Lex PowerGATE 400A User manual

PowerGATE™
400A - 800A
Input / Output Panels
User Manual
Switches & Panels
PowerGATE™
A safe, convenient and
reliable way to connect
and access temporary
power
LM-PIP400

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2
Contents
2 Contents / Important
3 PriortoInstallaon(Input/Output)
3 Shipment:UnpackingandInspecon(Input/Output)
4 ProductFeatures(Input/Output)
5 Installaon(Input/Output)
6 InstallaonConnued(Input)
7 Set-up(Input)
8 DisconnecngCircuits(Input)
8-9 Installaon(Output)
9 Set-up(Output)
10 DisconnecngCircuits(Output)
10 ProductFeatureInstrucons(Input)
11 KirkKeyInstallaon
12 Limited Warranty
12 Maintenance
12 TechnicalSupport
Appendices
12  Pre-OperaonandMaintenanceChecklist
13 Parts Dimensions
13 Replacement Parts
14 - 15 Labels for Replacement
16  RepresentedModelNumbersandRangs
Important:
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2
PowerGATE™ Power Input / Output Panel
Thismanualcontainsinformaoncricaltotheproper
installaonandoperaonoftheLexProductsPowerGATE™
Panels.Becertaintoreadandunderstandallinstruconsprior
toinstallaonandoperaon.
Lex Products PowerGATE™ Panels mustbeinstalledin
conjunconwithaTransferSwitch.
Thismanualisfurnishedexclusivelytosupportinstallaon
andoperaonoftheLexProductsPowerGATEInput/Output
Panels. All concepts and ideas are the sole property of Lex
Productsandarenottobeduplicatedorulizedinany
mannerwithoutwrienpermission.
LexProductsPowerGATE™InputPanelsareListedtoUL1008.
LexProductsPowerGATE™OutputPanelsareListedtoUL891
for Switchboards.

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Prepareinstallaonsiteaccordingtolocalcodes.
ThePowerGATE™Panelistobesecuredtoabuildingusing
appropriate3/8“fasteners(SeeFigure1).
ThesurfacewherethePowerGATE™Panelistobesecured
mustbecapableofsupporngtheweightofthecabinetas
wellasthecableaachedtoit.
Thefollowingshouldbetakenintoconsideraonwhen
locangthePowerGATE™Panel:
–ThePowerGATE™Panelisdesignedforexterioroperaon
ONLY.
–IdenfyandmeetlocalcodesandlocalAuthorityHaving
Jurisdicon(AHJ).
– To prevent carbon monoxide poisoning from improperly
venlatedgeneratoremissions,thePowerGATE™Panel
mustbemountedoutdoorsonly.Themounnglocaonis
tobecarefullyselectedtoallowconvenientconnecon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aachmentofexternallyconnectedcables.This
distanceshouldbenolessthansix(6)feetfromthefaceof
the panel.
–Whilepadlockproteconisprovided,potenalaccessby
unauthorizedpersonnelandvandalsshouldbetakeninto
consideraonwhenlocangthisdevice.
Note:Becarefulintheuseofsharpobjectswhencung
packagingasdamagetotheouterenclosuremayresult.
Performavisualinspecontoensurethedoorandalllatching
hardwareareinfunconingcondionandthatthepanel
integrity is intact.
Prior to Installaon: Site Preparaon
PowerGATE™ Power Input / Output Panel
Frontviewwithmounngholes
Shipment: Unpacking and Inspecon
Figure 1 (Input / Output Panel)

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Product Features InputPanelPictured
PowerGATE™ Power Input Panel
Seamless gasket
provides water &
dust ght seal
Enclosed CAM
connecon cabinet
prevents exposed
live connecons
Ample contractor
wiring room to
accommodate wire
bend radii
Lug terminals
provide secure
connecons to
building wiring
Industry standard
Cam-type
connecons for
rapid terminaon
Integral mounng
brackets secure
the panel to the
building
Padlock handle
prevents
unauthorized
access
Low prole
aluminum
enclosure is only
11 ½ inches deep
Individual cable
entry holes restrict
access, reducing
cable the
-EnreassemblyiscULusListedNEMA3RRainproof
-Lowprole
- Cables drape straight down
- Dead front panel prevents accidental contact with wiring
chamber
Figure 2
Figure 3
Figure 4
Kirk Key Provision
hole knockout
Phase Rotaon
Monitor and 2
Wire Start Stop
Terminals
(inputPanel)

