Meltric DSDC - Manual

GENERAL
Meltric’s 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.
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. DSDC plugs and receptacles are
not designed for current interrupting. Standard
locking features should be used to prevent accidental
connection or disconnection under load. 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.
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 appropriate for the application, and
that the conductors meet code requirements and are
within the capacities of the terminals noted in Table 1.
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.
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.
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 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. On the larger sized
DSDC9 and DSDC2, the finger drawplates are not
needed because an easy closing mechanism is
provided as standard.
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.
Compression
Nut
Handle
Strain
Relief
Color-Coded
Gasket
Receptacle
(or Inlet)
Bushing
Finger Drawplate Gasket
Finger Drawplate
Table 2 - Wire Strip Lengths – Dimensions A
Receptacle Plug/Inlet
Device/Contact Inches mm Inches mm
DSDC1 Phase
7/16 10 3/4 19
DSDC3 Phase 9/16 14 7/8 22
DSDC6 Phase 15/16 24 15/16 24
DSDC9 Phase 1 3/16 30 1 3/16 30
DSDC2 Phase 1 3/16 30 1 3/16 30
C
A
B
B
Table 3 - Terminal Screw Tightening Torques
Torque Required Screwdriver
Device/Contact in-lbs N-m or Allen Wrench
DSDC1 Phase 15 1.7 4 mm or 3/16” precision tip
DSDC3 Phase 25 2.8 5 mm or 3/16” precision tip
DSDC6 Phase 48 5.4 4 mm hex head
DSDC9 Phase 90 10.2 4 mm hex head
DSDC2 Phase 110 12.4 5 mm hex head
Table 1 - Wiring Terminal Capacity 1 (in AWG) Cable Range OD
Main
Contacts
Device Min Max
DSDC1 14 8 .30 1.380
DSDC3 14 6 .51 1.380
DSDC6 10 2 .50 1.812
DSDC9 6 2/0 .50 1.812
DSDC2 4 4/0 2 .87 2.400
1 Capacity is based on THHN wire sizes
2 2/0 AWG if part number does not include the ‘A06’ suffix.
Min Max
Table 4 - Custom Mounting Dimensions
‘A’ ‘B’ ‘C’
Model Inches mm Inches mm Inches mm
DSDC1 2.25 57 1.89 48 .19 5.0
DSDC3 2.50 64 2.17 55 .19 5.0
DSDC6 3.25 83 2.59 66 .22 5.5
DSDC9 4.00 102 3.20 81 .22 5.5
DSDC2 4.50 114 3.86 98 .28 7.0
OPERATING INSTRUCTIONS
Meltric Corporation / 4640 Ironwood Drive Franklin, WI 53132
Tel. : 800 433 7642 / Fax : 414 817 6161 / e-mail : [email protected]
A manufacturer of products using Marechal technology
meltric .com
DSDC
INSDSDC D
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO