Lex Powergate PGIP12G-GWBRB-GKS Manual

A safe, convenient and reliable
way to connect and access
temporary power
Input / Output Panels
1200A / 1600A
Installation Instructions &
User Manual
LM-PGIP16001200 - Rev. 001

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected]
2
Contents
2 Contents / Important
3 Prior to Installation: Site Preparation
3 Shipment: Unpacking and Inspection
4 Product Features (Input / Output)
5 Installation (Input / Output)
6 Installation Continued (Input)
7 Set-up (Input)
8 Disconnecting Circuits (Input)
9 Installation (Output)
9 Set-up (Output)
10 Disconnecting Circuits (Output)
11 Kirk Key Installation
12 Product Feature Instructions (Input)
12 Limited Warranty
12 Maintenance
12 Technical Support
Appendices
12 Appendix A - Pre-Operation and Maintenance Checklist
13 Appendix B - Parts Dimensions
14 Appendix C - Labels for Replacement
16 Represented Model Numbers and Ratings
Important:
This manual contains information critical to the proper
installation and operation of the Lex Products PowerGATE™
Input and Output Panels. Be certain to read and understand all
instructions prior to installation and operation.
Lex Products PowerGATE™ Panels must be installed in
conjunction with transfer switch.
Lex Products PowerGATE™ Input Panels are Listed to UL 1008.
Lex Products PowerGATE™ Output Panels are Listed to UL 891
for Switchboards.

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected] 3
Prior to Installation: Site Preparation
Prepare installation site according to local codes.
The PowerGATE™ Panels are to be set on an exterior pad and
secured to a building or secured to a pad using 3/8“ fasteners
(See Figure 1).
The surface where the PowerGATE™ Panels are to be secured
must be capable of supporting the weight of the cabinet as well
as the cable attached to it.
The following should be taken into consideration when locating
the PowerGATE™ Panel:
– The PowerGATE™ Panels are designed for exterior operation
ONLY
– Identify and meet local codes and local Authority Having
Jurisdiction (AHJ) requirements
– To prevent carbon monoxide poisoning from improperly
ventilated generator emissions, the PowerGATE™ Panel
must be mounted outdoors only. The mounting location is
to be carefully selected to allow convenient connection to a
generator or load bank, and located a suitable distance away
from any building openings or HVAC inlets.
– Proper clearance must be allowed in front of the
PowerGATE™ Panel to allow for opening of access doors and
attachment of externally connected cables. This distance
should be no less than six (6) feet from the face of the panel
– While key lock protection is provided, potential access by
unauthorized personnel and vandals should be taken into
consideration when locating this device.
Shipment: Unpacking and Inspection
NOTE: Be careful in the use of sharp objects when cutting
packaging as scratching of outer coating may result in rusting.
Perform a visual inspection to ensure all key locks and doors are
in functioning condition and that the panel integrity is intact.
Figure 1

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected]
4
Product Features (Input Panel Pictured)
Purpose-built
Type 3R cabinet
independently tested
to current code
Large upper termination
chamber to ease cable
routing and installation
from top or bottom entry
Industry-standard Series 16 single pole cam
devices for rapid termination
(3) Key locked access
doors for ease of
inspection, termination
and prevention of
unauthorized access
Large copper bus bars with numerous locations for
securing load wiring
Figure 2
Figure 4
Cable access door for
mechanical strain reduction
and theft deterrence
Kirk Key Provision
hole knockouts
Phase Rotation Monitor
and 2 Wire Start / Stop
Terminals
(Input Panel)
Forklift Pockets
Figure 3
Figure 5
Removable access
panel for bottom entry
installation

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected] 5
Installation - Input / Output Panels
WARNING
The PowerGATE™ Panel is top heavy and therefore the
center of gravity is well above the forklift slots (See
Figure 6). Care must be taken to secure the device when it
is lifted and moved.
– Please note that the 1200 Amp versions weigh
approximately 495 pounds and the 1600 Amp versions
weigh approximately 505 pounds
The installation of the PowerGATE™Panel should be
carried out by qualied personnel in accordance with local
electrical codes.
Step 1: Fasten the PowerGATE™Power Panel
to secure base
1. Base must be level and plumb to allow for proper drainage
from the PowerGATE™ Panel weep holes
2. Fastening onto an external pad using 3/8” fasteners must
be completed prior to proceeding with any terminations (See
Figure 1 for hole spacing)
Step 2: Installing the Conduit
NOTE: Conduit to enter through the top, top rear or bottom
of the device (See Figure 1 and 7).
NOTE: To maintain TYPE 3R Rating compliance for the
enclosure, proper sealing procedures must be followed.
This is to include, but not limited to, the use of proper
gaskets.
1. Open upper to door to expose termination chamber
2. Conduit to be sized according to cabinet and cabling rating
3. It is recommended that a knockout punch be used to cut hole
for conduit. Place the punch on the inside of the enclosure
and draw the punch through to the die on the outside
4. Vacuum entire upper chamber to ensure no metal shavings
are left behind
Figure 6
Figure 7
Forklift Pockets

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected]
6
Installation - Input / Output Panels (continued)
(For Output Panels continue to page 9)
Step 3: Wiring the Bus Bars
WARNING
Ensure circuit breakers are OFF and the transfer switch is
locked out from utility power prior to connection.
Failure to install transfer switch will create the potential
for the generator to energize utility lines and endanger
utility personnel. Conversely, utility lines may energize the
PowerGATE™ Input Panel and endanger generator personnel.
The PowerGATE™Input Panel is for use only for
connection of a generator to the source terminals of a
transfer switch, such that the inlets are only energized
from the generator.
1. Secure ring terminals on ends of cable
– The recommended input (contractor direct wire) wire
gauge for this unit is 350 MCM
– Terminal crimp rings to have 1/2” opening
2. Secure ring terminals to bus bar
– Use 1/2” bolts tightened to ninety-eight (98) foot pounds
of torque
3. Secure a solid and permanent electrical ground between the
building ground point and the PowerGATE Power Input Panel
NOTE: Conduit shall NOT be relied upon to provide grounding
protection to tap box
4. Vacuum entire upper chamber to ensure no metal shavings
are left behind
WARNING
Three phase power systems consist of three phase or hot
conductors that are shifted by 120 degrees. Three phase
loads such as motors may only work properly if the phases
are connected in the correct order. Some motors may work
with connected improperly, but will operate backwards.
Utility power and electrical generators may be wired either in
a clockwise or counter-clockwise order. It is important that
any generator connected to the PowerGATE™ Input Panel
is connected in the same rotation (clockwise or counter-
clockwise) as the utility power.
Step 4: Determine Phase Rotation
This information will be needed when connecting a generator.
A: Determine phase rotation of the utility power
– Connect a phase rotation meter to a three phase power
source in the building and record whether the building is
wired clockwise or counter-clockwise
B: Apply the provided label (Figure 8) to the inside of the
PowerGATE™ Input Panel on the inside of the cam
connection chamber door (Figure 9).
Step 5: Conduct a safety test to ensure proper installation
Do not attempt to use the PowerGATE™ Input Panel prior to
installation and completing the Pre-Operation and Maintenance
Checklist under Appendix A.
Place rotation label here
Lex Products Part Number – LBL-PGIP-ROTATION
Figure 8
Figure 9

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected] 7
Set-up - Input Panels
Step 6: Review Pre-Operation Checklist under
Appendices A prior to operation (page 13)
WARNING
DO NOT ATTEMPT CONNECTION WHILE CIRCUITS ARE
LIVE
– Do not use cables if they appear frayed
– Do not use cable if connectors or plug do not seat
properly
– Do not use cables if any copper cabling is exposed
– To limit risk of shock, disable generator automatic start
to prevent unintended starting
Step 7: Determining phase rotation of generator
1. Disconnect generator from all loads if needed
2. Connect a phase rotation meter to the output phases of the
generator
3. Record generator phase rotation (clockwise or counter-
clockwise)
Step 8: Making Cam Connections
1. Open lower chamber door
2. Complete the Ground (green) connections, beginning with
the furthest from the front door to the left
Proper connection (See Figure 10)
A. Grasp connector jacket and rmly insert cam connector
into cam plug
B. Push on cam connector jacket until connector fully seats
in cam plug
C. Rotate cam connector jacket counterclockwise until it
stops
3. Continue with connections, beginning with the rear of the
cabinet and working forward
4. Complete ALL Ground connections working from back to
front prior to proceeding
5. Complete the Neutral (white) connections, beginning with the
furthest from the front door
Proper connection (See Figure 10)
A. Grasp connector jacket and rmly Insert cam connector
into cam plug
B. Push on cam connector jacket until connector fully seats
in cam plug
C. Rotate cam connector jacket counterclockwise until it
stops
6. Continue with connections, beginning with the rear of the
cabinet and working forward
7. Complete the Phase (hot) connection
A. Should the phase rotation of the generator (as determined
in Step 7.3) and utility power (label found on the inside
of the door for the Cam connection chamber) match,
connect the Hots as follows:
Generator Hot PowerGATE™Power Input Panel Hot
A A
B B
C C
B. Should the phase rotation of the generator (as determined
in Step 7.3) and utility power (label found on the inside
of the door for the Cam connection chamber) NOT match,
connect the Hots as follows:
Generator Hot PowerGATE™Power Input Panel Hot
A B
B A
C C
Proper connection (See Figure 8):
A. Grasp connector jacket and rmly Insert cam connector
into cam plug
B. Push on cam connector jacket until connector fully seats
in cam plug
C. Rotate cam connector jacket counterclockwise until it
stops
Figure 10

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected]
8
Step 10: Powering Up
WARNING
Power MUST BE supplied from a single generator
1. Start generator per manufacturer instructions
2. Toggle the transfer switch, diverting power from utility to
generator feed
Disconnecting Circuits - Input Panels
Step 11: Disconnecting Circuits
WARNING
DO NOT ATTEMPT DISCONNECTING WHILE CIRCUITS ARE LIVE
1. To limit risk of shock, disable generator automatic start to
prevent unintended starting
– Open lower chamber door
– Order of disconnect
2. Disconnect the Phase (hot) connections, beginning with the
closest to the front door to the right
Proper disconnection (See Figure 12):
A. Grasp connector jacket rmly and rotate cam connector
clockwise until it stop
B. Firmly pull on connector until it separates from the plug
C. Set aside
3. Continue with ALL Phase (hot) connections, beginning with
the front of the cabinet and working from front to back
4. Complete disconnect of ALL Hot connections prior to
proceeding
Figure 12
5. Disconnect the Neutral (white) connections, beginning with
the closest to the front door
Proper disconnection (See Figure 12):
A. Grasp connector jacket rmly and rotate cam connector
clockwise until it stop
B. Firmly pull on connector until it separates from the plug
C. Set aside
Figure 11
Set-up – Input Panels (continued)
8. Continue with connections, beginning with the rear of the
cabinet and working forward
9. Complete ALL Phase connections working from back to
front prior to proceeding
10. Make sure all connections are correct and secure
Step 9: Close and lock lower chamber door,
allowing cables to exit through smaller cable door

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected] 9
Disconnecting Circuits - Input Panels (continued)
6. Continue with ALL Neutral (white) connections, beginning
with the front of the cabinet and working from front to
back
7. Complete disconnect of ALL Neutral connections prior to
proceeding
8. Disconnect the Ground (green) connections, beginning with
the closest to the front door
Proper disconnection (See Figure 12):
A. Grasp connector jacket rmly and rotate cam
connector clockwise until it stop
B. Firmly pull on connector until it separates from the plug
C. Set aside
9. Continue with ALL Ground (green) connections, beginning
with the front of the cabinet and working rearward
10. Complete disconnect of ALL Neutral connections prior to
proceeding
Step 12: Secure the three (3) key locks to complete
procedure
Installation – Output Panels (continued)
(Output Panels continued from page 6)
WARNING
Ensure circuit breakers are OFF and the transfer switch is
locked out from Source power prior to connection.
Failure to install transfer switch will create the potential for
the source to energize the Lex Products PowerGATE™ Power
Output Panel and endanger installation personnel
The Lex Products PowerGATE™ Output Panel is for the
connection of a Load Bank to the Output terminals of a
transfer switch.
1. Secure wiring to the power feeds as appropriate
2. Secure a solid and permanent electrical ground between the
building ground point and the PowerGATE™ Input Panel
NOTE: Conduit shall NOT be relied upon to provide grounding
protection to tap box
3. Vacuum entire upper chamber to ensure no metal shavings
are left behind
Step 4: Conduct a safety test to ensure proper installation
Do not attempt to use the PowerGATE™ Output Panel prior to
installation and completing the Pre-Operation and Maintenance
Checklist under Appendix A.
Step 5: Review Pre-Operation Checklist under Appendices
A prior to operation (page 13)
WARNING
DO NOT ATTEMPT CONNECTION WHILE CIRCUITS ARE LIVE
– Do not use cables if they appear frayed
– Do not use cable if connectors or plug do not seat
properly
– Do not use cables if any copper cabling is exposed
– To limit risk of shock, disable generator automatic start
to prevent unintended starting
Step 6: Making Cam Connections
1. Open lower chamber door
2. Complete the Ground (green) connections, beginning with the
furthest from the front door to the left
Proper connection (See Figure 10):
A. Grasp connector jacket and rmly insert cam connector
into cam plug
B. Push on cam connector jacket until connector fully seats
in cam plug
C. Rotate cam connector jacket counterclockwise until it
stops
3. Continue with connections, beginning with the rear of the
cabinet and working forward
4. Complete ALL Ground connections working from back to
front prior to proceeding
5. Complete the Neutral (white) connections, beginning with
the furthest from the front door
Proper connection (See Figure 10):
A. Grasp connector jacket and rmly Insert cam connector
into cam plug
B. Push on cam connector jacket until connector fully seats
in cam plug
C. Rotate cam connector jacket counterclockwise until it
stops

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected]
10
Installation – Output Panels (continued)
6. Continue with connections, beginning with the rear of the
cabinet and working forward
7. Complete the Phase (hot) connections
Proper connection (See Figure 10):
A. Grasp connector jacket and rmly Insert cam connector
into cam plug
B. Push on cam connector jacket until connector fully seats in
cam plug
C. Rotate cam connector jacket counterclockwise until it
stops
Step 7: Close and lock lower chamber door, allowing cables
to exit through smaller cable door (See Figure 11)
Step 8: Powering Up
WARNING
Power MUST BE supplied from a source wired to a Transfer
Switch
1. Toggle the transfer switch, diverting power from building
loads to load bank
Disconnecting Circuits - Output Panels (continued)
Step 9: Disconnecting Circuits
WARNING
DO NOT ATTEMPT DISCONNECTING WHILE CIRCUITS ARE
LIVE
– Open lower chamber door
– Order of disconnect
1. Disconnect the Phase (hot) connections, beginning with the
closest to the front door to the right.
Proper disconnection (See Figure 12):
A. Grasp connector jacket rmly and rotate cam connector
counter clockwise until it stops
B. Firmly pull on connector until it separates from the plug
C. Set aside
3. Continue with ALL Phase (hot) connections, beginning with
the front of the cabinet and working from front to back
4. Complete disconnect of ALL Hot connections prior to
proceeding
5. Disconnect the Neutral (white) connections, beginning with
the closest to the front door
Proper disconnection (See Figure 12):
A. Grasp connector jacket rmly and rotate cam connector
counter clockwise until it stops
B. Firmly pull on connector until it separates from the plug
C. Set aside
6. Continue with ALL Neutral (white) connections, beginning
with the front of the cabinet and working from front to back
7. Complete disconnect of ALL Neutral connections prior to
proceeding
Proper disconnection (See Figure 12):
A. Grasp connector jacket rmly and rotate cam connector
counter clockwise until it stops
B. Firmly pull on connector until it separates from the plug
C. Set aside
8. Continue with ALL Ground (green) connections, beginning
with the front of the cabinet and working rearward
9. Complete disconnect of ALL Neutral connections prior to
proceeding
Proper disconnection (See Figure 10):
A. Grasp connector jacket rmly and rotate cam connector
counter clockwise until it stops
B. Firmly pull on connector until it separates from the plug
C. Set aside
Step 10: Secure the three (3) key locks to complete
procedure

