Meltric DR Series Operating Instructions

DR, DSR,
DN7 & DS7
Rev. A
Meltric Corporation
4640 Ironwood Drive
Franklin, WI 53132
(800)433-7642
www.meltric.com

GENERAL

Meltric's DR, DSR, DN7, and DS7 series industrial
plugs and receptacles are designed to ensure user
safety and provide reliable connections. Please fol-
low the instructions below to ensure the proper instal-
lation and use of the product.

RATINGS

These products are manufactured and rated in com-
pliance with applicable UL and CSA standards. The
products ratings are indicated on the device labels.

INSTALLATION

These products should be installed by qualified elec-
tricians in accordance with all applicable local and
national electrical codes. Before starting, verify that
the power is off, that the product ratings are appropri-
ate for the application, and that the conductors meet
code requirements and are within the capacities of
the terminals noted in Table 1.
Table 1 - Wiring Terminal Capacity
Main Contacts
Device Minimum Maximum
DR 30A 14 8
DR 50A 12 4
DR 100A 6 2
DR 150A 4 2/0
DR 225A 4 4/0
DR 250A 4 4/0
DSR 50A 12 4
DSR 100A 6 2
DSR 150A 4 2/0
DN7 50A 14 6
DN7 90A 8 2
DN7 150A 4 2/0
DS7/DR7 14 6
Capacity is based on THHN wire sizes.
1
Auxiliary contacts are optional and may not be on all products.
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 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.
Table 2 - Wire Strip Lengths – Dimensions A
Issued: 06/06/2006
Device
DR 30A
DR 50A
DR 100A
DR 150A
DR 225A
DR 250A
DSR 50A
DSR 100A
DSR 150A
DN7 50A
DN7 90A
DN7 150A phase
DN7 150A ground
DS7/DR7 phase
DS7/DR7 auxiliary
4. 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.
Table 3 - Terminal Screw Tightening Torques
Device
DR 30A
DR 50A
DR 100A
DR 150A
DR 225A
DR 250A
DSR 50A
DSR 100A
DSR 150A
DN7 50A
DN7 90A
(in AWG)
DN7 150A
1
Aux. Contacts
DS7/DR7
2
Maximum
8

Assembly for In-Line Connections

12
14
When these products are used as in-line connectors,
14
finger drawplates (or a drawbar mechanism) should
14
be installed on both the receptacle and plug in order
14
for the user to more easily provide the leverage
12
required to connect the device.
14
14
n/a
n/a Bushing
10
10
Strain
Relief
Compression
Nut
Receptacle Plug/Inlet
Inches mm Inches
1/2 12 3/4
9/16 14 7/8
15/16 24 15/16
1 3/16 30 1 3/16
1 3/16 30 1 3/16
1 3/16 30 1 3/16
9/16 14 7/8
15/16 24 15/16
1 3/16 30 1 3/16
3/4 20 3/4
1 25 1
1 26 1
5/8 17 5/8
1 1/16 27 1 1/16
5/8 15 5/8
Torque Required Screwdriver
in-lbs N-m or Allen Wrench
13 1.5 4 mm or 3/16" precision tip
16 1.8 5 mm or 3/16" precision tip
35 4.0 1/4" precision tip
80 9.0 4 mm hex head
130 15.0 5 mm hex head
130 15.0 5 mm hex head
16 1.8 5 mm or 3/16" precision tip
35 4.0 1/4" precision tip
80 9.0 4 mm hex head
13 1.5 4 mm or 3/16" precision tip
30 3.5 7 mm or 1/4" precision tip
80 9.0 4 mm hex head
16 1.8 3.5 mm or 1/8" precision tip
Finger Drawplate Gasket
Finger Drawplate
Handle Color-Coded Receptacle
Gasket (or Inlet)
Adjust the bushing diameter to fit the cable by remov-
ing inner sections of it as required. Insert the bush-
ing 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 recep-
tacle (or inlet), the color coded gasket, the finger
drawplate, and the thin black drawplate gasket to the
mm
handle with the four self-tapping screws provided.
19
Adjust the cable location so that it will not be under
22
tension inside the handle and tighten the compres-
24
sion nut to secure the cable.
30
30

Assembly for Mounted Receptacles (or Inlets)

30
22
In applications where the receptacles (or inlets) are
24
mounted to wall boxes, panels or other equipment,
30
optimal operation is achieved when the device is
20
installed with the latch at the top.
25
26
17
27
15
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 indi-
cated in Table 2, and twist the strands of each con-
ductor 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 hard-
ware. Assemble the mating plug (or receptacle) to
the cord end as indicated in the assembly instruc-
tions 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.