LAPP POWERLOCK BOX User manual

POWERLOCK BOX
User manual
Inhalt
1 Colour Coding.......................................................................................................................... 2
2 Un-packing & content.............................................................................................................. 2
3 Mounting at the control cabinet/ buliding .............................................................................. 2
3.1 Mechanical mounting ....................................................................................................... 2
3.2 Power installation ............................................................................................................. 3
3.3 Connector for remote sensing ......................................................................................... 3
4 Installation and usage.............................................................................................................. 4
4.1 Warnings........................................................................................................................... 4
4.2 Connection with cable connectors................................................................................... 4
5 Technical data ......................................................................................................................... 5
6 Maintenance & disposal .......................................................................................................... 5
7 Appendix –Mounting of the micro switch connector ............................................................. 6

1 Colour Coding
Region
Earth
Neutral
L1
L2
L3
Europe
United States
Australia
2 Un-packing & content
Before unpacking, make sure that the packaging is undamaged. Before unpacking, the part
number of the POWERLOCK BOX should be checked against your order. Also check that the
current rating label on the unit matches your requirements. The carton should contain the
following:
1x POWERLOCK BOX
1x 6 mm Allen wrench
1x 2-pole cable connector for remote sensing
1x Operating / Maintenance guide
3 Mounting at the control cabinet/ building
3.1 Mechanical mounting
POWERLOCK BOXES are designed for 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 2.94 Nm min. to 3.43 Nm max. The
screws / bolts should be tightened evenly. Adequate support during assembly must be pro-
vided.

If the 19” rack does not support all IEC 60297 requirements, the use of additional mounting
plates may apply.
3.2 Power 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 the safe practices are
adopted.
Power installation: M12 threaded posts on the rear of the unit are for connecting power ca-
bles 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 27.5 Nm min. to 31.4 Nm max.
It is recommended that insulated spanners are used when making these connections.
3.3 Connector for remote sensing
A 2-pole Trident connector is at the back of the POWERLOCK BOX to enable remote sensing.

The 2 pole connector mounted on the rear
is connected to a micro-switch inside the
unit: If all connectors are in place and the
unit is locked, the micro switch is locked A
complete assembly instructions for this
connector are shown at the end of this doc-
ument.
Micro switch with POWERLOCK BOX - open
Micro switch with POWERLOCK BOX - closed
4 Installation and usage
4.1 Warnings
This box should only be operated by suitably qualified persons.
Only original 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.
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 / disconnect under load!
4.2 Connection with cable connectors
The necessary mating connectors have to be ordered separately and are not part of the deliv-
ery. Recommended cross-sections are printed on the rear of the box:
400- 120 mm² and 660 A –240 mm².
1. Use the Allen wrench to open the cover (version with safety cover).
2. The POWERLOCK connectors are plugged sequentially in a row. Starting on the left with
the Ground/Earth connection (Green) going to the right with N, L1, L2, L3.
3. Insert the Ground (Green) connector, aligning the “PUSH” arrow on the label of the con-
nector 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 locks with an audible „click‟.
4. Repeat the above process for the Neutral connector and the rest of the connectors. If at
any time a connectors does not rotate fully, check if the previous connector is fully
turned.
5. The lock is located to the right of the L3 connector on the front panel. The needed square
drive key is provided.

6. Remove the key. All connectors are now locked in place and cannot be removed until the
box is unlocked.
7. To remove the connectors, ensure that the power is turned off and reverse the above pro-
cedure.
5 Technical data
The POWERLOCK BOX is CE labeled and fullfills all relevant requirements.
Current rating
400 or 660 ampere (depending on the version)
Voltage rating
1000V AC /1500V DC
Dielectric strength
9500 V DC
Micro-switch operating voltage
125 V AC max.
Micro-switch operating current
5 A
Operating temperature
- 30°C to +85°C
Environmental protection
IP65 connectors plugged
IP65 with closed safety cover (box with cover)
Weight
3,25 kg (without cover) 3,75 kg (with cover)
Flammability rating
UL94 –V0
Mating cycles
500
6 Maintenance & disposal
Mounting and maintenance should only be performed by qualified staff.
Periodic greasing of the O-Ring seals on the connector ports is recommended.
The POWERLOCK BOX should regularly be inspected for damage, including a visual in-
spection of the source contacts.
Periodic retention testing of PS (Power Source) contacts is recommended to confirm
that contact life has not been exceeded
Disposal:
After use the device should be disposed of in accordance with national or local author-
ity guidelines.
The carton and its packing are recyclable and should be disposed according to na-
tional or local authority guidelines.

7 Appendix –Mounting of the micro switch connector
Bag content Trident connector
1. Cross-sectional area 14 - 26 AWG
2. Strip 6 mm of the wire. Twist the braids
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 cavaties A & C.
Position B & D are preloaded to prevent a
wrong positioning of the contacts.
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.
U.I. Lapp GmbH
D-70565 Stuttgart/Germany
www.lappgroup.com
A Company of the Lapp Group