ITT POWERLOCK BOX User manual

POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 1von 48
TRANSLATION OF THE ORIGINAL
OPERATING INSTRUCTIONS
CAS25123E
POWERLOCK
Connector System
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POWERLOCK Connector System
Page 2von 48 Operating Instructions POWERLOCK Rev. -
IMPRINT
ITT Cannon GmbH
Cannonstraße 1
D-71384 Weinstadt
www.ittcannon.com
2021 © ITT Cannon GmbH
All rights reserved
INFORMATION!
This publication is an integral part of the Technical Documen-
tation for the “POWERLOCK Connector System”and is pro-
tected by copyright.
Any use beyond the limits of copyright law without written per-
mission is forbidden and subject to penalty.
This also applies to reproductions, translations, microfilms, as
well as storage and processing in electronic media. Violations
will give rise to a right to compensation.
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 3von 48
TABLE OF CONTENTS
Imprint .......................................................................................................... 2
Declaration of conformity.............................................................................. 5
INFORMATION ABOUT THE document...........................................................7
Intended use.................................................................................................. 8
Overview and description.............................................................................. 9
Introduction to the Powerlock System ...............................................................9
Description of the terms...................................................................................10
Technical specifications ....................................................................................12
Optional system accessories.............................................................................14
Overview of the individual connectors .............................................................16
Connector POWERLOCK “NLS” .........................................................................17
Connector POWERLOCK “NLDFT” .....................................................................20
Connector POWERLOCK “NPS” .........................................................................23
Connector POWERLOCK “NPDFT”.....................................................................27
Connector POWERLOCK “NPDFT SKPP”............................................................30
Transportation and storage ......................................................................... 33
Delivery .............................................................................................................33
Transportation ..................................................................................................34
Storage..............................................................................................................34
Installation/Commisioning .......................................................................... 35
Installation/Commisioning information............................................................35
Coupling of the connectors...............................................................................36
Uncoupling of the connectors...........................................................................38
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POWERLOCK Connector System
Page 4von 48 Operating Instructions POWERLOCK Rev. -
Cable connection to connector.....................................................................40
Maintenance................................................................................................43
Control of the components...............................................................................43
Cleaning of the components.............................................................................43
Disposal of the connectors ...............................................................................44
List of Figures ...............................................................................................45
Remarks and notes.......................................................................................47
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 5von 48
DECLARATION OF CONFORMITY
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POWERLOCK Connector System
Page 6von 48 Operating Instructions POWERLOCK Rev. -
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 7von 48
INFORMATION ABOUT THE DOCUMENT
This document “Operating Instructions POWERLOCK”contains important infor-
mation about transportation, assembly (function), installation, operation and
maintenance of the POWERLOCK type connectors.
This document is part of the technical documentation for the POWERLOCK type
connectors. Other applicable documents include the declaration of conformity,
risk assessment, drawings and circuit diagrams.
This document is intended for the operator or persons authorized by the operator
to perform tasks such as transportation, assembly (function), installation, opera-
tion and maintenance of the POWERLOCK type connectors and other tasks re-
lated to the POWERLOCK type connectors.
It additionally contains information and instructions regarding the disposal of
packaging, transportation material, and possibly accumulating problematic sub-
stances (e.g. liquids or similar) during assembly and disassembly of the POWER-
LOCKtype connectors.
CAUTION!
Non-adherence to the information contained in this document may result
in injury or property damage!
Always observe and comply with the warning and safety no-
tices in this document. They are the basic prerequisites for safe
execution of the tasks described in this document. If handled
improperly contrary to the specifications in this document, the
manufacturer will not accept any liability or offer any refund or
compensation. In this case, the operator alone shall be respon-
sible
Modifications (of any kind) to components of the POWER-
LOCK type connectors are strictly forbidden!
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POWERLOCK Connector System
Page 8von 48 Operating Instructions POWERLOCK Rev. -
INTENDED USE
The POWERLOCK connector system described herein is a single-pole connector
system for high-current applications up to 660 amps. The POWERLOCK connectors
are color coded to suit the requirements of three-phase electrical systems.
Typical fields of application for this product are
In mobile or stationary power distribution boards for low voltage, e.g. emer-
gency power systems or inland navigation
Connections of motors, transformers or generators, e.g. wind turbines
In entertainment technology, e.g. power supply for lighting and sound sys-
tems in sports events and concerts
The POWERLOCK type connectors has been designed and manufactured using
state-of-the-art techniques and in accordance with approved safety regulations
and the recognized standards EN 61984, 60512, 60664-1 and 60529. Neverthe-
less, when not used as intended, risks for the user or third parties may still arise
or the high power charging system and other material assets may be damaged.
