Marechal Electric MELTRIC DR Series Operating Instructions

ENGLISH OPERATING INSTRUCTIONS
DR/DR7C/DS7C
©2024 MELTRIC Corporation. All rights reserved.
A manufacturer of products using MARECHAL
meltric.com
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GENERAL
MELTRIC
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 associated with electrical products. Failure
WARNING
to follow safety precautions can result in serious injury or death. These
DANGER
instructions must be followed to ensure the safe and proper installation, operation and
CAUTION
maintenance of the MELTRIC
power to the circuit to eliminate the risk of electrical shock.
NOTICE
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RATINGS
ADVERTENCIA
DANGER
All DR devices are rated to withstand short circuit currents with appropriate fusing as
CAUTION
indicated in Table 1.
AVISO
Device
DR30 30 A
DR50 50 A
DR100 100 A
DR150 150 A
DR225 225 A
DR250 250 A
DR400 400 A
* Rating applies with fusing up to this amperage. Ratings are based on tests
performed with Mersen non-time delay current limiting fuses.
The DR products are manufactured and rated in compliance with applicable UL and
CSA standards. The products ratings are indicated on the device labels. Some DR,
DR7 and DS7 devices are provided with optional auxiliary contacts that make after
and break before the phase contacts. The ratings for auxiliary contacts are shown in
Table 2.
Device
DR30, DR50
DR100 2 Aux
DR100 3&4 Aux
DR150, DR400
DR225, DR250
DS7c
DR7c
* Rating is not UL or CSA listed
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INSTALLATION
These products should be installed by qualified electricians in accordance with all
applicable local and national electrical codes.
WARNING
Before starting, verify that the power is off, that the product ratings are appropriate for
DANGER
the application, and that the conductors meet code requirements and are within the
capacities of the terminals noted in Table 3.
CAUTION
NOTICE
Table 3 - Wiring Terminal Capacity
ADVERTENCIA
DANGER
Device
CAUTION
DR30
AVISO
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 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 4. 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 4 - Wire Strip Lengths - Dimensions A
Device/Contact
DR30
DR50
DR100
DR150
DR225, DR250
DR400
DS7c/DR7c
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 5.
5. NOTICE: MELTRIC
The use of fitting seal tape is recommended to maintain watertightness of all
NPT fittings and joints.
Table 5 - Terminal Screw Tightening Torques
Device/Contact
DR30 Phase
Auxil.
DR50 Phase
Auxil.
DR100 Phase
DR150 Phase
DR250 Phase
DR400 Phase
DS7c/DR7c Phase
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 for the user to DANGER
more easily provide the leverage required to connect the device.
CAUTION
NOTICE
Bushing
ADVERTENCIA
DANGER
CAUTION
AVISO
Compression
Nut
For poly handles with strain relief, adjust the bushing diameter to fit the cable by removing
inner sections of the bushing 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 4 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 5.
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.
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.
Reverse Service Installations
Type 3R
rated devices
180°
Type 3R
rated devices
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 6.
Model
DR30
DR50
DR100
DR150
DR250
DR400
DS7c/DR7c
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OPERATION
To ensure safe and reliable operation MELTRIC
used in accordance with their assigned ratings.
WARNING
MELTRIC plugs can only be used in conjunction with mating receptacles or plugs
®
DANGER
manufactured by MELTRIC
technology trademark.
CAUTION
NOTICE
MELTRIC plugs & receptacles are designed with different keying arrangements, so
®
that only plugs and receptacles with compatible contact configurations and electrical
ADVERTENCIA
ratings will mate with each other.
DANGER
Connection
CAUTION
AVISO
To connect a plug and receptacle, first depress the pawl to open the lid on 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 latch on the receptacle
casing. Using a straight motion, push the plug partially into the receptacle until it hits a
stop, then rotate the plug in the clockwise direction until it hits another stop after about
30° of rotation.
At this point, the circuit is still open. Push the plug straight into the receptacle as
shown in figure 2 until it becomes securely latched in place. On in-line connectors
with drawplates, squeeze the drawplates on both sides of the device together until
the plug latches in place.
On the DR150, DR250 & DR400 devices, an integral mechanism provides easy
connection of the plug to the receptacle. With the DR150, DR250 & DR400 plug
partially inserted and rotated 30° so that it is positioned for connection, hook the
clamps around the latches 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. The electrical connection is now made. The mechanism must
be released to allow disconnection of the device.
KEY FEATURE
Disconnection
To break the connection, simply depress the pawl as shown in figure 5.
This will break the circuit and eject the plug straight out to the rest, or off, position.
The plug contacts are de-energized at this point. To remove the plug, rotate it
counter-clockwise (about 30°) until it releases from the receptacle as shown in
figure 6. Close and latch the lid on the receptacle.
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.
WARNING
Rated ingress protection applies to the device when the plug and receptacle are mated
and latched together. It also applies to the receptacle when the lid is latched closed.
DANGER
CAUTION
Lockout Provisions
NOTICE
Some MELTRIC
®
ADVERTENCIA
insert a locking device through the hole provided in the casing. This will prevent the
plug from being inserted into a receptacle.
DANGER
CAUTION
Some receptacles may be purchased with optional lockout provisions and used with
5/16-inch shank locks. To lockout the receptacle, close and latch the lid and then
AVISO
attach the locking device through the hole provided in the pawl. This will prevent the
lid from being opened for the insertion of a plug.