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected] 11
Kirk Key Installation
Kirk Key Installation
Parts Kit
– Lex Products Power Input / Output Panel
– Lex Products Kirk Key Install Kit (comes with unit)
• Seeloc washer
• Silicone Sealant
– HD Series Kirk Key (Type D of DM) (not provided by Lex
Products)
Equipment Needed
– Torque wrench
– Nut driver or wrench
Installation Instructions
– Install catch to bracket provided on the inside of the
enclosure
– Install kirk key lock/housing to the inside of the door
panel
– Remove bracket from door panel
– Attached Kirk Key lock/housing to the bracket
– Torque 30 in-lb
Apply provided (UL50/50E 3R Rated) sealant to the junction
where the Kirk Key lock will meet the door panel and the
aperture of the door panel intended for the lock.
Form a complete circular ring around the shoulder in order to
provide a 360 ° seal.
Attach the Kirk Key to the door panel using the Seeloc washers
provided.
– Place the Kirk Key cylinder head through the aperture
provided in the front door of the enclosure
– Secure the Kirk Key to the panel by inserting the 3/8” bolts
using the following order:
1. Seeloc
2. Front Panel
3. Kirk Key Housing
4. Spring Washer
5. 3/8” Nut
NOTE: Seeloc washers provided may vary in color from the ones
shown above.
– Ensure that the Kirk Key lock properly engages with the
catch when the unit is closed.

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected]
12
Appendix A
Pre-Operation Checklist
1. Visual inspection of enclosure
– Ensure the PowerGATE™ Panel is rmly secured to its
base and/or building
– Review conduit connection for signs of leakage
– Ensure paint is intact with no signs of rust or corrosion
2. Open all chamber doors
– Ensure chambers are dry and free of debris
– Ensure that gaskets are pliable and no cracking exists
– Ensure that door hinges are secure and lubricated
– Ensure that keylocks are intact and operational
– Ensure that all load terminals are securely fastened and
that the bolts are set at ninety-eight (98) foot pounds of
torque
– Ensure paint is intact with no signs of rusting or corrosion
– Ensure electrical connections are intact with no signs of
corrosion or cracking
3. Review all safety labels and ensure that they are present
and legible
– See Appendix D for label nomenclature and location
– Replace as needed
4. Inspect all portable cables
– Do not use cables if they appear frayed
– Do not use cable if connectors or plug do not seat
properly
– Do not use cables if any copper wiring is exposed
5. Lex Products Technical Service department is available 24/7
to assist in resolving issues. If you have any questions or
need technical advice or suggestions regarding this product,
please contact Lex Products at 800.643.4460 or e-mail
[email protected].
Product Feature Instructions
Phase Rotation Monitor
Visually Monitor the correct sequence of phases L1, L2 and
L3 by the presence of a yellow LED light. If connected to a
generator and the yellow light is not present, reverse any two
phases. The LED light will then illuminate.
Limited Warranty
When this PowerGATE™ Input / Output Panel is installed and
operated according to the manual’s instructions Lex Products
will repair or replace any of its mechanical or electrical parts
if they are found to be defective in material or workmanship
within one year of the purchase date.
Maintenance
The PowerGATE™ Input / Output Panel will require periodic
maintenance. Lex Products recommends annual inspections
to keep the panel in safe operating condition. Lex Products
recommends that the Pre-Operation and Maintenance Checklist
under Appendix A serve as a basis for annual inspection.
Technical Support
Lex Products technical services are available to assist in
resolving issues by calling 800.643.4460 or email info@
lexproducts.com.
For any other information, please call Lex Products at
800.643.4460 or e-mail [email protected].