Intended use includes:
Application within the stated performance limits.
Application when in efficient working order without any damage
Application within the regulations and provisions for the operation of con-
nectors applicable at the place of use.
INFORMATION!
Store the documentation required for operating, maintaining,
and servicing the POWERLOCK type connectors at the point of
use, ensuring it is available whenever needed.
Further applicable documents are, for example: Declaration of
Conformity, risk assessment, drawings, wiring plans, specifica-
tions, data sheets, and component operating instructions (if
available).
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 9von 48
OVERVIEW AND DESCRIPTION
INTRODUCTION TO THE POWERLOCK SYSTEM
The POWERLOCK connector system consists of single-pole connectors in insulated
plastic housings. They are used in high-current applications up to 660 amps in sin-
gle-phase or multi-phase power distribution systems.
The connectors are color-coded and mechanically keyed, making mismating im-
possible. A bayonet lock enables a quick connection. The secondary lock discour-
ages tampering and reduces the risk of accidental or unauthorized disconnection.
POWERLOCK connectors are moisture and impact resistant and feature insulated
contact tips to prevent accidental touching of electrically live parts.
In order to meet the worldwide requirements of three-phase electrical systems,
the insulator bodies are available in the following harmonized colors according to
IEC 60445:
Ground
E
Neutral
N
Line 1
1
Line 2
2
Line 3
3
Australia
GREEN
BLACK
RED
WHITE
BLUE
Europe
GREEN
BLUE
BROWN
BLACK
GREY
North America
GREEN
WHITE
BLACK
RED
BLUE
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POWERLOCK Connector System
Page 10 von 48 Operating Instructions POWERLOCK Rev. -
DESCRIPTION OF THE TERMS
Source: Connector fitted with a male contact in a female housing. The contact is
fitted with an insulated end cap to prevent accidental finger touching of live parts.
Drain: Connector fitted with a female contact in a male housing. The contact in-
cludes a spring loaded insulated cap to prevent finger touching.
The Drain connector is fitted with a secondary locking pin that locks into the mat-
ing half when the two connectors are fully engaged. A simple release key is re-
quired to disconnect the parts.
Line: Free connector fitted to a cable. Crimp contacts or Set-Screw contacts are
available for attaching the conductor. (Depending on the version of the con-
nector). For better handling, the insulator body can optionally be equipped with
a rubber hand grip.
Panel: Panel connectors feature a square 4 holes flange for attaching to a panel.
The 4 holes are normally supplied open, however can be pre-fitted with threaded
inserts to reduce mounting time. Panel Source connectors are supplied fully as-
sembled with the male contact having anM12 threaded post, with nut and spring
washer for connection to a standard cable lug, or M12 threaded hole for fixing
with a bolt.
The POWERLOCK connector system allows following connection and mounting
variants:
Line Source: Free connector (Line), it is usually attached to the source of the
power (Source).
Line Drain: Free connector (Line), it is usually attached to the appliance side
(Drain).
Panel Source: Connector features a flange attaching to a panel (Panel). It is
usually attached to the source of the power (Source).
Panel Drain: Connector features a flange attaching to a panel (Panel). It is
usually attached to the appliance side (Drain).
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 11 von 48
Figure 1: Connection usage
Line Source
Line Drain
Panel Source
Panel Drain
Figure 2: Connection styles
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POWERLOCK Connector System
Page 12 von 48 Operating Instructions POWERLOCK Rev. -
TECHNICAL SPECIFICATIONS
Mechanical:
Description
Value
Material contact
Brass (up to 400 A), silver
plated
Copper (up to 660 A), silver
plated
Material housing
PBT high temperature
thermoplastic
Material contact retention pin
PA
Locking
Bayonet lock with secondary locking
pin
Mating cycles
Min. 500
Connection type
Screw connection (up to 400 A)
Crimp connection (up to 660 A)
Threaded bolt M12
Threaded hole M12
Conductor cross-section
Crimp 35-300mm²
Screw 25-120mm²
Cable jacket diameter
ø15mm up to ø38mm
Vibration range
10-2000 Hz / 15 g
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 13 von 48
Electrical:
Description
Value
Rated current
400 A resp. 660 A
Rated voltage
1000 V AC / 1000 V DC
Test voltage
4500 V (AC)
Short-circuit current
16 kA for 1s (34 kA Peak)
Insulation resistance
> 5000 MOhm
Electrical protection class
IP2X
Contact resistance
< 0,1 mΩ
Pollution degree
3
Environment:
Description
Value
Permissible operating temperature
-30° C up to +125° C
Protection class, plugged
IP67
Flammability
UL94-V0
RoHS Directive (Hazardous
Substances)
Compliant
Certification:
Description
Value
VDE tested and certified
VDE Reg.No. D042
Certificate with production control
no. 40030523
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POWERLOCK Connector System
Page 14 von 48 Operating Instructions POWERLOCK Rev. -
OPTIONAL SYSTEM ACCESSORIES
Unlocking key: A special unlocking key is required to unlock the connectors.
