OPERATING INSTRUCTIONS
WARNING
DR/DR7C/DS7C
NSDR/DR7/DS7 E
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eltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
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Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : mail@meltric.com
manufacturer of products using Marechal technology
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meltric.com
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
These 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 1.
Table 1 - Auxiliary Contact Ratings
Device 120VAC 240VAC 480VAC 600VAC
DR30,DR50,DR100 6A 3A 1.5A 1.2A
DR225, DR250 3A 1.5A .75A 0.6A
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
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 2.
associated with electrical
5A (400V max)* –
1
able 2 - Wiring Terminal Capacity
T
Device Min Max Max
R 30A 14 8 14 .30 1.380
D
R 50A 14 4 14 .51 1.380
D
DR 100A 10 2 14
DR 150A 4 2/0 14
DR 250A 4 4/0 14
S7c/DR7c 14 8 10 .50 1.812
D
1
Capacity is based on THHN wire sizes
2
uxiliary contacts are optional and may not be on all products.
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3
Auxiliary contacts are prewired at the factory.
eneral Notes & Precautions
G
. Self-tapping screws are provided for use with
1
ome polymeric accessories. High torque may
s
ain Aux.
M
ontacts Contacts
C
in AWG)
(
3
3
3
able Range OD
C
in Max
M
2
.50 1.812
.50 1.812
.87 2.400
Blue
Casings
be required to drive them in. Once they are
eated, care should be taken in order to avoid
s
over-tightening them against the plastic material.
. Various handles and cord grip options may be used.
2
These instructions are based on handles provided
ith integral multi-layer bushing cord grips.
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3. Wire strip lengths are indicated in Table 3. Strip
engths for cable sheathing will depend on the
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specific application. When used with handles, the
able sheathing should extend into the handle to
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nsure secure cord gripping.
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Table 3 - Wire Strip Lengths – Dimensions A
Device/Contact Inches mm Inches mm
DR30A Phase 7/16 11 3/4 19
Auxil. 1/2 13 3/4 19
DR50A Phase 9/16 14 7/8 22
Auxil. 1/2 13 5/8 16
DR100A Phase 15/16 24 15/16 24
DR150A Phase 1 3/16 30 1 3/16 30
DR250A Phase 1 3/16 30 1 3/16 30
DS7c/DR7c Phase 1 1/16 27 1 1/16 27
DS7c/DR7c Auxil. 5/8 16 5/8 16
Receptacle Plug/Inlet
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 or Allen Wrench
DR30 Phase 15 1.7 4 mm or 3/16” precision tip
DR50 Phase 15 1.7 5 mm or 3/16” precision tip
DR100 Phase 48 5.4 4 mm hex head
DR150 Phase 90 10.2 4 mm hex head
DR250 Phase 130 14.7 5 mm hex head
DS7c/DR7cPhase 16 1.8 3.5 mm or 1/8” precision tip
Torque Required Screwdriver
Auxil. 13 1.5 4 mm or 3/16” precision tip
Auxil. 7 .8 3 mm or 1/8” precision tip
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.
When these products are used as in-line connectors,
finger drawplates (or a drawbar mechanism) should
e installed on both the receptacle and plug in order
b
for the user to more easily provide the leverage
equired to connect the device.
r
ushing
B
Compression
Nut
S
R
train
elief
Handle
Finger Drawplate Gasket
inger Drawplate
F
olor-Coded
C
asket
G
eceptacle
R
or Inlet)
(
Adjust the bushing diameter to fit the cable by
emoving inner sections of it as required. Insert the
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bushing into the strain relief, then insert the assembly
nto the handle and loosely install the compression
i
ut. Insert the cable through the handle, the thin
n
black drawplate gasket and finger drawplate (if
pplicable) and the color coded gasket. Strip the
a
cable sheath to provide a workable wire length, being
mindful that the sheath must extend into the handle
o achieve a secure cord grip. Then strip the
t
individual wires to the lengths indicated in Table 3
nd twist the strands of each conductor together.
a
ack out the terminal screws on the receptacle (or
B
nlet) far enough (but not completely) to allow the
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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 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 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 colorcoded 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.
ole Pattern for Custom Mounting
WARNING
H
n applications where custom mounting to a panel
I
r box is desired, the clearance and mounting holes
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should be drilled as indicated in the following diagram
nd Table 5.
a
B
C
able 5 - Custom Mounting Dimensions
T
Model Inches mm Inches mm Inches mm
R 30A 2.25 57 1.89 48 .19 5
D
R 50A 2.50 64 2.17 55 .19 5
D
DR 100A 3.25 83 2.59 66 .22 5.5
DR 150A 4.00 102 3.20 81 .22 5.5
DR 250A 4.50 114 3.86 98 .28 7
DS7c/DR7c 3.25 83 2.59 66 .22 5.5
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‘A’ ‘B’ ‘C’
B
OPERATION
o ensure safe and reliable operation Meltric
T
lugs and receptacles must be used in
p
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
M
T
technology trademark.
isconnection
D
o break the connection, simply depress the pawl as
T
hown in figure 3 . This will break the circuit and
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eject the plug straight out to the rest, or off, position.
he plug contacts are de-energized at this point. To
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emove the plug, rotate it counter-clockwise (about
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0°) until it releases from the receptacle as shown in
3
igure 4 . Close and latch the lid on the receptacle.
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Check the mounting screws for tightness.
•
Verify that the weight of the cable is supported
•
by the strain relief mechanism and not by the
erminal connections.
t
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
itting.
p
Deposits of dust or similar foreign materials can be
ubbed off the contacts with a clean cloth. Sprays
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should not be used, as they tend to collect dirt. If
ny significant pitting of the contacts or other serious
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amage is observed, the device should be replaced.
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eceptacle contacts may be inspected by a qualified
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electrician. This should only be done with the power
ff. It is accomplished by depressing the numbered
o
ing around the circumference of the interior on two
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opposite points. This will allow the shutter to be
anually turned clockwise as required to permit
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access to the contacts. Once the inspection is
complete, the shutter must be rotated counter-
lockwise until it is locked in the closed position.
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ANUFACTURER’S RESPONSIBILITY
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eltric’s responsibility is strictly limited to the repair
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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 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. 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. The electrical
connection is now made. On in-line connectors,
squeeze the drawplates on both sides of the device
together until the plug latches in place.
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.
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.
Meltric Corporation shall not be held liable when its
products are used in conjunction with products not
bearing the
use of Meltric products in conjunction with mating
devices that are not marked with the
TM
technology trademark. The
M
T
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 is a also member of BECMA,
the international Butt-contact Electrical Connectors
Manufacturers’ Association. Like all members,
Meltric additionally designs and manufactures its
products in accordance with BECMA standards
established to ensure intermatablility with similarly
rated products manufactured by other members.
www.becma.ch
MAINTENANCE
Before inspecting, repairing, or
maintaining Meltric products,
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:
INSDR/DR7/DS7 E
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