Connect Power Block Wiring

To connect the Power Block wiring, complete all steps given below.

Risk of shock
  • Before any procedure, disconnect the power.
  • Follow local code and site lockout/tagout procedure to de-energize the station.
  • Wait for energy to dissipate (approximately five minutes).
  • Keep power off until all covers and panels are reinstalled and the work is complete.
Failure to follow these instructions can result in serious injury, loss of life, or property damage.
Ensure a grounding conductor that complies with local code is properly grounded to earth at service equipment or, when supplied by a separate system, at the supply transformer.

Disconnect Power

Disconnect power at the site electrical panel. Follow standard practice and local code to de-energize the applicable circuit and lock out/tag out the disconnect before proceeding. Use a multimeter to test that power is off.

Disconnect power at the site electrical panel while following standard practice and local codes

Cut and Prepare Conductors

To cut and prepare conductors, complete the following steps:

  1. Install lugs without the conductors onto bus bars and hand-tighten.

    1. DC output

    2. AC input

    Install lugs without the conductors onto bus bars and hand-tighten.

    Use included bolts, washers, and nuts.

  2. Measure the length from each conductor to its corresponding lug. Mark the conductor at the point where you will need to cut it.

  3. Strip and cut the conductors to the desired length.

    Strip and cut the conductors to the desired length.

Install DC Fuse Kits

  • To prevent damage to the Bus bar insulators (plastic), the DC Fuse Kits should be installed before the DC conductors.

  • Route all wiring away from the fuses. Each fuse can reach very high temperatures.

  • The rating on the fuse label will be higher than the rating on the fuse packaging. This is normal and is done so that the fuse performance is sufficient at elevated temperatures.

  • To prevent damage to the Bus bar insulators (plastic), the DC Fuse Kits should be installed before the DC conductors.

  • Route all wiring away from the fuses. Each fuse can reach very high temperatures.

  • The rating on the fuse label will be higher than the rating on the fuse packaging. This is normal and is done so that the fuse performance is sufficient at elevated temperatures.

In the DC Fuse Kit Box:

  • Make sure to install the PB amperage sticker that is included in this box.

  • Note that this DC Fuse Kit Box box could have been packaged and shipped to you using either one of the following two configurations: either as Type A configuration or as Type B configuration (see details below).

Type A configuration:

Type A
Fuses Contents

 


Four fuses

 

Type A configuration contains:

  • Fuses (x4)

OR

Type B configuration:

Type B
Fuses and bus bars Contents


 

Two fuses and two bus bars


Type B configuration contains:

  • Fuses (x2)

  • Bus bars (x2) that have already been installed at the factory

    These two bus bars (in Type B configuration) take the place of the other two fuses (that are in Type A configuration).

To install all C fuses, complete the following steps:

  1. Install all DC fuses (regardless of number of lugs used) between the landing bus bar and the DC bus bar. Torque to 19 Nm (14 ft-lb).

    Install all DC fuses (regardless of number of lugs used) between the landing bus bar and the DC bus bar. Torque to 19 Nm or 168 in-lb.

    For high voltage DC or AC lugs, 2-hole lugs are specified in North America. Single hole lugs are only permitted in Europe. The lugs must be installed within +/- 10° from vertical to avoid interference.

Connect Wires

To connect wires, complete all steps given below.

Locate DC Output Wire Landings

Locate the wire landing locations for the DC output and DC ground wires.

DC output lugs and Dc ground wire locations

  1. DC output lugs

  2. DC ground wire

For each AC and DC bus bar, only one washer per bus bar hole is required, even if lugs are installed onto the front and back of the same bus bar.

Connect DC Output Wires

To install the DC output wires, complete the following steps:

  1. Uninstall the lugs (if you installed them previously to measure length). Apply dielectric grease onto the back of each lug.

  2. Crimp a DC output lug onto each conductor.

    Use the lug manufacturer's crimp tool and die.

  3. Install lugs onto each bus bar and torque fasteners to 21 Nm (15.5 ft-lb).

    Installing the lugs onto each bus bar and torquing them

  4. Mark all torqued power connections.

    Mark all torqued power connections.

Connect DC Ground Wires

To install DC ground wires, complete the following steps:

  1. Crimp a 13 mm (1/2 in) single-hole lug onto the DC ground wire.

    Crimp a 13 mm (1/2 in) single-hole lug onto the DC ground wire.

  2. Connect the GNDClosed Ground (protective earth) service wiring to the stud on the left side of the enclosure.

    Connect the GND (protective earth) service wiring to the stud on the left side of the enclosure.

Adhere Ratings Label

Position the label near the serial number label, next to Ethernet port.