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Installaon
The installaon of the PowerGATE™ Panel should be
carried out by qualied personnel in accordance with
local electrical codes.
The PowerGATE™ Panel must be installed in conjuncon
with a transfer switch.
The transfer switch shall not have a rang greater than
the PowerGATE™Panel.
Step 1: Fasten the PowerGATE Power Panel
to secure locaon
NOTE: The PowerGATE™ Panel weighs approximately 58
lbs. without aached cables.
1.Thepanelshouldbelocatedsothereisadequateroom
for the externally connected cables to hang below the
panel
-Typicallyallowaminimumof36”clearancefromthe
boomofthepaneltonishedgroundlevel
2.Fasteningontoanexternalwallusing3/8”fasteners
mustbecompletedpriortoproceedingwithany
terminaons(SeeFigure1A/1Bforholespacing)
Step 2: Installing the Conduit
NOTE: Conduit to enter through the top of the device
(See Figure 5)
PowerGATE™ Power Input / Output Panel
NOTE: To maintain TYPE 3R Rang compliance for the
enclosure, proper sealing procedures must be followed. This
is to include, but is not limited to, the use of proper gaskets.
NOTE: In order to prevent enclosure damage and to aain
the enclosure requirements, the conduit must be aligned to
prevent unnecessary stress on the enclosure walls.
1.Openuppertodoortoexposedeadfrontpanel
2.Unfastenthedeadfrontpanelbyremovingthefour(4)
Phillips-headed10-32x1/2”screwssecuringit(SeeFigure
6Aand6B)
3.Conduittobesizedaccordingtocablingrang
4.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.
5.Vacuumenreupperchambertoensurenoshavingsare
lebehind
Figure 5
Figure 6A Figure 6B
Input / Output Panel
Frontviewwithhinged
cover removed
Frontviewwithdead
front panel removed

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Step 3: Wiring the Lug Terminals
The PowerGATE™ Power Input Panel is for the connecon
of a generator to the source terminals of a transfer switch,
such that the inlets are only energized from the generator.
1.PullthecablesfromthetransferswitchtothePowerGATE™
InputPanel
2.Beginningwiththeground,stripandinstallthecablesinthe
appropriate compression terminals
NOTE: The terminals can accommodate #2 to 600 MCM,
Copperoraluminumwire
3.Tightenterminalscrewsto375lb-intorqueeach
4.Ifmetallicconduitisused,connectgroundwirefrom
groundbushingonconduittothegroundconneconpoint
intheupperrightquadrantofthepanel
A.Groundconductormustbeaminimumof#3AWG
NOTE:ConduitshallNOTbereliedupontoprovide
groundingprotecontotapbox
5.Connuetoconnecttheneutralandthenthephases
6.Vacuumenreupperchambertoensurenometalshavings
arelebehind
7.Replacedeadfrontpaneldoorandsecureusingfour(4)10-
32x1/2”Phillips-headedscrews
Step 4: Determine Phase Rotaon
Thisinformaonwillbeneededwhenconnecngagenerator.
1.Determinephaserotaonoftheulitypower.
A.Connectaphaserotaonmetertoathreephasepower
sourceinthebuildingandrecordwhetherthebuildingis
wiredclockwiseorcounter-clockwise
2.Applytheprovidedlabel(Figure7)totheinsideofthe
PowerGATE™InputPanelontheinsideofthecamconnecon
chamberdoor(Figure8).
WARNING
EnsurecircuitbreakersareOFFandthetransferswitchis
lockedoutfromulitypowerpriortoconnecon.
Failuretoinstalltransferswitchwillcreatethepotenal
forthegeneratortoenergizeulitylinesandendanger
ulitypersonnel.Conversely,ulitylinesmayenergize
thePowerGATE™ InputPanelandendangergenerator
personnel.
WARNING
Three phase power systems consist of three phase or hot
conductorsthatareshied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
whenconnectedimproperly,butwilloperatebackwards.
Ulity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rotaon(clockwiseor
counter-clockwise)astheulitypower.
PowerGATE™ Power Input Panel
Installaon – Connued
(For Output Panels connue to page 9)
Place rotaon label here
WARNING
AVERTISSEMENT
Risk of Electric Shock
Plug connection should be in the following order:
1) Equipment grounding conductor connectors,
2) Grounded circuit conductor connectors, and
3) Ungrounded conductor connectors.
Disconnection should be in the reverse order”
Risque de choc électrique
Le raccordement devrait être effectué dans l’ordre qui suit:
1) Conducteur de mise à la terre de l’appareillage
2) Conducteur du circuit mis à la terre
3) 3) Conducteurs non mis à la terre
La mise hors tension doit se faire dans l’ordre inverse
DANGER
HIGH VOLTAGE
KEEP OUT
HAUTE TENSION
NE PAS TOUCHER
Do not start the generator until all connectors are connected
or made to be inaccessible. Any terminal may be energized
when any cable is connected. De-energize cables at the
generator prior to connecting or removing any connectors
Ne pas mettre la génératrice en marche avant que tous les
connecteurs soient connectés ou rendus inaccessibles.
N’importe quelle borne peut être mise sous tension si un
câble est raccordé. Débrancher les câbles à la génératrice
avant de brancher ou de débrancher les connecteurs
DANGER
Model
Rating
S/N
Transfer Switch Accessory
Made in USA www.lexproducts.com 1-800-643-4460
LBL-PGIP
TYPE 3R
RAINPROOF
A
LBL-A
B
LBL-B
C
LBL-C
N
LBL-N
G
LBL-G
DANGER
HIGH VOLTAGE
KEEP OUT
HAUTE TENSION
NE PAS TOUCHER
DANGER
DANGER
DANGER
HIGH VOLTAGE
KEEP OUT
HAUTE TENSION
NE PAS TOUCHER
DANGER
Do not start the generator until all connectors are connected
or made to be inaccessible. Any terminal may be energized
when any cable is connected. De-energize cables at the
generator prior to connecting or removing any connectors
Ne pas mettre la génératrice en marche avant que tous les
connecteurs soient connectés ou rendus inaccessibles.
N’importe quelle borne peut être mise sous tension si un
câble est raccordé. Débrancher les câbles à la génératrice
avant de brancher ou de débrancher les connecteurs
Risk of Electric Shock
Plug connection should be in the following order:
1) Equipment grounding conductor connectors,
2) Grounded circuit conductor connectors, and
3) Ungrounded conductor connectors.
Disconnection should be in the reverse order
Risque de choc électrique
Le raccordement devrait être effectué dans l’ordre qui suit:
1) Conducteur de mise à la terre de l’appareillage
2) Conducteur du circuit mis à la terre
3) 3) Conducteurs non mis à la terre
La mise hors tension doit se faire dans l’ordre inverse
WARNING
AVERTISSEMENT
C
LBL-C
3Ø Power
Counter
Clockwise
3ØPower
Clockwise
3Ø Power
Clockwise
3Ø Power
Counter
Clockwise
LBL-PGIP-D1LBL-PGIP-D2LBL-PGIP-W1
Apply 1 to inside door of
Input Panel Connection Chamber
LBL-PGIP-ROTATION
Figure 7
Figure 8
Lex Products Part Number – LBL-PGIP-ROTATION
Step 5: Conduct a safety test to ensure proper
installaon
DonotaempttousethePowerGATE™InputPanelprior
toinstallaonandcomplengthePre-Operaonand
MaintenanceChecklistunderAppendixA.

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Step 6: Review Pre-Operaon Checklist under
Appendices A prior to operaon (page 10)
Step 7: Determining phase rotaon of generator
1. Disconnect generator from all loads if needed
2.Connectaphaserotaonmetertotheoutputphasesofthe
generator
3.Recordgeneratorphaserotaon(clockwiseorcounter-
clockwise)
Step 8: Making Cam Connecons
1. Remove padlock, rotate handle and open chamber door
2.Feedground(green)cablethroughappropriateportin
boom
3.Completetheconnecon
Properconnecon(SeeFigure9):
A.Graspconnectorjacketandrmlyinsertcamconnector
intocamplug
B.Pushoncamconnectorjacketunlconnectorfullyseats
incamplug
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automacstartto
preventunintendedstarng
PowerGATE™ Power Input Panel
Set-up
Figure 9
C.Rotatecamconnectorjacketclockwiseunlitstops
4.CompletetheNeutral(white)connecon
Properconnecon(SeeFigure9):
A.GraspconnectorjacketandrmlyInsertcamconnector
intocamplug
B.Pushoncamconnectorjacketunlconnectorfullyseats
incamplug
C.Rotatecamconnectorjacketclockwiseunlitstops
5.CompletethePhase(hot)connecons
A.Shouldthephaserotaonofthegenerator(as
determinedinStep7.3.above)andulitypower(label
foundontheinsideofthedoorfortheCamconnecon
chamber)match,connecttheHotsasfollows:
Generator Hot PowerGATE™Input Panel Hot
A A
B B
C C
B.Shouldthephaserotaonofthegenerator(as
determinedinStep7.3.above)andulitypower(label
foundontheinsideofthedoorfortheCamconnecon
chamber)NOTmatch,connecttheHotsasfollows:
Generator Hot PowerGATE™ Input Panel Hot
AB
BA
C C
Properconnecon(SeeFigure9):
A.Graspconnectorjacketandrmlyinsertcamconnector
intocamplug
B.Pushoncamconnectorjacketunlconnectorfullyseats
incamplug
C.Rotatecamconnectorjacketclockwiseunlitstops
6.Makesureallconneconsarecorrectandsecure

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8
Step 9: Close chamber door, rotate handle and
replace padlocks, allowing cables to exit cable ports
at boom.
Step 10: Powering Up
1.Startgeneratorpermanufacturerinstrucons
2.Togglethetransferswitch,diverngpowerfromulityto
generator feed
Step 11: Disconnecng Circuits
1.Tolimitriskofshock,disablegeneratorautomacstartto
preventunintendedstarng
– Remove padlock and open chamber door
–Orderofdisconnect
2.DisconnectthePhase(hot)connecons,beginningwiththe
furthesttothele
Properdisconnecon(SeeFigure10):
A.Graspconnectorjacketrmlyandrotatecamconnector
counterclockwiseunlitstops
B.Firmlypullonconnectorunlitseparatesfromtheplug
C. Set aside
3.ConnuewithALLPhase(hot)connecons
4.CompletedisconnectofALLhotconneconspriorto
proceeding
5.DisconnecttheNeutral(white)connecon.
Properdisconnecon(SeeFigure10):
A.Graspconnectorjacketrmlyandrotatecamconnector
counterclockwiseunlitstops
B.Firmlypullonconnectorunlitseparatesfromtheplug
C. Set aside
6.DisconnecttheGround(green)connecons.
Properdisconnecon(SeeFigure10):
A.Graspconnectorjacketrmlyandrotatecamconnector
counterclockwiseunlitstops
B.Firmlypullonconnectorunlitseparatesfromtheplug
C. Set aside
Step 12: Close chamber door, rotate handle and
replace padlock.
PowerGATE™ Power Input Panel
Set-up –Connued
Figure 10
WARNING
PowerMUSTBEsuppliedfromasinglegenerator
WARNING
DONOTATTEMPTDISCONNECTINGWHILECIRCUITSARE
LIVE
Disconnecng Circuits