NOTICE: Attaching the receptacle locking device with the receptacle lid open will not
prevent the insertion of a plug. Lockout of the receptacle is only accomplished when
the lid is locked closed.
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MAINTENANCE
Before inspecting, repairing, or maintaining MELTRIC
WARNING
disconnect electrical power to the receptacle to eliminate the risk of
DANGER
electrical shock.
CAUTION
MELTRIC products require little on-going maintenance. However, it is a good practice
®
NOTICE
to periodically perform the following general inspections:
• Check the mounting screws for tightness.
ADVERTENCIA
DANGER
• Verify that the weight of the cable is supported by the strain relief mechanism and
CAUTION
not by the terminal connections.
AVISO
• Check the IP gaskets for wear and resiliency. Replace as required.
• 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
shall not be liable for any penalties or consequential 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
of MELTRIC products in conjunction with mating devices that are not marked with the
technology trademark shall void all warranties on the 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 designs and manufactures its products in accordance with Marechal
®
keying standards established to ensure intermatablility with similarly rated products
manufactured by Marechal Electric Group.
MELTRIC Corporation
Tel. : 800 433 7642 / Fax : 414 433 2701 / e-mail : mail@meltric.com
INSTRUCCIONES
MODE D'EMPLOI
devices. Before installation, disconnect all sources of
®
Table 1 - Short Circuit Withstand Rating
Fuse Rating
100 kA @ 600 VAC
100 kA @ 600 VAC
100 kA @ 600 VAC
65 kA @ 600 VAC
10 kA @ 600 VAC
10 kA @ 600 VAC
18 kA @ 600 VAC/VDC
Table 2 - Auxiliary Contact Ratings
120 VAC
6 A
6 A
3 A
1.5 A
1.5 A
-
-
Inches
Phase 7/16
Auxil. 7/16
Phase 3/4
Auxil. 7/16
Phase 15/16
Phase 1-3/16
Phase 1-1/2
Phase 2-3/8
Phase 5/8
Auxil. 5/8
threaded handles come with tapered style threads.
®
Torque
in-lbs
15
13
15
7
48
90
110-133 12.5-15.0
70-90
16
Strain
Relief
Handle
Type 4X
rated
180°
Type 4X
devices
C
Table 6 - Custom Mounting Dimensions
'A'
Inches mm
2.25 57
2.50 64
3.25 83
4.00 102
4.50 114
4.50 114
3.25 83
or another licensed producer of products bearing the
®
1
3
Standard Locking Pawl - 5/16" hole (standard).
DR400 receptacles are provided with a screw-type
locking pawl that prevents accidental disconnections
under load.
5
plugs are provided with lockout provisions. To lockout the plug,
/ 4765 W. Oakwood Park Drive Franklin, WI 53132
240 VAC
3 A
3 A
1.5 A
.75 A
.75 A
- 5 A (400 V max)*
5 A*
Main Contacts
Min Max
14 8
14 4
10 2
4 2/0
4 4/0
2 350 MCM
14 8
Receptacle
mm
10
10
19
10
24
30
38
60
16
16
Required Screwdriver or
N-m
1.7
1.5
1.7
.8
5.4
10.2
7.9-10.1
1.8
Finger Drawplate Gasket
Finger Drawplate
Color-Coded
Gasket
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 4. 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 5.
Assemble the receptacle (or inlet) and the color-
For reverse service applications having
inlets rigidly moutned to a wall panel
or box + angle, the mating connector
(receptacle + handle) may require a 180°
Open Lid.
Most DR Receptacles have 180° open
devices
lids as standard. They are an available
option on; DR100 metal, DR150 metal,
DR250, DR7c metal and DS7c metal.
For reverse service applications where
use of a receptacle with a 180° Open Lid
is not possible, install inlet with latch
on bottom.
When facing downwards Type-3R inlets
do not protect mating connectors against
streaming water. Use Type-4X devices
or a rain hood for additional water
protection.
rated
Periodic inspection and replacement
of the gaskets may be required to
maintain water tightness in the pictured
Type 4X installations.
B
'B'
Inches mm
1.89
2.17
2.59
3.20
3.86
3.86
2.59
®
technology trademark. The use
INSDR/DR7/DS7 R
TECHNOLOGY
®
Type*
RK5
RK1
RK1
RK1
RK1
RK1
RK1
RK1
480 VAC
1.5 A
1.5 A
.75 A
.37 A
.37 A
-
(in AWG)
1
Auxiliary Contacts
Max
14
14
14
14
14
14
Plug/Inlet
Inches
3/4
3/4
7/8
5/8
15/16
1-3/16
1-1/2
2-3/8
1-1/16
5/8
Allen Wrench
4 mm or 3/16" precision tip
4 mm or 3/16" precision tip
5 mm or 3/16" precision tip
3 mm or 1/8" precision tip
4 mm hex head
4 mm hex head
5 mm hex head
4 mm hex head
3.5 mm or 1/8" precision tip
Receptacle
(or Inlet)
B
'C"
Inches
48 .19
55 .19
66 .22
81 .22
98 .28
98 .28
66 .22
plugs and receptacles must be
2
4
6
products,
®
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30 A
30 A
50 A
100 A
175 A
250 A
250 A
400 A
600 VAC
1.2 A
1.2 A
.6 A
.3 A
.3 A
-
-
2
3
3
3
3
8
mm
19
19
22
16
24
30
38
60
27
16
mm
5
5
5.5
5.5
7
7
5.5
®
INSDR/DR7/DS7 R