GENERAL
CS1000 single pole plugs and connectors are de-
signed with safety and durability in mind. A finger
guard on the receptacle provides IP2X protection
from live parts. A locking pin prevents unwanted dis-
connection. Each of the phases as well as the neutral
and ground are color coded and keyed to prevent
improper connection. Please follow the instructions
below to ensure the proper installation and use of the
product.
There are inherent dangers
associated with electrical prod-
ucts. 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
CS1000 plugs and receptacles are UL and CSA
listed in accordance with UL 1691 and CSA 1691-12.
CS1000 devices are for use in Non-Load Break
applications up to 400A at 600VAC, 600VDC (in
North America) or 1000VAC, 1500VDC (in Europe –
CE rated).
The CS1000 devices are NOT designed or
listed for current interruption.
Risk of Electric Shock. Do
Not Disconnect Under Load.
INSTALLATION
These products should be installed by qualified
personnel 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 lugs noted in Table 1.
NOTICE:
Connect only copper or copper-clad wire to
this device.
NOTICE:
For correct operation, the power cable
must not exert significant force on the product.
Wiring of the main conductor
Strip the conductor by approximately 1-1/8" depending
on the lug used. Lugs to be crimped with Greenlee
EK6IDL11 Crimping Tool, Dieless 120V CHRG.
Tighten small (through 45-3A12D) Straight Threaded
Lugs (Type D) with a 21 mm wrench and large
(45-3A18D and up) with a 24 mm wrench. Tighten
Straight With Terminal Lug (Type C) screw and
washer with a 19 mm socket.
The tightening torque must not be transmitted
to the insulated casing. To avoid transmitting
torque to the device when securing the lugs, hold the
terminal in place with a 20 mm wrench.
Torque both Type C and Type D style lugs to 30 ft-lb.
Assembly of the handle
Screw handle onto the product and tighten the cable
gland with an appropriate tool. Block the rotation of
the handle with the supplied screw. Assemble as
shown below.
Assembly with adapter plate
Assemble the adaptor plate on the product and
tighten the M40 nut with an appropriate tool.
Align tabs and assemble as shown below.
Hole pattern for adapter plate
NOTICE:
In order to maintain IP66/67 protection in
custom installations, watertight seals must be used
under the heads of the four mounting fasteners and
they must be retained by a lock washer and nut on
the inside of the box or panel. Alternatively, four blind
holes can be drilled and threaded to accommodate
#8-32 x 5/8" mounting screws. The hole depth must
be sufficient to achieve adequate gasket compres-
sion.
Assembly on an inclined sleeve
(with adapter plate)
Assemble the adapter plate on the inclined sleeve.
Do not forget the gasket between the adaptor plate
and the inclined sleeve, and between the inclined
sleeve and the panel. Assemble as shown below.
When mounting on a wall or panel, position the inlet or
receptacle so that the locking pin or latch is at the top.
Assembly on a panel board
Direct assembly
Assemble the product on the panel board and tighten
the M40 nut supplied, with an appropriate tool.The
watertightness is achieved by the color-coded ring.
Color coded ring and color-coded ring for the lid
In order to achieve watertightness, do not forget the
color-coded ring at the rear of the inlet or receptacle
and the panel.
5 Mechanical Keying Postions
(North America color codes shown.)
M40 nut
Color-coded ring
Adapter
plate
Cap (partial
view)
M40 nut
Cap with Color-coded ring
Adapter plate
Inclined sleeve
M40 nut
Watertightness gaskets
Color-coded ring
1.89"
.19Ø mount
holes
2.25"
1.89"
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
Locking latch
Locking pin
L1
L2
L3
Neutral
Ground
Positive
Negative
Table 1 CS1000 Crimping Lugs
1
Conductor
Size
2
Allowable
Current (A)
3
Straight With
Terminal
Straight
Threaded
1/0
4
200
45-3A50C
45-3A50D
2/0
250
45-3A70C
45-3A70D
3/0
275
4/0
300
45-3A95C
45-3A95D
45-3A12C
45-3A12D
250
325
350
350
45-4A18C
45-4A18D
450
5
400
45-4A24C
45-4A24D
1. Lugs to be crimped with Greenlee EK6IDL11 Crimping Tool,
Dieless 120V CHRG.
2. Type W or Compact Cable.
3. Intended to be wired with conductors rated 90°C or higher.
4. The ground conductor for the CS1000 series devices shall be
limited to a maximum size of 1/0 AWG.
5. 444 Locomotive or Diesel Cable to 500MCM Compact Cable.
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
Screw to block rotation
Watertightness gasket
WARNING
DANGER
CAUTION
NOTICE
ADVERTENCIA
DANGER
CAUTION
AVISO
CS1000
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 : mail@meltric.com
INSCS1000 G
A manufacturer of products using
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