Adhere the associated ratings label.

Adhere the associated ratings label.

Locate AC Input Wire Landings

Note the wire landing locations for the AC input wires.

If the AC input wiring uses only one 750 kcmil conductor, it must be installed on the bus bar in the position farthest from the wall (toward the center) to avoid interference.

Ground wire, L3, L2, and L1 lug positions

  1. Ground wire

  2. L3

  3. L2

  4. L1

Connect AC Input Wires

To install AC input wires, complete the following steps:

  1. Uninstall the lugs (if you installed them previously to measure length). Apply dielectric grease onto the back of each lug.

  2. Strip and crimp an AC input lug onto each conductor.

    Use the lug manufacturer's crimp tool and die.

    Strip and crimp an AC input lug onto each conductor.

  3. Install the L1, L2, and L3 lugs onto each bus bar with M12 bolts. Torque to 21 Nm (15.5 ft-lb).

    Install the L1, L2, and L3 lugs onto each bus bar with M12 bolts.

    Ensure the L1, L2, and L3 cables are installed in the correct order for counter-clockwise phase rotation. Incorrect installation creates a phase rotation error later in the process.

  4. Mark all torqued power connections.

    Mark all torqued power connections.

Connect AC Ground Wires

To install AC ground wires, complete the following steps:

  1. Crimp a 13 mm (1/2 in) single-hole lug onto the AC ground wire.

    Crimp a 13 mm (1/2 in) single-hole lug onto the AC ground wire.

  2. Connect the GNDClosed Ground (protective earth) service wiring to the stud on the left side of the enclosure and torque to 21 Nm (15.5 ft-lb).

    Connect the GND (protective earth) service wiring to the stud on the left side.

    Ensure that the deep socket and extension is used to avoid side or angular loading of the ground stud.

Connect 48 V DC and (if Applicable) Shunt Trip Wires

Check the 48 V DC wiring requirements in the site drawings:

48 V DC Wiring

48 V DC Wire Size

Conduit Size

Installation

16 mm2 (6 AWGClosed American Wire Gauge)

21 mm (3/4 in)

Install two 48 V DC wires and one Ethernet cable into one conduit.

Use only copper conductor wire rated for 90 °C (194 °F).

48 V DC and shunt trip labels

  1. 48 V DC

  2. Shunt trip (if any)

Notice the labels.

To install 48 V DC and shunt trip wires, complete the following steps:

  1. Strip each 48 V DC and any shunt trip wires to 15 mm (5/8 in).

    Strip each 48 V DC and any shunt trip wires to 15 mm (5/8 in).

  2. Loosen each terminal tab and seat the wire. Tighten the screw. Push-pull to test.

    Loosen each terminal tab and seat the wire. Tighten the screw. Push-pull to test.

Connect Cat6 STP Ethernet Cables

To connect Ethernet cables, complete the following steps:

  1. Trim each Cat6 STPClosed Shielded Twisted Pair Ethernet cable to provide a 914 mm (36 in) service loop.

    Trim each Cat 6 STP Ethernet cable to provide a 914 mm (36 in) service loop.

  2. Terminate both ends. Field crimp a shielded connector onto each Ethernet wire.

    Terminate both ends. Field crimp a shielded connector onto each Ethernet wire.

  3. Use a straight-through T568B pattern.

    Use a straight-through T568B pattern.

  4. Connect the shield wire termination.

  5. Test each Ethernet wire functionality.

  6. Connect each Ethernet connector to an available port (at lower right). Push-pull to test.

    Connect each Ethernet connector to an available port (at lower right). Push-pull to test. The ports are interchangeable

    Ports are interchangeable.

Route and Secure LV Wires

To route and secure the LVClosed Low Voltage wires, complete the following steps:

  1. Route the Ethernet, 48 V DC, and shunt trip wires down the front, right side. Secure onto the cable-routing clips.

  2. Position excess Ethernet wire loops behind the controller board mounts.

    Position excess Ethernet wire loops behind the controller board mounts to prevent covers from pinching the wires.

    This is to prevent covers from pinching these wires.

Seal Completely

The conduit opening must be sealed to protect the wiring from any debris, pests, and other matter.

To seal conduit openings, complete the following steps:

  1. Vacuum all wire ends and metal shavings from the enclosure.

  2. Use duct seal compound (included) to seal all wiring openings and seal inside conduits.

    Use duct seal compound (included) to seal all wiring openings and seal inside conduits.

  3. Use the duct seal compound to seal the conduits around and to the gland plates.

    Use the duct seal compound to seal the conduits around and to the gland plates.