Marechal Electric MELTRIC DSDC Series Operating Instructions

ENGLISH OPERATING INSTRUCTIONS
DSDC
©2024 MELTRIC Corporation. All rights reserved.
meltric.com
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GENERAL
®
MELTRIC
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: 750 VDC DEVICES NOT UL LISTED.
WARNING
DANGER
result in serious injury or death. These instructions must be followed to
ensure the safe and proper installation, operation and maintenance of the
®
MELTRIC CAUTION
devices. DSDC plugs and receptacles are not designed for
current interrupting. Standard locking features should be used to prevent
NOTICE
accidental connection or disconnection under load. Before installation,
disconnect all sources of power to the circuit to eliminate the risk of
electrical shock.
ADVERTENCIA
DANGER
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RATINGS
CAUTION
These products are manufactured and rated in compliance with applicable
UL and CSA standards. The products ratings are indicated on the device
AVISO
labels.
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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
WARNING
appropriate for the application, and that the conductors meet code
requirements and are within the capacities of the terminals noted in Table 1.
DANGER
Table 1 - Wiring Terminal Capacity 1 (in AWG)
CAUTION
NOTICE
DSDC1
ADVERTENCIA
DSDC3
DANGER
DSDC6
DSDC9
CAUTION
DSDC2
AVISO
1 Capacity is based on THHN wire sizes
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.
Table 2 - Wire Strip Lengths - Dimensions A
Device/Contact
DSDC1
DSDC3
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
DSDC1
DSDC2
DSDC6
DSDC9
DSDC2
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.
When these products are used as in-line connectors, finger drawplates (or a
WARNING
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
DANGER
the device. On the larger sized DSDC9 and DSDC2, the finger drawplates
are not needed because an easy closing mechanism is provided as
CAUTION
standard.
NOTICE
ADVERTENCIA
DANGER
CAUTION
Compression
AVISO
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 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.
Model
DSDC1
DSDC3
DSDC6
DSDC9
DSDC2
The DSDC series offers a NEMA Type 3R or IP54/IP55 protection standard.
NOTICE: An option for Type 4X or IP66/IP67 protection is available in
custom installations. Watertight seals should be used under the heads of
the four mounting bolts and they must be retained by a lock washer and
nut on the inside of the box or panel. Alternatively, four blind holes may be
drilled and threaded to accomodate the mounting screws, provided that the
hole depth is sufficient to achieve adequate gasket compression.
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OPERATION
To ensure safe and reliable operation MELTRIC
receptacles must be used in accordance with their assigned ratings.
They can only be used in conjunction with mating receptacles or plugs
WARNING
manufactured by MELTRIC
bearing the
DANGER
®
MELTRIC
plugs & receptacles are designed with different keying
CAUTION
arrangements, so that only plugs and receptacles with compatible contact
configurations and electrical ratings will mate with each other.
NOTICE
Factory jumpers are installed on devices intended for applications of
ADVERTENCIA
600VDC and 750VDC. The figure below shows the location of these
jumpers, DO NOT REMOVE them.
DANGER
NOTE: 750 VDC DEVICES NOT UL LISTED.
WARNING
CAUTION
DANGER
AVISO
CAUTION
NOTICE
ADVERTENCIA
Dual Circuit DC Wiring Instruction for Non-Load Break Applications
DANGER
Some applications require connections with 2 separate DC circuits.
This requires 4 contacts (or 5 if a ground contact is used). In these cases: CAUTION
• L3 and L2 are used for the (+) and (-) of the up to 250 VDC circuit with AVISO
the highest voltage.
• L1 and N are used for the (+) and (-) of the up to 250 VDC circuit with
the lowest (or equal) voltage.
Connection
Verify the power source is de-energized.
DO NOT ENGAGE ON AN ENERGIZED CIRCUIT.
WARNING
To connect a plug and receptacle, first depress the pawl to open the lid on
DANGER
the receptacle, then orient the plug as shown in figure 1 so that the red dot
on the outside of the casing lines up with the red dot just to the left of the
CAUTION
latch on the receptacle casing. Push the plug partially into the receptacle
until it hits a stop, then rotate the plug in the clockwise direction until it hits
NOTICE
another stop after about 30° of rotation.
At this point, the circuit is still open. Push the plug straight into the
ADVERTENCIA
receptacle as shown in figure 2 until it becomes securely latched in place.
The electrical connection is now made. On in-line connectors, squeeze the
DANGER
drawplates on both sides of the device together until the plug latches in
place.
CAUTION
AVISO
As an added safety feature, the DSDC2 is provided with a "locking pawl"
to prevent any unintended connections. To mate the devices, loosen the
thumb screw on the pawl, and follow steps 1 and 2. On the DSDC9 and
DSDC2 devices, an integral mechanism provides easy connection of the
plug to the receptacle. With the DSDC9 or DSDC2 plug partially inserted
and rotated 30° so that it is positioned for connection, place the wire clamps
around the bolt heads as shown in figure 3.
To pull the plug into the receptacle, simply push the handles back along
the side of the receptacle and then push the plug into the receptacle until
the plug is latched in place, as shown in figure 4. On the DSDC2, tighten
the thumb screw on the pawl to prevent any unintended disconnection. A
locking device should be used when the devices are mated.
Disconnection
Before disconnection, verify the power source is de-energized.
DO NOT DISENGAGE ON AN ENERGIZED CIRCUIT.
