1.8 3.5 mm or 1/8” precision tip
Table 3 - Wire Strip Lengths – Dimensions A
Receptacle Plug/Inlet
Device/Contact Inches mm Inches mm
DR30 Phase 7/16 11 3/4 19
Auxil. 1/2 13 3/4 19
DR50 Phase 9/16 14 7/8 22
Auxil. 1/2 13 5/8 16
DR100 Phase 15/16 24 15/16 24
DR150 Phase 1 3/16 30 1 3/16 30
DR250 Phase 1 3/16 30 1 3/16 30
DR400 Phase 2 3/8 60 2 3/8 60
DS7c/DR7c Phase 1 1/16 27 1 1/16 27
DS7c/DR7c Auxil. 5/8 16 5/8 16

Hole Pattern for Custom Mounting
In applications where custom mounting to a panel
or box is desired, the clearance and mounting holes
should be drilled as indicated in the following diagram
and Table 5.
OPERATION
To ensure safe and reliable operation Meltric
plugs and receptacles must be used in
accordance with their assigned ratings.
Meltric plugs can only be used in conjunction with
mating receptacles or plugs manufactured by Meltric or
another licensed producer of products bearing the
TM technology trademark.
Meltric plugs & receptacles are designed with
different keying arrangements, so that only plugs and
receptacles with compatible contact configurations and
electrical ratings will mate with each other.
Connection
To connect a plug and receptacle, first depress the
pawl to open the lid on the receptacle, then orient the
plug as shown in figure 1 so that the red dot on the
outside of the casing lines up with the red dot just to
the left of the latch on the receptacle casing. Push the
plug partially into the receptacle until it hits a stop, then
rotate the plug in the clockwise direction until it hits
another stop after about 30° of rotation.
At this point, the circuit is still open. Push the plug
straight into the receptacle as shown in figure 2 until
it becomes securely latched in place. The electrical
connection is now made. On in-line connectors,
squeeze the drawplates on both sides of the device
together until the plug latches in place.
On the DR150, DR250 & DR400 devices, an integral
mechanism provides easy connection of the plug to the
receptacle. With the DR150, DR250 & DR400 plug
partially inserted and rotated 30° so that it is positioned
for connection, place the wire clamps around the
boltheads as shown in figure 3
To pull the plug into the receptacle, simply push the
handles back along the side of the receptacle and then
push the plug into the receptacle until the plug
is latched in place, as shown in figure 4. After
connection, the mechanism must be released to
allow disconnection of the device.
Disconnection
To break the connection, simply depress the pawl
as shown in figure 5. This will break the circuit and
eject the plug straight out to the rest, or off, position.
The plug contacts are de-energized at this point. To
remove the plug, rotate it counter-clockwise (about 30°)
until it releases from the receptacle as shown in figure
6. Close and latch the lid on the receptacle.
Achieving Environmental Ratings and Watertightness
For devices rated Type 4, 4X or 3R, use only
with mating devices having identical markings to
maintain enclosure rating of the mated pair.
Rated ingress protection applies to the device when
the plug and receptacle are mated and latched
together. It also applies to the receptacle when the lid
is latched closed.
Lockout Provisions
Some Meltric plugs are provided with lockout
provisions. To lockout the plug, insert a locking device
through the hole provided in the casing.
This will prevent the plug from being inserted into
a receptacle.
Some receptacles may be purchased with optional
lockout provisions and used with 5/16-inch shank
locks. To lockout the receptacle, close and latch the
lid and then attach the locking device through the hole
provided in the pawl. This will prevent the lid from
being opened for the insertion of a plug.
NOTICE: Attaching the receptacle locking device with
the receptacle lid open will not prevent the insertion of
a plug. Lockout of the receptacle is only accomplished
when the lid is locked closed.
MAINTENANCE
Before inspecting, repairing, or
maintaining Meltric products,
disconnect electrical power to the receptacle to
eliminate the risk of electrical shock.
Meltric products require little on-going maintenance.
However, it is a good practice to periodically perform
the following general inspections:
• Check the mounting screws for tightness.
• Verify that the weight of the cable is supported
by the strain relief mechanism and not by the
terminal connections.
• Check the IP gaskets for wear and resiliency.
Replace as required.
• Verify the electrical continuity of the ground circuit.
• Check the contact surfaces for cleanliness and
pitting.
Deposits of dust or similar foreign materials can be
rubbed off the contacts with a clean cloth. Sprays
should not be used, as they tend to collect dirt. If
any significant pitting of the contacts or other serious
damage is observed, the device should be replaced.
Receptacle contacts may be inspected by a qualified
electrician. This should only be done with the power
off. It is accomplished by depressing the numbered
ring around the circumference of the interior on two
opposite points. This will allow the shutter to be
manually turned clockwise as required to permit access
to the contacts. Once the inspection is complete, the
shutter must be rotated counter-clockwise until it is
locked in the closed position.
MANUFACTURER’S RESPONSIBILITY
Meltric’s responsibility is strictly limited to the repair or
replacement of any product that does not conform to
the warranty specified in the purchase contract. Meltric
shall not be liable for any penalties or consequential
damages associated with the loss of production, work,
profit or any financial loss incurred by the customer.
Meltric Corporation shall not be held liable when its
products are used in conjunction with products not
bearing the ™technology trademark. The use
of Meltric products in conjunction with mating devices
that are not marked with the ™technology
trademark shall void all warranties on the product.
Meltric Corporation is an ISO 9001 certified company.
Its products are designed, manufactured and rated in
accordance with applicable UL, CSA and IEC standards.
Meltric designs and manufactures its products in accor-
dance with Marechal keying standards established
to ensure intermatablility with similarly rated products
manufactured by Marechal Electric Group.
INSDR/DR7/DS7 H
Table 5 - Custom Mounting Dimensions
‘A’ ‘B’ ‘C’
Model Inches mm Inches mm Inches mm
DR30 2.25 57 1.89 48 .19 5
DR50 2.50 64 2.17 55 .19 5
DR100 3.25 83 2.59 66 .22 5.5
DR150 4.00 102 3.20 81 .22 5.5
DR250 4.50 114 3.86 98 .28 7
DR400 4.50 114 3.86 98 .28 7
DS7c/DR7c 3.25 83 2.59 66 .22 5.5
C
A
B
B
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