ITT POWERLOCK BOX Quick guide

POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 1of 40
TRANSLATION OF THE ORIGINAL
OPERATING INSTRUCTIONS
CAS25124E
POWERLOCK BOX
Connection box to the connector system
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POWERLOCK BOX
Page 2of 40 Operating Instructions POWERLOCK BOX 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 BOX” and is protected by copy-
right.
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 BOX
Operating Instructions POWERLOCK BOX Rev. - Page 3of 40
TABLE OF CONTENTS
Imprint .......................................................................................................... 2
Declaration of conformity.............................................................................. 5
Information about the document ..................................................................7
Description of the terms................................................................................8
Intended use................................................................................................ 10
Short description...........................................................................................10
Area of aplication..........................................................................................11
Overview and description............................................................................ 12
Introduction of POWERLOCK System............................................................12
POWERLOCK BOX connection box ....................................................................12
CONNECTOR POWERLOCK................................................................................12
Color coding according to IEC 60445 ............................................................13
Designs and versions.....................................................................................14
Housing versions...............................................................................................14
Contact versions................................................................................................14
Regional color coding........................................................................................14
Power rating......................................................................................................14
Technical Specifications ................................................................................17
Certification ......................................................................................................17
Mechanical........................................................................................................17
Electrical............................................................................................................18
Enviroment........................................................................................................18
Dimensions and measurements ...................................................................19
POWERLOCK BOX with flange...........................................................................19
POWERLOCK BOX without flange .....................................................................20
Label and marking.........................................................................................21
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POWERLOCK BOX
Page 4of 40 Operating Instructions POWERLOCK BOX Rev. -
MICROSWITCH FOR REMOTE MONITORING ................................................22
Transportation and storage..........................................................................23
Delivery of POWERLOCK BOX .......................................................................23
Scope of delivery POWERLOCK BOX .................................................................23
Transportation OF POWERLOCK BOX ...........................................................24
Installation/Commisioning...........................................................................25
Installation/Commisioning information .......................................................25
Mounting in installation frame (Rack) ..........................................................26
Cutout installation frame..................................................................................27
Electrical connection (current conductor)....................................................28
Connection for remote monitoring ..............................................................29
Trident Connector assembly.............................................................................29
Connection connector POWERLOCK.............................................................32
Exemplary connection (EU-Coding) ..................................................................33
Disconnecting the connections.........................................................................36
Maintenance................................................................................................36
Control of the components ..........................................................................36
Cleaning of the components.........................................................................37
Disposal of the POWERLOCK BOX.................................................................37
List of figures................................................................................................38
Remarks and notes.......................................................................................39
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POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 5of 40
DECLARATION OF CONFORMITY
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POWERLOCK BOX
Page 6of 40 Operating Instructions POWERLOCK BOX Rev. -
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POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 7of 40
INFORMATION ABOUT THE DOCUMENT
This document “Operating Instructions POWERLOCK BOX”contains important in-
formation about transportation, assembly (function), installation, operation and
maintenance of the connection box POWERLOCK BOX.
This document is part of the technical documentation for the connection box
POWERLOCK BOX. Other applicable documents include the declaration of con-
formity, 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 BOX and other tasks related to the
POWERLOCK BOX.
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-
LOCK BOX.
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 connection
box of the type POWERLOCK BOX are strictly forbidden!
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POWERLOCK BOX
Page 8of 40 Operating Instructions POWERLOCK BOX Rev. -
DESCRIPTION OF THE TERMS
In the designation of the POWERLOCK BOX technical terms or abbreviations of
technical terms can be found which are listed and described here.
Contact type PD Power Drain: Connector equipped with a "female" contact in a
"male" housing. The contact body is fitted with a spring-loaded insulated cap to
prevent contact.
This type is usually connected on the non-current carrying side
Contact type PS Power Source: Connector equipped with a "male" contact in a
"female" housing. The contact body is fitted with an insulated cap to prevent con-
tact.
This type is usually connected on the side of the power source.
Fig. 1: Connecting Uses
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POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 9of 40
Lid: Lid of the POWERLOCK BOX provided with a seal. The lid can be locked with
a 6 mm square key. Both the variants of the POWERLOCK BOX with lid and the
variants without lid comply with protection class IP 65.
Fig. 2: POWERLOCK BOX with lid (A) and without lid (B)
Flange: The flange attached horizontally to the housing of the POWERLOCK BOX,
for additional stabilization when installed in a 19" rack. All variants of the POW-
ERLOCK BOX are designed with a flange in vertical direction, which is not a distin-
guishing feature.
Fig. 3: POWERLOCK BOX with flange (A) and without flange (B)
A
3
B
3
A
3
B
3
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POWERLOCK BOX
Page 10 of 40 Operating Instructions POWERLOCK BOX Rev. -
INTENDED USE
SHORT DESCRIPTION
The POWERLOCK BOX connection box described here is a connection unit in 19"
format with 5 inputs for the power supply of a three-phase network for high-cur-
rent connections with up to 660 A current intensity. The POWERLOCK BOX con-
nection box is designed for the use of POWERLOCK type connectors. For outdoor
installation, the POWERLOCK BOX with cover and flange is recommended.
The individual connections of the POWERLOCK BOX junction box are color-coded
to meet the requirements of three-phase electrical systems.
Typical fields of application for this product in conjunction with the POWERLOCK
connector system are:
In a mobile or stationary power distribution system for low voltage, e.g.
emergency power system or inland waterway transport.
Connections of motors, transformers or generators, e.g. wind power
plants.
In event technology, e.g. power supply for sports events and concerts.
INFORMATION!
