Eaton Cuttler-Hammer Pow-R-Command 100 Manual

April2003
Pow-R-CommandTM (PRCTM) 100
Instruction Leaflet
IL01412003 For More Information visit www.cutler-hammer.com

Installation Leaflet
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Pow-R-Command System
Installation Leaflet
Notes and Warnings
-Read this guide completely and carefully prior to any installation. Failure to follow the instructions or the
prescribed procedures may cause severe injury or death and/or damage to the equipment.
-All installation and service must be performed by qualified personnel or service technicians. Keep this guide
available to those responsible for installation, programming, operation, and maintenance of the system.
-All installation and wiring information contained herein is based on industry-accepted standards and practices.
This information is not meant to conflict with or overrule any applicable codes or ordinances. If any conflicts
exist, please contact your Cutler-Hammer Representative before proceeding with the installation.
-USE EXTREME CAUTION WHEN OPERATING THE SYSTEM. DANGEROUS VOLTAGES MAY EXIST
INSIDE THE UNITS. Failure to follow any or all warnings and instructions contained herein may cause severe
injury or death and/or damage to the equipment.
-Panels are shipped from the factory with the electronic boards installed and tested. Many of the electronic
components may be sensitive to static electricity. Do not handle electronic parts without proper electrostatic
protection.
-Document all wiring, device termination and locations. This information will be required for system start up and
programming.
-Under no circumstances switch on the power to the electronics during or after installation. Power up,
programming and system configuration should be performed by qualified personnel during the system start up.
-The instructions and prescribed procedures in this Installation Guide do not purport to cover all possible
contingencies, which may arise during installation, and all details and variations of the system. If further
information is desired by regarding the particular installation of the system, please contact your
Cutler-Hammer Representative.

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Table Of Contents
SECTION 1: MOST COMMON CONFIGURATIONS AND DESCRIPTIONS 4
1-1POW-R-COMMANDPANELBOARDS 4
1-2EXPANSION/CONTROLCABINET 5
1-3 RELAY PANEL 5
SECTION 2: POWER SUPPLY TERMINATION 6
2-1PANELBOARD 6
2-2RELAYPANEL,EXPANSION/CONTROLCABINET 6
SECTION 3: LOW-VOLTAGE TERMINATION 7
3-1PANELBOARD 7
3-2RELAYPANEL,EXPANSION/CONTROLCABINET 8
3-3CONTROLLABLEBREAKERREMOTETERMINATION 9
SECTION 4: APPLICATION SPECIFIC CARD TERMINATION 10
4-1UNIVERSALSYSTEMCONTROLLER 10
4-2SWITCHOVERRIDECONTROLLER 10
4-3UNIVERSALI/OMODULE 11
4-4LOW-VOLTAGE INPUTS & OUTPUTS 11
4-5LOW-VOLTAGEWIRINGAPPLICATION 13
SECTION 5: NETWORK TERMINATION 21
5-1NETWORKTERMINATION 22
5-1.1PANELBOARD 22
5-1.2RELAYPANEL, EXPANSION/CONTROL CABINET 23
5-27X EXPANSIONCHASSISNETWORKTERMINATION 24
5-3NETWORKREPEATER 25
SECTION 6: PERSONAL COMPUTER TERMINATION 26
6-1NIB TOPCCONNECTION 26
6-2ETHERNETSERVERTOPCCONNECTION 26
6-3NIB TOMODEMCONNECTION 27
6-4ETHERNETSERVERTOETHERNETWITHBACKUPCONNECTION 27
SECTION 7: CONTROLLER ADDRESSING 28
7-1ADDRESSINGUSINGAPC 28
7-2ADDRESSINGUSINGAPOCKETPCTESTTOOL 30

