ITT POWERLOCK BOX Instruction Manual

BBAI 1328 Issue E
BAS10642
05/02/2013
POWERLOCK BOX
OPERATION AND MAINTAINENCE GUIDE
PART NUMBER BREAKDOWN
Product
Description
PBX
Contact Type
PS
Power Source
PD
Power Drain
Box Type
SL
Sealed Lid
SLF
Sealed lid
With flange
NL
No Lid
NLF
No lid
With flange
Region Colour Code
EU – European
US– United States
AU– Australia
Maximum Current
Rating
400
660
Part number example: PBX-PD-SL-US-400 is a 400 amp unit with drain contacts and lid,
colour coded for the USA
COLOUR CODING
Region Earth Neutral L1 L2 L3
Europe
United States
Australia
UN-PACKING
Ensure the unit is up the correct way before un-packing. The carton and its packing are
recyclable and should be disposed of according to national or local authority guidelines.

CONTENTS
After un-packing, the part number of the PowerLock Box should be checked against your order
and that on the carton. Also check that the current rating label on the unit matches your
requirements. The carton should contain the following:-
Qty Description
1 PowerLock Box
1 6mm square drive key
1 3 pole cable connector for remote sensing
1 Operating / Maintenance guide
If any parts are missing or the unit’s description does not match, you should contact your
supplier.
MOUNTING INSTRUCTIONS
The unit may be mounted into standard 19’’ rack systems or to dedicated panel mounts within
buildings or remote cabinets. It is recommended that M6 screws / bolts and flat washers are
used, and tightened to a torque of 2.94NM min. to 3.43NM max.
Caution – Tighten screws / bolts evenly and ensure the unit is adequately supported during
mounting.
88.90 6.50
MIN
(107.00 for
Flange type.)
CUT OUT BELOW FOR FLANGE TYPE ONLY.
If fitting to a 19” rack that does not support all IEC 60297 fixing holes it may be necessary to
use additional mounting plates. ITT part number 003-7586-000 available on request.

ELECTRICAL INSTALLATION
Caution – Electrical installations should only be carried out by a suitably qualified electrical
engineer. It is the responsibility of the installer and user to ensure that safe practices are
adopted.
Power cable connections – M12 threaded posts on the rear of the unit are for connecting
power cables fitted with cable lugs. Each position is marked on the back of the box,
E (Ground), N, L1, L2 & L3. The threaded posts have a spring washer and nut that should be
tightened to a torque of 27.5NM min. to 31.4NM max.
It is recommended that insulated spanners are used when making these connections.
REMOTE SENSING CONNECTOR
A 3 pole ITT Cannon Trident connector is located on the rear of the unit to provide a remote
sensing function.
The 3 pole connector mounted on the rear is connected to a micro-switch inside the unit that
is activated only when all connectors are in place and the unit is locked.
A Trident cable connector is provided with 2 loose contacts and an endbell strain relief. The
connector body has 4 cavities with 3 contacts wired to the switch. Using the 3 loose contacts
that are provided, the cable connector can be wired to suit your requirements, either ‘Normally
Open’ or ‘Normally Closed’ or both.
Contact Position
A Common
B Normally Open
C Normally Closed
D Not used
Full assembly instructions for this connector are shown in the Appendix.

