Meltric DSDC Series Operating Instructions Manual

ENGLISH OPERATING INSTRUCTIONS
DSDC
©2020 MELTRIC Corporation. All rights reserved.
MELTRIC Corporation / 4765 W. Oakwood Park Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 433 2701 / e-mail : mail@meltric.com
A manufacturer of products using MARECHAL® TECHNOLOGY
meltric.com

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.
NOTE: 750VDC DEVICES NOT UL LISTED.
There are inherent dangers
WARNING
associated with electrical
products. Failure to follow safety precautions can result
DANGER
in serious injury or death. These instructions must be
followed to ensure the safe and proper installation,
CAUTION
Operation and maintenance of the MELTRIC devices.
DSDC plugs and receptacles are not designed for current
NOTICE
interrupting. Standard locking features should be
used to prevent accidental connection or disconnection
under load. Before installation, disconnect all sources
ADVERTENCIA
of power to the circuit to eliminate the risk of electrical
DANGER
shock.

RATINGS

CAUTION
These products are manufactured and rated in compliance
AVISO
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.
WARNING
Before installing, verify that the power is off, that the
product ratings are appropriate for the application, and
DANGER
that the conductors meet code requirements and are
within the capacities of the terminals noted in Table 1.
CAUTION
Table 1 - Wiring Terminal Capacity
NOTICE
Device Min
DSDC1 14
ADVERTENCIA
DSDC3 14
DSDC6 10
DANGER
DSDC9 6
DSDC2 4
CAUTION
Capacity is based on THHN wire sizes
1
AVISO
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
INSDSDC J
supplied between terminals and should not be
removed.
WARNING
DANGER
CAUTION
NOTICE
Table 2 - Wire Strip Lengths – Dimensions A
ADVERTENCIA
DANGER
Device/Contact
CAUTION
DSDC1
DSDC3
AVISO
DSDC6
DSDC9
DSDC2
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.
Table 3 - Terminal Screw Tightening Torques
Device/Contact in-lbs N-m
DSDC1 Phase 15
DSDC3 Phase 15
DSDC6 Phase 48
DSDC9 Phase 90
DSDC2 Phase 110 12.4
6. 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.
WARNING
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 DANGER
for the user to more easily provide the leverage
required to connect the device. On the larger sized
CAUTION
DSDC9 and DSDC2, the finger drawplates are not
needed because an easy closing mechanism is
NOTICE
provided as standard.
ADVERTENCIA
Bushing
DANGER
(in AWG)
1
Main
CAUTION
Contacts
Max
AVISO
Strain
8
Relief
4
Compression
2
Nut
2/0
4/0
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
Receptacle Plug/Inlet
Inches mm Inches
Phase 7/16 10 3/4
Phase 9/16 14 7/8
Phase 15/16 24 15/16
Phase 1 3/16 30 1 3/16
Phase 1 1/2 30 1 1/2
Torque Required Screwdriver
or Allen Wrench
1.7 4 mm or 3/16" precision tip
1.7 5 mm or 3/16" precision tip
5.4 4 mm hex head
10.2 4 mm hex head
5 mm hex head
Finger Drawplate Gasket
Finger Drawplate
Color-Coded Receptacle
Handle
Gasket (or Inlet)
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)

mm In applications where the receptacles (or inlets) are
mounted to wall boxes, panels or other equipment,
19
optimal operation is achieved when the device is
22
24 installed with the latch at the top and with the force
30 of the cable being exerted in a downward direction
30 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.
C
Table 4 - Custom Mounting Dimensions
'A'
Model Inches mm Inches mm Inches mm
DSDC1 2.25 57
DSDC3 2.50 64
DSDC6 3.25 83
DSDC9 4.00 102
DSDC2 4.50 114
B
B
'B' 'C'
1.89 48 .19 5.0
2.17 55 .19 5.0
2.59 66 .22 5.5
3.20 81 .22 5.5
3.86 98 .28 7.0