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected] 13
Appendix B
Parts Dimensions

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected]
14
Appendix C
Labels for Replacement - Input Panel

PowerGATE™ Power Input / Output Panel
Contact Lex Products: 800.643.4460 [email protected] 15
Appendix C - Continued
Labels for Replacement - Output Panel

PowerGATE™ 1200 / 1600 Amp
Power Input / Output Panels
Installation Instructions and User
Manual
Ordering Information
TYPE 3R Rainproof
Input Panels Output Panels
1200 Amp Part Numbers PGIP12G-GWBRB-GKS PGIP12G-GWBOY-GKS PGOP12G-GWBRB-KS PGOP12G-GWBOY-KS
Rating 1200A, 3 Phase (H,H,H,N,G), 4 Pole, 5 Wire, 60 Hz
480 VAC Maximum
400A, 3 Phase (H,H,H,N,G), 4 Pole, 5 Wire, 60 Hz
600 VAC Maximum
Environmental Rating TYPE 3R Rainproof
Input (3) Sets of (5) Panel Mount 16 Series Cam-type
Inlets, Color-coded Copper Bus Bars with 1/2” Holes
Output Copper Bus Bars with 1/2” Holes (3) Sets of (5) Panel Mount 16 Series Cam-type
Receptacles, Color-coded
Enclosure Galvanized Steel - Textured Powder Coat ANSI 61 Gray
Dimensions 56” H x 35”W x 30”D
Approximate Weight 495 lbs.
1600 Amp Part Numbers PGIP08A-BRBWG-GKL PGIP08A-BOYWG-GKL PGOP08A-BRBWG-KL PGOP08A-BOYWG-K
Rating 1600A, 3 Phase (H,H,H,N,G), 4 Pole, 5 Wire, 60 Hz
480 VAC Maximum
1600A, 3 Phase (H,H,H,N,G), 4 Pole, 5 Wire, 60 Hz
600 VAC Maximum
Environmental Rating TYPE 3R Rainproof
Input (4) Sets of (5) Panel Mount 16 Series Cam-type
Inlets, Color-coded Copper Bus Bars with 1/2” Holes
Output Copper Bus Bars with 1/2” Holes (4) Sets of (5) Panel Mount 16 Series Cam-type
Receptacles, Color-coded
Enclosure Galvanized Steel- Textured Powder Coated ANSI 61 Gray
Dimensions 56” H x 35”W x 30”D
Approximate Weight 505 lbs.
Lex Products
11 Forest Parkway
Shelton CT 06484
203.363.3738
203.363.3742 Fax
Lex West
12701 Van Nuys Blvd.
Pacoima, CA 91331
Suite Q
818.768.4474
818.768.4040 Fax
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Produced in the United States of America
All Rights Reserved.
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trademarks or registered trademarks of Lex Products
in the United States, other countries, or both.
www.lexproducts.com
[email protected]
800.643.4460
Additional Cam options and enclosure materials available.
Contact a Lex Products Sales Representative for more information.