Meltric DR, DR7C, DS7C Operating Instructions

WARNING

ENGLISH OPERATING INSTRUCTIONS

A

COMPANY OF MARECHAL ELECTRIC

OPERATING INSTRUCTIONS

DR/DR7C/DS7C

©2019 MELTRIC Corporation. All rights reserved.

DR/DR7c/DS7c

A manufacturer of products using MARECHAL

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

products. Failure to follow safety precautions can
result in serious injury or death. These instructions must
be followed to ensure the safe and proper installation,
operation and maintenance of the MELTRIC devices.
Before installation, disconnect all sources of power to
the circuit to eliminate the risk of electrical shock.

RATINGS

All DR devices are rated to withstand short circuit
currents with appropriate fusing as indicated in Table 1.

Table 1 - Short Circuit Withstand Rating

Device Fuse Rating Type*

DR30 30A 100kA @ 600 VAC

DR50 50A 100kA @ 600 VAC RK1 50A
DR100 100A 100kA @ 600 VAC RK1 100A
DR150 150A 65kA @ 600 VAC RK1 175A
DR225 225A 10kA @ 600 VAC RK1 250A
DR250 250A 10kA @ 600 VAC RK1 250A
DR400 400A 18kA @ 600 VAC/VDC RK1 400A

* 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.

Table 2 - Auxiliary Contact Ratings

Device 120VAC 240VAC 480VAC 600VAC

DR30, DR50 6A 3A 1.5A 1.2A
DR100

2 Aux
DR100

3 & 4 Aux
DR150, DR400 1.5A .75A .37A .3A

DR225, DR250 1.5A .75A .37A .3A
DS7c – – 5A (400V max)* –
DR7c – 5A* – –

* Rating is not UL or CSA listed

associated with electrical

6A 3A 1.5A 1.2A

3A 1.5A .75A .6A

INSDR/DR7/DS7 O

®

TECHNOLOGY

RK5 30A

RK1 30A

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
product ratings are appropriate for the application,
and that the conductors meet code requirements
and are within the capacities of the terminals noted
in Table 3.

Table 3 - Wiring Terminal Capacity1 (in AWG)

Device

DR30
DR50
DR100
DR150
DR250

4

DR400
DS7c/DR7c

1

Capacity is based on THHN wire sizes

2

Auxiliary contacts are optional and may not be on all products.

3

Auxiliary contacts are prewired at the factory.

4

Use with 75 degree C wire.

Main Contacts

Min Max Max

14 8 14
14 4 14
10 2 14

4 2/0 14
4 4/0 14

350 MCM

2

14 8 8

Aux.

Contacts

3

3

3

3

14

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 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

Receptacle Plug/Inlet

Device/Contact Inches mm Inches mm

DR30 Phase 7/16 10 3/4 19

DR50 Phase 3/4 18 7/8 22

DR100 Phase 15/16 24 15/16 24
DR150 Phase 1-3/16 30 1-3/16 30
DR225,DR250Phase 1-1/2 30 1-1/2 30
DR400 Phase 2-3/8 60 2-3/8 60
DS7c/DR7c Phase 1-1/16 27 1-1/16 27

Auxil. 7/16 10 3/4 19

Auxil. 7/16 10 3/4 19

Auxil. 5/8 16 5/8 16

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 threaded handles come with
tapered style threads. 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 15 1.7 4 mm or 3/16” precision tip

Auxil. 13 1.5 4 mm or 3/16” precision tip

DR50 Phase 15 1.7 5 mm or 3/16” precision tip

Auxil. 7 .8 3 mm or 1/8” precision tip
DR100 Phase 48 5.4 4 mm hex head
DR150 Phase 90 10.2 4 mm hex head
DR250 Phase 110-133 12.5-15.0 5 mm hex head
DR400 Phase 70-90 7.9-10.1 4 mm hex head
DS7c/DR7c Phase 16 1.8 3.5 mm or 1/8” precision tip

Torque

in-lbs N-m

Required Screwdriver or

Allen Wrench

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 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 the device.

Bushing

Compression

Nut

Strain
Relief

Handle

Finger Drawplate Gasket

Finger Drawplate

Color-Coded

Gasket

Receptacle

(or Inlet)

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.

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-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

For reverse service
applications having inlets
rigidly moutned to a wall

Type 3R
rated devices

180°

180°

Type 4X
rated
devices

panel or box + angle,
the mating connector
(receptacle + handle)
may require a 180°
Open Lid.

Most DR Receptacles
have 180° open lids
as standard. They are
an available option on;
DR100 metal, DR150
metal, DR250, DR7c
metal and DS7c metal.

For reverse service

WARNING

applications where use
of a receptacle with a
180° Open Lid is not

Type 4X

possible, install inlet

Type 3R

rated devices

Periodic inspection and replacement of the gaskets may be
required to maintain water tightness in the pictured Type
4X installations.

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.

C

Table 6 - Custom Mounting Dimensions

‘A’ ‘B’ ‘C’

Model Inches mm Inches mm Inches mm

DR30 2.25 57 1.89 48 .19 5
DR50 2.50 64 2.17 55 .19 5
DR100 3.25 83 2.59 66 .22 5.5
DR150 4.00 102 3.20 81 .22 5.5
DR250 4.50 114 3.86 98 .28 7
DR400 4.50 114 3.86 98 .28 7
DS7c/DR7c 3.25 83 2.59 66 .22 5.5

OPERATION

To ensure safe and reliable operation MELTRIC
plugs and receptacles must be used in
accordance with their assigned ratings.

MELTRIC plugs can only be used in conjunction
with mating receptacles or plugs manufactured by
MELTRIC or another licensed producer of products
bearing the technology trademark.

MELTRIC plugs & receptacles are designed with
different keying arrangements, so that only plugs and
receptacles with compatible contact configurations and
electrical ratings will mate with each other.

Connection

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.

rated

with latch on bottom.

devices

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.

B

A

1

B

2

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, place the wire clamps around the
boltheads as shown in figure 3

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

Standard Locking Pawl ­5/16" hole (standard).

DR400 receptacles are
provided with a screw-type
locking pawl that prevents
accidental disconnections
under load.

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.

5

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 are mated and latched
together. It also applies to the receptacle when the lid
is latched closed.

Lockout Provisions

Some MELTRIC plugs are provided with lockout
provisions. 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.

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 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.

4

6

MAINTENANCE

Before inspecting, repairing, or

disconnect electrical power to the receptacle to
eliminate the risk of electrical shock.

MELTRIC products require little on-going maintenance.
However, it is a good practice to periodically perform
the following general inspections:

• Check the mounting screws for tightness.

• Verify that the weight of the cable is supported
by the strain relief mechanism and not by the
terminal connections.

• 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’s 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
trademark shall void all warranties on the product.

MELTRIC Corporation is an ISO 9001 certied 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.

maintaining MELTRIC products,

technology trademark. The use

technology

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.

INSDR/DR7/DS7 O