Further information on the POWERLOCK connector system can
be found in the current operating instructions.
https://www.ittcannon.com/products/powerlock/
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POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 11 of 40
AREA OF APLICATION
The POWERLOCK BOX connection box has been designed and manufactured us-
ing state-of-the-art techniques and in accordance with approved safety regula-
tions and the recognized standards EN 61984, 60512, 60664-1 and 60529. Never-
theless, 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 dam-
aged.
Intended use of the connection box POWERLOCK BOX 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 BOX connection box 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 BOX
Page 12 of 40 Operating Instructions POWERLOCK BOX Rev. -
OVERVIEW AND DESCRIPTION
INTRODUCTION OF POWERLOCK SYSTEM
POWERLOCK BOX CONNECTION BOX
The POWERLOCK BOX is a connection unit in 19" format with 5 inputs for the
power supply of a three-phase network. It guarantees sequential plugging and
unplugging of connectors in correct order (PE, N, L1, L2, L3). The POWERLOCK
BOX is designed for the use of the POWERLOCK type connectors.
An interlock protects the sequential connection against unauthorized disconnec-
tion. The integrated microswitch can be used to connect a load-break switch or
an alarm line. The POWERLOCK-BOX is available in different versions:
400A or 660A version
For drain and source contacts
With or without lockable cover
Different harmonized colors according to IEC 60445
CONNECTOR POWERLOCK
The POWERLOCK connector system consists of single-pole connectors in insulated
plastic housings. They are used in high current applications up to 660 A current
intensity in single or multi-phase power distribution systems.
Further information on the POWERLOCK connector system can be found in the
current operating instructions. The operating instructions can be accessed with
the following link:
https://www.ittcannon.com/products/powerlock/
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POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 13 of 40
COLOR CODING ACCORDING TO IEC 60445
Fig. 4: POWERLOCK BOX with POWERLOCK connectors (EU coding)
Ground
(E)
Neutral
(N)
Line 1
(L1)
Line 2
(L2)
Line 3
(L3)
Australia
GREEN
BLACK
RED
WHITE
BLUE
Europe
GREEN
BLUE
BROWN
BLACK
GREY
North America
GREEN
WHITE
BLACK
RED
BLUE
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POWERLOCK BOX
Page 14 of 40 Operating Instructions POWERLOCK BOX Rev. -
DESIGNS AND VERSIONS
The POWERLOCK-BOX is available in different versions or variants of the same.
HOUSING VERSIONS
with cover and flange: PBX-SLF-xx-xx-xxx
with cover, without flange: PBX-SL-xx-xx-xxx
without cover, with flange: PBX-NLF-xx-xx-xxx
with cover, without flange: PBX-NL-xx-xx-xxx
CONTACT VERSIONS
Source contact, „male“: PBX-xx-PS-xx-xxx
Drain contact, „female“: PBX-xx-PD-xx-xxx
REGIONAL COLOR CODING
Europe: PBX-xx-xx-EU-xxx
North America: PBX-xx-xx-US-xxx
Australia: PBX-xx-xx-AU-xxx
POWER RATING
Up to 400 A rated current: PBX-xx-xx-xx-400
Up to 660 A rated current: PBX-xx-xx-xx-660
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POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 15 of 40
Fig. 5: Ordering information for the POWERLOCK BOX
Fig. 6: PBX-NL-PS-EU-660, without cover, without flange, EU coding, 660 A
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POWERLOCK BOX
Page 16 of 40 Operating Instructions POWERLOCK BOX Rev. -
Fig. 7: PBX-SL-PD-EU-400, with cover, without flange, EU coding, 400 A
Fig. 8: POWERLOCK BOX with cover and flange
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POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 17 of 40
TECHNICAL SPECIFICATIONS
CERTIFICATION
Description
Value
VDE tested and certified
VDE Reg.Nr. D042
Certificate with manufacturing
supervision no. 40030523
MECHANICAL
Description
Value
Material contact
Brass (up to 400 A), silver-
plated
Copper (up to 660 A), silver
plated
Material housing
PBT High temp. thermoplastic
Material seals
Neoprene
Material springs
Austenitic steel
Release pins inside
Austenitic steel
Material contact retaining pin
PA
Material locking / lock
Brass and stainless steel
Mating cycles
Min. 500
Connection type
Threaded bolt M12
Weight with cover
3,75 kg
Weight without cover
3,25 kg
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POWERLOCK BOX
Page 18 of 40 Operating Instructions POWERLOCK BOX Rev. -
ELECTRICAL
Description
Value
Rated current
400 A resp. 660 A
Rated voltage
1 000VAC / 1000VDC
acc. to DIN EN 61984
Test voltage
4500 V (AC)
Short circuit current
16 kA for 1s (34 kA peak)
Insulation resistance
> 5000 MOhm
Electrical protection class
IP2X
Micro switch
Operating voltage
125 V AC (max.)
Micro switch
Rated current
5 A
Contact resistance
< 0,1 mΩ
Pollution degree
3
ENVIROMENT
Description
Value
Permissible operating temperature
-30° C up to +85° C
Protection class, plugged
IP65
Flammability
UL94-V0
RoHS Directive (Hazardous
Substances)
Consistent
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POWERLOCK BOX
Operating Instructions POWERLOCK BOX Rev. - Page 19 of 40
DIMENSIONS AND MEASUREMENTS
POWERLOCK BOX WITH FLANGE
Fig. 9: PBX SLF (with cover, with flange), bottom PBX NLF (without cover, with flange)
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POWERLOCK BOX
Page 20 of 40 Operating Instructions POWERLOCK BOX Rev. -
POWERLOCK BOX WITHOUT FLANGE
Fig. 10: PBX SL (with cover, without flange), bottom PBX NL (without cover, without
flange)
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