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SECTION 1: MOST COMMON
CONFIGURATIONSAND
DESCRIPTIONS
Cutler-Hammer offers a full line of different
types of chassis and configurations for
Pow-R-Command 100 applications. Most
common configurations are described
below.
1-1 POW-R-COMMAND PANELBOARD
Pow-R-Command 100 Panelboard can come
in two main configurations:
1) Panelboard with 5X-Controller
Chassis (see Fig. 1-1). The 5X-Controller
Chassis contains the Universal Systems
Controller (USC) allowing the user to
control the GHBS or BABR breakers
using the time schedules or the console.
Panelboard with 5X-Controller Chassis
and 7X-Expansion Chassis
(see Fig. 1-2).
2) Combining the 5X Controller Chassis, the
7X Expansion Chassis accommodates
one of the Application Specific Control-
lers which expand the panels capabili-
ties.
For low-voltage device termination, please
refer to SECTION 3 Subsection 3-1.
Panelboards can operate as stand-alone or
be a part of network system. For network
termination, please refer to SECTION 5.
RemotelyControlled
Branch Circuit Breakers
5X-Controller Chassis With
USCControllerCardInstalled
P/SCable
7x-Expansion Chassis
Figure 1-1 (Left): Pow-R-Command 100 Panelboard With 5X-Controller Chassis &
Figure 1-2 (Right): Pow-R-Command 100 Panelboard With 5X-Controller Chassis and 7X-Expansion Chassis

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1-2 EXPANSION / CONTROL CABINET
An Expansion Cabinet is mounted exter-
nally, and in close proximity to a panelboard
containing GHBS or BABR breakers. The
expansion cabinet is used in conjunction
with a smart panelboard. In these condi-
tions, the Expansion Cabinet is linked to the
panelboard using the network. For the
termination of the Network, please refer to
SECTION5.
A Control Cabinet provides control
capabilities to a standard panelboard
equipped with remote controlled breakers
(Panelboard without the 5X-Controller
Chassis). This configuration, includes the
USC (control board) mounted in an
Expansion Cabinet. The remote controlled
breakers are then controlled remotely, using
pigtails between the Expansion / Control
Cabinet and remote controlled breakers
mounted in the panel. For low-voltage
device termination, please refer to SECTION
3 Subsection 3-2. For remote controlled
breaker termination, please refer to
SECTION 3 Subsection 3-3.
1-3 RELAYPANEL
A Relay Panel is an another option for
controlling circuits with noncontrollable
breakers. The USC Control Card, as well as
Application Specific Controller cards, can
be installed in the Relay panel. The Relay
Panel can operate as stand-alone or be a
part of the network system. For Network
termination, please refer to SECTION 5. For
low-voltage device termination, please
refer to SECTION 3 Subsection 3-2.
Power Supply Terminals Cover
Power Supply Section
Relay Termination Adaptor Board
Network Terminals
Low-Voltage Device Terminals
Relay/Breaker Connectors
Figure 1-3: Expansion/Control Cabinet
Line Power Terminals
Transformer Tap Terminal
Relay Panel Control Card (USC)
Relay Termination Adaptor Board
RelayTermination Board
Network Terminal
Switch Override Controller
Low-Voltage Device Terminals
Lighting Relays
Figure 1-4: Pow-R-Command 100 Relay Panel
RelayTermination Board

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SECTION2: POWER SUPPLY
TERMINATION
2-1 PANELBOARD
Panelboards are shipped with the
Controller’s Chassis power supply for the
electronics terminated to the correct
voltage. There is no need for the personnel
installing the panel to supply connections to
the power supply of the 5X-Controller
Chassis or 7X-Expansion Chassis. Please
verify that the panels supply voltage
matches the voltages specified on the label
of the panel. On the left side of the 5X-
Controller Chassis find the wires feeding
primary side of the power supply. If wire is
not used for the application, it should
contain isolating cap. Wires are color coded
as follows:
-RED 120VAC
- YELLOW 277VAC
-BROWN NEUTRAL
-GREEN GROUND
2-2 RELAYPANEL, EXPANSION / CONTROL
CABINET
The personnel installing the Relay Panel or the
Expansion/Control Cabinet are responsible for
providing and terminating the power wires to
these panels.
If the trim is installed, remove the trim (for the
Expansion/Control Cabinet, remove the door
and the power supply cover). There are two
terminal sets on the power supply. The right
side of the power supply is marked “Trans-
former Tap 120/277VAC” and the left side is
marked “Line Power 120/277VAC”.
On the Transformer Tap terminal, verify the
correct jumper position for the voltage that
you will be connecting to the panel. Move the
jumper if necessary. The correct jumper
positions are:
- 277 to COM for 277VAC
- 120 to COM for 120VAC.
Note: All units are generally shipped with the
jumper strapped for 277VAC. However, be
sure to verify this setting. Applying 277VAC to
the unit set for 120VAC may damage the unit.
On the Line Power terminal, connect
ground wire to the terminal marked:
“GND”. Connect neutral wire to the
terminal marked: “LO”. Connect hot
wire to the terminal marked: “HI”. For
power connections use a minimum #12
AWG copper wire.
Power Terminal Cover
Line Power Terminals
Transformer Tap Terminal
Figure 2-1: Power Supply Terminations In Pow-R-Command 100 Relay Cabinet & Control Cabinet