POWERLOCK BOX OPERATING INSTRUCTIONS
Note - This box should only be operated by suitably qualified persons
Only original ITT Veam PowerLock connectors should be used with this unit. The use of non
approved connectors may cause damage to the box and will invalidate any warranty.
On versions with the sealed lid, it will be necessary to open this using the square drive key
before connections can be made.
Ensure that the current rating of the cables and connectors being used are suitable for the
current rating of the PowerLock Box and connected supply.
Do not connect live cables.
Ensure that power is switched off before connection / disconnection
Connection of PowerLock connectors is made sequentially, starting with the Ground / Earth
connection (Green) and working to the right.
1. Insert the Ground (Green) connector, aligning the ‘PUSH’ arrow on the label of the
connector in a 12 o’clock position. Fully insert the connector until it bottoms in the
cavity and turn through 45 degrees clockwise until the connector stops.
2. Repeat the above process for the Neutral connector, followed in order by L1, L2, and
L3. (If at any time a connectors does not rotate fully, check that the previous connector
is fully turned)
3. Lock the box as indicated on the front panel, using the square drive key provided, the
lock is situated adjacent to the L3 connection
4. Remove the key. All connectors are now locked in place and can not be removed until
the box is unlocked.
5. To remove the connectors, ensure that the power is turned off and reverse the above
procedure.
GENERAL
Fitting and maintenance should only be carried out by suitably qualified persons.
Mating cable connectors are not supplied with the PowerLock Box .
Recommended cross section area of wire for connection to back of the unit is -
120mm² – 400 amp
240mm² – 660 amp
The use of insulated spanners is recommended when connecting or disconnecting this
box.
The PowerLock Box is CE marked and complies with the relevant regulatory
requirements.
It is the responsibility of the installer to ensure that the PowerLock Box is located in a
safe location.
PowerLock connectors used to make connections with the PowerLock Box should be
checked for damage and excessive wear, damaged or worn connectors may not
function correctly.
The Connector and wiring should be checked before making live, to have no damage
to metal parts or insulators, loose strands, conducting lubricants, scarf or any other un-
desired conducting particles.
Circuit resistance and continuity check should be made to make certain that there are
no high resistance joints or spurious conducting paths.
Always use the correct tools as specified in the data sheet/catalogue.
Do not permit untrained personnel to wire, assemble or tamper with connectors. For
operating voltage, please see appropriate national regulations.

HANDLING:
Care must be taken to avoid damage to any component parts of electrical connectors
during installation and use. Although there are normally no sharp edges, care must be
taken when handling certain components to avoid injury to fingers.
CHARACTERISTICS
Current rating 400 amp or 660 amp (check label for rating)
Voltage rating 1000V AC / 1500 DC
Dielectric strength 9.5Kv dc
Micro-switch operating voltage 125Vac max.
Micro-switch current rating 5 amp
Operating temperature -30ºC to +85ºC
Environmental protection IP65 – Environmental protection applies to the ‘power connector
ports’ only when connectors are mated or the lid is closed and
locked.
PowerLock Box weight Unit with lid – 3.75Kg. approx
Unit without lid – 3.25Kg. approx
Flammability rating UL94-V0
Endurance 500 connection cycles
MAINTAINENCE
1. Periodic greasing of the O ring seals on the connector ports with Molykote® 3451 is
recommended
2. The PowerLock Box should regularly be inspected for damage, including a visual
inspection of the contacts on PS (Power Source) versions
3. Periodic retention testing of PS (Power Source) contacts using ITT Veam tool T4907 is
recommended to confirm that contact life has not been exceeded
Note – Molykote® is a registered trade name of Dow Corning Corporation
DISPOSAL
After use, the device should be disposed of in accordance with national or local authority
guidelines
MANUFACTURE INFORMATION
ITT Interconnect Solutions
Jays Close,
Viables Estate
Basingstoke
Hampshire
RG22 4BA, UK
Telephone [phone]
www.ittcannon.com

Appendix
Cannon Trident Connector assembly instructions
1. Contacts will accept wire of between 14 and 26 AWG
2. Strip back insulation on wires by 6 mm twist together
stranded wires, and pre-tin contacts and wire
3. Solder wire to contact
4. Separate the endbell clamping parts
5. Pass the wires / cable through the endbell
6. Insert the insulator into the coupling nut
7. Insert contacts into cavities of the connector
Cavities A & B connects to the switch ‘Normally Open’
Cavities A & C connects to the switch ‘Normally Closed’
8. Screw the endbell to the connector, and hand tighten
9. Select and fit a suitable clamp bar for your wire / cable
and tighten screws