Meltric DSDC User Manual

Dsdc, Operating instructions, Warning danger caution notice

GENERAL

Meltric’s DSDC Series industrial plugs and

receptacles provide safe and robust connections

for direct current applications up to 750 VDC. The

DSDC’s spring-loaded, silver-nickel, butt contacts and

dead front construction provide more consistent and

reliable connections and significant improvements in

operator safety. 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. DSDC plugs and receptacles are

not designed for current interrupting. Standard

locking features should be used to prevent accidental

connection or disconnection under load. 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.

INSTALLATION

These products should be installed by qualified

personnel in accordance with all applicable

local and national electrical codes.

Before installing, 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 1.

General Notes & Precautions

1. Self-tapping screws are provided for use with

some polymeric accessories. High torque may

be required to drive them in.

NOTICE: 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 2. 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. For some applications a jumper may be

supplied between terminals and should not be

removed.

5. Wiring terminals are spring assisted to prevent

loosening due to stand settlement, vibration and

thermal cycling. They should not be over-tightened.

Appropriate tools and tightening torques are

indicated in Table 3.

NOTICE: Proper steps must be taken to maintain

watertightness at NPT fittings on the plug handles

or at the junction box. Use of sealer tape is

recommended.

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. On the larger sized

DSDC9 and DSDC2, the finger drawplates are not

needed because an easy closing mechanism is

provided as standard.

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 2

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 3.

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 and with the force

of the cable being exerted in a downward direction

opposite the latch.

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 2, 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 3.

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.

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 4.

Compression

Nut

Handle

Strain

Relief

Color-Coded

Gasket

Receptacle

(or Inlet)

Bushing

Finger Drawplate Gasket

Finger Drawplate

Table 2 - Wire Strip Lengths – Dimensions A

Receptacle

Plug/Inlet

Device/Contact Inches mm Inches mm
DSDC1 Phase

7/16

3/4

DSDC3 Phase 9/16 14 7/8 22

DSDC6 Phase 15/16 24 15/16 24

DSDC9

Phase

1 3/16

DSDC2

Phase

1 3/16

Table 3 - Terminal Screw Tightening Torques

Torque

Required Screwdriver

Device/Contact in-lbs N-m

or Allen Wrench

DSDC1 Phase 15 1.7 4 mm or 3/16” precision tip

DSDC3 Phase 25 2.8 5 mm or 3/16” precision tip

DSDC6 Phase 48 5.4

4 mm hex head

DSDC9 Phase 90 10.2

4 mm hex head

DSDC2 Phase 110 12.4

5 mm hex head

Table 1 - Wiring Terminal Capacity

(in AWG)

Cable Range OD

Main

Contacts

Device

Min

Max

DSDC1

.30 1.380

DSDC3

.51 1.380

DSDC6

.50 1.812

DSDC9

2/0

.50 1.812

DSDC2

4/0

.87 2.400

Capacity is based on THHN wire sizes

2/0 AWG if part number does not include the ‘A06’ suffix.

Min

Max

Table 4 - Custom Mounting Dimensions

‘A’

‘B’

‘C’

Model

Inches mm Inches mm Inches mm

DSDC1

2.25 57 1.89 48

.19 5.0

DSDC3

2.50 64 2.17 55

.19 5.0

DSDC6

3.25 83 2.59 66

.22 5.5

DSDC9

4.00 102 3.20 81

.22 5.5

DSDC2

4.50 114 3.86 98

.28 7.0

OPERATING INSTRUCTIONS

Meltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : [email protected]

A manufacturer of products using Marechal technology

meltric

.com

DSDC

INSDSDC D

WARNING

DANGER

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