Unlocking key LL0023N, order no. AN389900010
Figure 3: Accessories unlocking key
Protective caps: When not mated, the connector interface can be protected by
using a sealing cap. Two types of cap are offered, a simple soft plastic cap provid-
ing IP53 protection and an environmentally sealed rigid plastic cap with IP67 pro-
tection and the secondary lock feature, these are color coded to suit the parent
connector.
All caps are fitted with a cord lanyard for securing to its parent connector. Caps
for panel connectors have an M6 ring terminal on the end of the lanyard.
Caps not only offer protection against ingress of moisture and dirt into the inter-
face of the PowerLock connector, they also offer a degree of protection against
mechanical damage that can be caused when connectors on cables are being han-
dled and transported.
Figure 4: Accessories protective cap IP53 (left) and protective cap IP67 (right)
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 15 von 48
POWERLOCK-BOX: A connection unit in 19”format with 5 inputs for the power
supply of a three-phase network. It guarantees sequential plugging and unplug-
ging of connectors in correct order (PE, N, L1, L2, L3). An interlock protects the
sequential connection against unauthorized disconnection. The integrated micro-
switch can be used to connect a load-break switch or an alarm line.
The POWERLOCK-BOX is available in different configurations:
For drain and source contacts
With or without lockable cover
400A or 660A version
Different regional colors according to IEC 60445
Figure 5: Accessories POWERLOCK-Box
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POWERLOCK Connector System
Page 16 von 48 Operating Instructions POWERLOCK Rev. -
OVERVIEW OF THE INDIVIDUAL CONNECTORS
This section describes the currently available POWERLOCK connectors and shows
them in figures and technical drawings.
Connector POWERLOCK
Connector POWERLOCK ”
Connector POWERLOCK ”
Connector POWERLOCK ”
Connector POWERLOCK ”
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 17 von 48
CONNECTOR POWERLOCK “NLS”
NLS is a free connector that is usually attached on the side of the power source.
The contact has an insulating plastic cap at the front, which prevents accidental
contact and meets IP2X requirement.
For a connection of the current conductor there are the following types of con-
tacts:
Crimp contact made of copper, for copper conductor cross-sections from
35mm² to 300mm², up to 660 amperes
Set-Screw contact made of brass, for copper conductor cross-sections from
25mm² to 120mm², up to 400 amperes
Different cable glands cover a total range from 15mm to 38mm cable jacket di-
ameter. With an M50 cable gland, an adapter is supplied which bridges the M40
thread on the housing.
For better handling, the connector can optionally be ordered with a rubber hand
grip (Hand Grip “HG”).
For a quick release of the secondary locking, the connector can optionally be or-
dered with a sliding collar “SC”.
This section describes the currently available POWERLOCK connectors and shows
them in figures and technical drawings.
Figure 6: NLS connector
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POWERLOCK Connector System
Page 18 von 48 Operating Instructions POWERLOCK Rev. -
Figure 7: NLS connector: components
Pos.
Designation
Pos.
Designation
1
Connector housing
3
Cotter pin
2
Contact body
4
Cable gland
Figure 8: Connector NLS: Label or marking 400/660A
1
3
2
4
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POWERLOCK Connector System
Operating Instructions POWERLOCK Rev. - Page 19 von 48
Figure 9: Connector NLS: Dimensions in mm (in)
Further dimensions of connector housing, contact body and cable gland are
shown on drawing SR1841 and are available on request.
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POWERLOCK Connector System
Page 20 von 48 Operating Instructions POWERLOCK Rev. -
CONNECTOR POWERLOCK “NLDFT”
NLDFT is a free connector that is usually attached on the non-power side. The
contact has an insulating plastic cap at the front, which prevents accidental con-
tact and meets the IP2X requirement.
For a connection of the current conductor there are the following contact types:
Crimp contact made of copper, for copper conductor cross-sections from
35mm² to 300mm², up to 660 amperes
Set-Screw contact made of brass, for copper conductor cross sections from
25mm² to 120mm², up to 400 amperes
Different cable glands cover a total range from 15mm to 38mm cable jacket di-
ameter. For the M50 cable gland an adapter is supplied which bridges the M40
thread on the housing.
For better handling the connector can optionally be ordered with a rubber hand
grip (Hand Grip “HG”).
See also “Introduction to the POWERLOCK System” and “Description of terms” for
more information.
Figure 10: NLDFT connector
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