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
associated with electrical
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.
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.
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.
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.
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.
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.
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
panel or box + angle,
the mating connector
(rece 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.
Compression
Nut
Handle
Strain
Relief
Color-Coded
Gasket
Receptacle
(or Inlet)
Bushing
Finger Drawplate Gasket
Finger Drawplate
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
Table 3 - Wiring Terminal Capacity
1
(in AWG)
Cable Range OD
Main
Aux.
Contacts Contacts
2
Device Min
Max
Max
DR30 14
8
14 .30 1.38
DR50 14
4
14 .51 1.38
DR100 10
2
14
3
.50 1.81
DR150 4 2/0
14
3
.50 1.81
DR250 4 4/0
14
3
.87 2.40
DR400
4
2
350 MCM
14
3
2.09 2.87
DS7c/DR7c 14
10
8
.50
1.81
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.
Min
Max
Blue
Casings
Table 5 - Terminal Screw Tightening Torques
Torque
Required Screwdriver
Device/Contact in-lbs N-m
or Allen Wrench
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 130 14.7
5 mm hex head
DR400
Phase 90 10.2
4 mm hex head
DS7c/DR7c
Phase 16 1.8 3.5 mm or 1/8” precision tip
Table 4 - Wire Strip Lengths – Dimensions A
Receptacle
Plug/Inlet
Device/Contact Inches mm Inches mm
DR30
Phase
7/16
10
3/4
19
Auxil.
7/16 10
3/4
19
DR50
Phase
3/4
18
7/8
22
Auxil.
7/16 10
3/4
19
DR100
Phase
15/16
24
15/16
24
DR150 Phase 1-3/16 30 1-3/16 30
DR250 Phase 1-5/8 30 1-5/8 30
DR400 Phase 2-3/8 60 2-3/8 60
DS7c/DR7c Phase
1-1/16
27
1-1/16
27
Auxil. 5/8 16 5/8 16
DR/DR7
c
/DS7
c
OPERATING INSTRUCTIONS
*
Rating applies with fusing up to this amperage. Ratings are based on tests
performed with Mersen non-time delay current limiting fuses.
Table 2 - Auxiliary Contact Ratings
Device
120VAC 240VAC
480VAC
600VAC
DR30, DR50 6A 3A 1.5A 1.2A
DR100
6A 3A 1.5A 1.2A
2 Aux
DR100
3A 1.5A .75A
.6A
3 & 4 Aux
DR150, DR400
1.5A
.75A
.37A
.3A
DR225, DR250
3A
1.5A
.75A
.6A
DS7c
–
–
5A (400V max)*
–
DR7c
– 5A* –
–
* Rating is not UL or CSA listed
Table 1 - Short Circuit Withstand Rating
Device
Fuse Rating
Type*
DR30
30A
100kA @ 600 VAC
RK5
30A
RK1
30A
DR50
50A
100kA @ 600 VAC
RK1
50A
DR100
100A
100kA @ 600 VAC
RK1
100A
DR150
150A
65kA @ 600 VAC
RK1
175A
DR250
250A
10kA @ 600 VAC
RK1
250A
DR400
400A 18kA @ 600 VAC/VDC
RK1
400A
180°
180°
Type 4X
rated
devices
Type 3R
rated devices
DR/DR7C/DS7C
ENGLISH OPERATING INSTRUCTIONS
A COMPANY OF MARECHAL ELECTRIC
MELTRIC Corporation / 4765 W. Oakwood Park Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 433 2701 / e-mail : [email protected]
INSDR/DR7/DS7 K
A manufacturer of products using
MARECHAL
®
TECHNOLOGY
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