Marechal Electric Meltric DR Operating Instructions

OPERATING INSTRUCTIONS
DR/DR7C/DS7C
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
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
WARNING
associated with electrical
products. Failure to follow safety precautions can
DANGER
result 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.
Before installation, disconnect all sources of power to
NOTICE
the circuit to eliminate the risk of electrical shock.

RATINGS

ADVERTENCIA
These products are manufactured and rated in
DANGER
compliance with applicable UL and CSA standards.
The products ratings are indicated on the device labels.
CAUTION
Some DR, DR7 and DS7 devices are provided with
optional auxiliary contacts that make after and break
AVISO
before the phase contacts. The ratings for auxiliary
contacts are shown in Table 1.
Table 1 - Auxiliary Contact Ratings
Device 120VAC 240VAC 480VAC 600VAC
6A 3A
DR30,DR50,DR100
DR150, DR400 1.5A 0.75A
DR225, DR250 3A 1.5A
DS7c – –
DR7c – 5A*
* Rating is not UL or CSA listed

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
WARNING
product ratings are appropriate for the application, and
that the conductors meet code requirements
DANGER
and are within the capacities of the terminals noted
in Table 2.
CAUTION
NOTICE
Table 2 - Wiring Terminal Capacity
Device
DR30
DR50
DR100
DR150
DR250
DR400
4
DS7c/DR7c
Capacity is based on THHN wire sizes
1
Auxiliary contacts are optional and may not be on all products.
2
Auxiliary contacts are prewired at the factory.
3
Use with 75 degree C wire.
4
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
INSDR/DR7/DS7 H
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.
Table 3 - Wire Strip Lengths – Dimensions A
Device/Contact
DR30
DR50
DR100
DR150
DR250
DR400
DS7c/DR7c Phase
DS7c/DR7c Auxil.
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.
Table 4 - Terminal Screw Tightening Torques
Device/Contact in-lbs N-m
1.5A 1.2A
DR30
.375A .30A
DR50
.75A 0.6A
–
5A (400V max)*
DR100
– –
DR150
DR250
DR400
DS7c/DR7c
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.
WARNING
Cable Range OD
1 (in AWG)
Main Aux. Min
Contacts Contacts
2
Min Max Max
14 8 14 .30
14 4 14 .51
10 2 14 .50
3
4 2/0 14 .50
3
4 4/0 14 .87
3
2 350 MCM 14 2.09
3
14 8 10 .50
Receptacle Plug/Inlet
Inches mm Inches
Phase 7/16 11 3/4
Auxil. 1/2 13 3/4
Phase 9/16 14 7/8
Auxil. 1/2 13 5/8
Phase 15/16 24 15/16
Phase 1 3/16 30 1 3/16
Phase 1 3/16 30 1 3/16
Phase 2 3/8 60 2 3/8
1 1/16 27 1 1/16
5/8 16 5/8
Torque Required Screwdriver
or Allen Wrench
Phase 15 1.7 4 mm or 3/16" precision tip
Auxil. 13 1.5 4 mm or 3/16" precision tip
Phase 15 1.7 5 mm or 3/16" precision tip
Auxil. 7 .8 3 mm or 1/8" precision tip
Phase 48 5.4 4 mm hex head
Phase 90 10.2 4 mm hex head
Phase 130 14.7 5 mm hex head
Phase 90 10.2 4 mm hex head
Phase 16 1.8 3.5 mm or 1/8" precision tip
When these products are used as in-line connectors,
finger drawplates (or a drawbar mechanism) should be
Max
installed on both the receptacle and plug in order for
Blue
the user to more easily provide the leverage required
Casings
to connect the device.
1.38
1.38
Bushing
1.81
1.81
2.40
2.87
1.81
Strain
Relief
Compression Handle
Nut
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
mm
handle and tighten the compression nut to secure the
19 cable.
19
22

Assembly for Mounted Receptacles (or Inlets)

16
24
In applications where the receptacles (or inlets) are
30
mounted to wall boxes, panels or other equipment,
30 optimal operation is achieved when the device is
60
installed with the latch at the top.
27
16
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.
Finger Drawplate Gasket
Finger Drawplate
Color-Coded Receptacle
Gasket (or Inlet)