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9. Re-install the cover of the control partition inside the enclosure by reinstalling the screws removed
previously and tightening them until snug. Do not over-tighten. Be sure not to pinch any wires or
strip the screws.
10.Install electrical lines from the supply breaker for the controlled device to the marked LINE SIDE (L1
& L2) of the contactor and bonding/ground attachment.
*** WARNING: Contactor electrical connections MUST be torqued to 40-44 in-lb (5 Nm) to avoid
objectionable operational noise, overheating issues, and premature failure. ***
11.Install electrical wires from the end device to be controlled (i.e. EV charger) to LOAD SIDE (T1 & T2)
of contactor and bonding/ground as required by local electrical codes. Ensure wire terminals are
torqued to 40-44 in-lb (5 Nm). If the neutral or identified conductor is used for the end device it can
be spliced in the enclosure with the wire nut provided for the following copper wire combinations -
2 #6, 2 #8, or 2 #10.
12.When safe, energize the device and check the control board for the red light to be on, indicating
power. The green output light should correspond to the state of the contactor and should not be
flashing. If the green light is flashing continuously, it indicates that there is little to no current being
read by one or both current monitoring devices. Most operating installations should have some
current flow on both monitored main electrical lines so a flashing green led may indicate improper
installation of one or both current monitoring devices. The green LED will stop flashing when it
senses some current on both main lines. Although it will still operate with one current monitoring
device not reading current, the installation should be verified. To do this, turn on a high-current
240V device in the electrical system and the LED should stop flashing. If it does not, recheck the
current monitoring device installation from step 3 ensuring that the polarity of the current
monitoring devices is correct, and all connections are secure. If this is all correct, contact the
manufacturer.
13.Install included “Black Box Device Controlled Label” on the end device being controlled to indicate it
is a controlled device and occasional off times are normal. Then record the values of the electrical
service and the end device that is connected to it in the indicated areas on the EVEMS label. Finally,
label the electrical panel schedule to indicate the breaker numbers that connect the controlled
device and indicate that it is controlled by the Black Box energy manager.
14.Install the enclosure cover and when safe to do so, energize the system.
(Note: The contactor may not close until a computational observation time of between 0 - 15
minutes. The algorithm must be satisfied that the system will remain below 80% of the rated main
breaker and other values included in it. This is partially dependent on the setting of the timer
adjustment screw (blue & white) on the control board. If this observation time is too long, it can be
adjusted by turning this dial setting counter-clockwise but this should not be set below 1 minute to
avoid undesired operation.)