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SECTION3:LOW-VOLTAGE DEVICE
TERMINATION
All open areas in the panels are considered
as low-voltage/class-2 termination areas.
No voltages above 28VAC are permitted in
this area. Inputs are designed so that only
dry contact devices are accepted.
NO EXTERNAL VOLTAGES SHOULD BE
APPLIED TO THE LOW-VOLTAGE
TERMINAL BLOCKS. ALL NECESSARY
POWER IS PROVIDED BY THE PANEL.
Low-voltage devices should be terminated
using a minimum #22AWG twisted pair
wire. Shielding is generally not required.
Low-voltage device cables should not be
located in the same conduit with the high-
voltage load wires. Be sure the wire type
you use is rated properly, especially for
plenum or hazardous applications.
3-1 PANELBOARD
In most cases, Application Specific Cards
will be located in the 7X Expansion Chassis
installed in the panel. Power supply and
Network connections will be provided in the
factory.
In rare case of the 7X-Expansion Chassis
located externally to the panel, the network
cable and the power supply cable should
be installed between the panel and the 7X-
Expansion Chassis. For Network termina-
tion, please refer to SECTION 5.
The personnel installing the panel are
responsible for providing and termination
wiring of all external low-voltage devices.
Use knockouts provided on the bottom and
sides of the chassis to enter the low-
voltage termination area.
All low-voltage (dry closure) devices
should be terminated on the 7X board
terminal blocks TB1, TB2, and TB3. Terminal
blocks TB1 and TB3 are designated
locations for inputs from low-voltage
devices—numbered respectively 1-24 and
25-48. Terminal block TB2 is a COMMON
(ground) terminal for all low-voltage
devices terminated in the panel.
Network “Out”
Connector
Power Supply
Connector
Network “In”
Connector
Low-Voltage Device
TerminalsCOMMON
Application Specific
Controller Connectors
Low-Voltage Device
Terminals 1-24
Low-Voltage Device
Terminals 25-48
Figure 3-1: 7X-Expansion Chassis Back-Plane Board

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3-2 RELAY PANEL, EXPANSION/CONTROL
CABINET
The Relay Panel and Expansion / Control
Cabinet use the same Relay Termination
Board for low-voltage (dry-contact) device
termination.
A Relay Panel is used to control loads
down-line from a breaker panel not
equipped with controllable breakers. A
Relay Panel is shipped from the factory
with the low-voltage side of the relays
terminated to the Relay Termination Board.
Personnel installing the Relay Panel are
responsible for providing and terminating
wires to load side of the relays. Maximum
wire size accepted by the relay terminals is
#10AWG.
An Expansion / Control Cabinet is installed
externally to a breaker panel. The person-
nel installing the above mentioned devices
are responsible for providing termination of
the power supply, network, and all external
low-voltage devices. For power supply
termination, please refer to SECTION 2
Subsection 2-2. For network termination,
please refer to SECTION 5.
Use bottom of the previously described
enclosure types to attach conduit and
provide access to the low-voltage
termination area.
Panels using Expansion Cabinet might or
might not contain 5X-Controller Chassis. For
panels with a 5X-Controller Chassis, the
Expansion Cabinet is used for Application
Specific Controllers only. Only low-voltage
devices and network are terminated in the
Expansion Cabinet. For panels not
containing the 5X-Controller Chassis the
additional step of terminating the remote
controlled breakers to the Control Cabinet
Relay Termination Board is required. For
remote controlled breaker termination,
please refer to SECTION 3 Subsection 3-3.
All low-voltage devices should be termi-
nated on the Relay Panel, Expansion /
Control Cabinet board terminal blocks TB3,
TB4, and TB5. Terminal blocks TB3 and TB5
are designated locations for inputs from
low-voltage devices—numbered respec-
tively 1-24 and 25-48. Terminal block TB4 is
a COMMON (ground) terminal for all low-
voltage devices terminated in the panel.
Power Supply Connector
Relay/Breaker
Connectors
Controller Ports
RelayTermination
Adaptor Board
Network Terminal
RelayTermination
Board
Low-Voltage Device
Terminals 1-24
Low-Voltage Device
Terminals 25-48
Low-Voltage Device
TerminalsCOMMON
Figure 3-2: Relay Panel, Expansion/Control Cabinet Interior

