Meltric DR Series - Manual

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 3 - Wire Strip Lengths – Dimensions A
Receptacle Plug/Inlet
Device/Contact Inches mm Inches mm
DR30A Phase 7/16 11 3/4 19
Auxil. 1/2 13 3/4 19
DR50A Phase 9/16 14 7/8 22
Auxil. 1/2 13 5/8 16
DR100A Phase 15/16 24 15/16 24
DR150A Phase 1 3/16 30 1 3/16 30
DR250A Phase 1 3/16 30 1 3/16 30
DS7c/DR7c Phase 1 1/16 27 1 1/16 27
DS7c/DR7c Auxil. 5/8 16 5/8 16
Table 2 - Wiring Terminal Capacity 1 (in AWG) Cable Range OD
Main Aux.
Contacts Contacts 2
Device Min Max Max
DR 30A 14 8 14 .30 1.380
DR 50A 14 4 14 .51 1.380
DR 100A 10 2 14 3 .50 1.812
DR 150A 4 2/0 14 3 .50 1.812
DR 250A 4 4/0 14 3 .87 2.400
DS7c/DR7c 14 8 10 .50 1.812
1 Capacity is based on THHN wire sizes
2 Auxiliary contacts are optional and may not be on all products.
3 Auxiliary contacts are prewired at the factory.
Min Max
Blue
Casings
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
DS7c/DR7c Phase 16 1.8 3.5 mm or 1/8” precision tip
Table 1 - Auxiliary Contact Ratings
Device 120VAC 240VAC 480VAC 600VAC
DR30,DR50,DR100 6A 3A 1.5A 1.2A
DR225, DR250 3A 1.5A .75A 0.6A
DS7c – – 5A (400V max)* –
DR7c – 5A* – –
* Rating is not UL or CSA listed
OPERATING INSTRUCTIONS
Meltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : [email protected]
INSDR/DR7/DS7 E
A manufacturer of products using Marechal technology
meltric .com
DR/DR7C/DS7C
WARNING