To release the connection after the power source has been turned
WARNING
off, simply depress the pawl as shown in figure 5 . This will eject the
plug straight out to the rest, or off, position. To remove the plug, rotate it
DANGER
counter-clockwise (about 30°) until it releases from the receptacle as shown
in figure 6 . Close and latch the lid on the receptacle. As an added safety
CAUTION
feature, DSDC2 is proved with a "locking pawl" to prevent any unintended
disconnections. To disconnect the devices, loosen the thumb screw on the
NOTICE
pawl, and follow steps 5 and 6.
ADVERTENCIA
DANGER
CAUTION
AVISO
Achieving Environmental Ratings and Watertightness
For devices rated Type 4, 4X or 3R, use only with mating devices
having identical markings to maintain enclosure rating of the mated pair.
Rated ingress protection applies to the device when the plug and receptacle
WARNING
are mated and latched together. It also applies to the receptacle when the
lid is latched closed.
DANGER
Lockout Provisions
CAUTION
All DSDC devices are provided with lockout provisions, which are designed
NOTICE
for a 5/16" lock shank. These may be used to "lock" the devices together to
prevent unintended disconnection, or to lock out the receptacle or inlet. To
ADVERTENCIA
prevent an unintended disconnection, lock the devices together by inserting
a locking device through the hole provided in the pawl after the plug and
DANGER
receptacle have been connected.
CAUTION
To lockout the plug, insert a locking device through the hole provided in the
casing. This will prevent the plug from being inserted into a receptacle.
AVISO
To lockout the receptacle, close and latch the lid and then insert the locking
device through the hole provided in the pawl. This will prevent the lid from
being opened for the insertion of a plug.
MAINTENANCE
WARNING
DANGER
the receptacle to eliminate the risk of electrical shock.
®
CAUTION
MELTRIC
products require little on-going maintenance. However, it is a
good practice to periodically perform the following general inspections:
NOTICE
• Check the mounting screws for tightness.
ADVERTENCIA
• Verify that the weight of the cable is supported by the strain relief
DANGER
mechanism and not by the terminal connections.
CAUTION
• Check the IP gaskets for wear and resiliency. Replace as required.
AVISO
• Verify the electrical continuity of the ground circuit.
• Check the contact surfaces for cleanliness and pitting.
Deposits of dust or similar foreign materials can be rubbed off the contacts
with a clean cloth. Sprays should not be used, as they tend to collect dirt.
If any significant pitting of the contacts or other serious damage is observed,
the device should be replaced.
Receptacle contacts may be inspected by a qualified electrician. This
should only be done with the power off. It is accomplished by depressing
the numbered ring around the circumference of the interior on two opposite
points. This will allow the shutter to be manually turned clockwise as
required to permit access to the contacts. Once the inspection is complete,
the shutter must be rotated counter-clockwise until it is locked in the closed
position.
MANUFACTURER'S RESPONSIBILITY
®
MELTRIC
responsibility is strictly limited to the repair or replacement of
any product that does not conform to the warranty specified in the purchase
contract. MELTRIC
damages associated with the loss of production, work, profit or any financial
loss incurred by the customer.
®
MELTRIC
Corporation shall not be held liable when its products are used
in conjunction with products not bearing the
mark. The use of MELTRIC
that are not marked with the
warranties on product.
®
MELTRIC
Corporation is an ISO 9001 certified company. Its products
are designed, manufactured and rated in accordance with applicable
UL, CSA and IEC standards. MELTRIC
its products in accordance with Marechal keying standards established
to ensure intermatablility with similarly rated products manufactured by
Marechal Electric Group.
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
MODE D'EMPLOI
INSTRUCCIONES
There are inherent dangers associated with electrical
products. Failure to follow safety precautions can
Device
Phase
Phase
Phase
Phase
Phase
in-lbs
Phase 15
Phase 15
Phase 48
Phase 90
Phase 110
Bushing
Strain
Relief
Handle
C
Table 4 - Custom Mounting Dimensions
'A'
Inches
2.25
2.50
3.25
4.00
4.50
®
technology trademark.
Wire clamp
around bolthead
Before inspecting, repairing, or maintaining
MELTRIC
®
shall not be liable for any penalties or conse-quential
®
Main Contacts
Min
14
14
10
6
4
Receptacle
Inches mm
7/16 10
9/16 14
15/16 24
1 3/16 30
1 1/2 38
Torque
Required Screwdriver or
N-m
1.7 4mm or 3/16" precision tip
1.7 5mm or 3/16" precision tip
5.4
10.2
12.4
Finger Drawplate Gasket
Color-Coded
Gasket
B
'B'
mm Inches
57 1.89
64 2.17
83 2.59
102 3.20
114 3.86
or another licensed producer of products
®
products, disconnect electrical power to
products in conjunction with mating devices
technology trademark shall void all
®
designs and manufactures
Max
2/0
4/0
Plug/Inlet
Inches
3/4
7/8
15/16
1 3/16
1 1/2
Allen Wrench
4mm hex head
4mm hex head
5mm hex head
Finger Drawplate
Receptacle
(or Inlet)
B
mm Inches
48 .19
55 .19
66 .22
81 .22
98 .28
®
plugs and
3
4
technology trade-
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p
INSDSDC K
8
4
2
mm
19
22
24
30
38
'C'
mm
5.0
5.0
5.5
5.5
7.0
INSDSDC K