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3-3 CONTROLLABLE BREAKER REMOTE
TERMINATION
For panels without a 5X-Controller Chassis,
a Control Cabinet must be used. In addition
to low-voltage device termination, connec-
tions to the GHBS, BABR, BABRS, or
GHQRS breakers in the panel should be
made using pigtails.
Figure 3-3: GHBS Pigtail Termination In Expansion/
Control Cabinet
Figure 3-5 BABR, BABRS, or GHQRS Pigtail
Termination In Expansion/Control Cabinet
On the Control Cabinet side, pigtails are
connected to the Relay Termination Board
using four pin AMP type connectors. The
connectors are numbered 1-24 on the left
side of the board, and 25-48 on the right
side of the board (see Fig. 3-3).
On the Panel side, the pigtails are connected
to the low-voltage connectors on the back
of the GHBS breakers using a three pin AMP
type connector (see Fig. 3-4) or the pigtail
four pin connector on the BABR, BABRS,
and GHQRS breakers.
The length of the pigtail should not exceed
50’ for #22 AWG stranded wire for single
pole breaker. For double pole remote
controlled breakers and longer distances,
higher gauge wire is recommended. Please
verify that the wire type used for pigtails is
rated properly.
TOENSURESIMPLEOPERATIONAND
MAINTENANCEBE CAREFULTOMATCHTHE
EXPANSIONCONTROLLERCIRCUITNUMBER
TOTHEAPPROPRIATEPANELBOARD
CIRCUITBREAKERPOSITION.
Figure 3-6: BABR, BABRS, or GHQRS Pigtail
Termination/Breaker
Figure 3-4: GHBS Pigtail
Termination/Breaker

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SECTION 4:APPLICATIONSPECIFIC
CARDSTERMINATION
4-1 UNIVERSAL SYSTEM CONTROLLER
The Universal Systems Controller (USC)
handles direct breaker control and status.
In addition to controlling breakers, the USC
has low voltage inputs and outputs which
can be used for switches, pilot lights,
photocells, dimmer ballasts, or other
external devices. The GHBS / BABRS
jumper is used to identify if the USC is
controlling GHBS/ BABR type breakers or
BABRS/GHQRS type breakers.
4-2 Switch Override Controller
The Switch Override Controller (SOC) is an
Application Specific Controller accepting
dry-contact closures as input. The SOC
can be installed in the 7X-Expansion
Chassis or in the bottom position of an
Expansion/Control Cabinet. The SOC will
accept only dry-contact closure devices
(i.e. switches, occupancy sensors,
Building Management System relay, etc.).
Contact closure is processed by the SOC
card, resulting in state control of the load
Relays / Breakers. Action of the devices
terminated for SOC card will not have any
effect on the system operation until the
system is correctly programmed. Program-
ming of the system must be performed by
qualified start-up personnel.
The personnel installing the panel with the
SOC card are responsible for providing and
terminating wires for low-voltage devices.
For low-voltage device termination for the
SOC card, please refer to SECTION 3.
GHBS/BABRS
SelectionJumper
Network/RS-485
Test Port
Reset Button
Low-Voltage
Inputs/Outputs
Figure 4-1: Universal System Controller (USC)
StandardPilot
Lamp Outputs
AdditionalPilot
Lamp Outputs/Card
Reset Button
Low-Voltage
Inputs/Outputs
Network/RS-485
Test Port
Figure 4-2 Switch Override Card (SOC) and Optional Pilot Lamp Output Card