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PowerGATE™ Power Output Panel
Step 3: Wiring the Lug Terminals
The PowerGATE™ Power Output Panel is for the connecon
of a Load Bank to the output terminals of a transfer switch.
1.Pullthecablesfromtheloadoutputterminalsofthe
transferswitchtothePowerGATE™ OutputPanel
2.Beginningwiththeground,stripandinstallthecablesinthe
appropriate compression terminals
NOTE: The terminals can accommodate #2 to 600 MCM,
Copper wire only
Installaon – Connued
(For Output Panels connued from page 5)
WARNING
EnsurecircuitbreakersareOFFandthetransferswitchis
lockedoutfromsourcepowerpriortoconnecon.
Failuretoinstalltransferswitchwillcreatethepotenalfor
thesourcetoenergizethePowerGATE™OutputPaneland
endanger personnel.
Step 5: Review Pre-Operaon Checklist under
Appendices A prior to operaon (page 12)
Step 6: Making Cam Connecons
1. Remove padlock and open chamber door
2.Feedground(green)cablethroughappropriateportin
boom
3.Completetheconnecon
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automacstartto
preventunintendedstarng
Set-up
3.Tightenterminalscrewsto375lb-intorqueeach
4.Ifmetallicconduitisused,connectgroundwirefrom
groundbushingonconduittothegroundconneconpoint
intheupperrightquadrantofthepanel
A.Groundconductormustbeaminimumof#3AWG
NOTE:ConduitshallNOTbereliedupontoprovide
groundingprotecontotapbox
5.Connuetoconnecttheneutralandthenthephases
6.Vacuumenreupperchambertoensurenometalshavings
arelebehind
7.Replacedeadfrontpaneldoorandsecureusingfour(4)10-
32x1/2”Phillips-headedscrews
Step 4: Conduct a safety test to ensure proper
installaon
DonotaempttousethePowerGATE™OutputPanel
priortoinstallaonandcomplengthePre-Operaonand
MaintenanceChecklistunderAppendixA.
Properconnecon(SeeFigure9):
A.Graspconnectorjacketandrmlyinsertcamconnector
intocamplug
B.Pushoncamconnectorjacketunlconnectorfullyseats
incamplug
C.Rotatecamconnectorjacketclockwiseunlitstops
4.CompletetheNeutral(white)conneconfollowingproper
connecon(SeeFigure9)
5.CompletethePhase(hot)conneconsfollowingproper
connecon(SeeFigure9)
6.Makesureallconneconsarecorrectandsecure
Step 9: Close chamber door and replace padlocks,
allowing cables to exit cable ports at boom.
Step 10: Powering Up
1.Startgeneratorpermanufacturerinstrucons
2.Startloadbankpermanufacturerinstrucons
2.Togglethetransferswitch,diverngpowerfromthe
generator to the load bank
WARNING
PowerMUSTBEsuppliedfromasourcewiredtoaTransfer
Switch

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10
PowerGATE™ Power Input / Output Panel
Step 11: Disconnecng Circuits
1.Tolimitriskofshock,disablegeneratorautomacstartto
preventunintendedstarng
– Remove padlock and open chamber door
–Orderofdisconnect
2.DisconnectthePhase(hot)connecons,beginningwiththe
furthesttothele
Properdisconnecon(SeeFigure10):
A.Graspconnectorjacketrmlyandrotatecamconnector
counterclockwiseunlitstops
B.Firmlypullonconnectorunlitseparatesfromtheplug
C. Set aside
3.ConnuewithALLPhase(hot)connecons
4.CompletedisconnectofALLhotconneconspriorto
proceeding
5.DisconnecttheNeutral(white)connecon.
Properdisconnecon(SeeFigure10):
A.Graspconnectorjacketrmlyandrotatecamconnector
counterclockwiseunlitstops
B.Firmlypullonconnectorunlitseparatesfromtheplug
C. Set aside
6.DisconnecttheGround(green)connecons.
Properdisconnecon(SeeFigure10):
A.Graspconnectorjacketrmlyandrotatecamconnector
counterclockwiseunlitstops
B.Firmlypullonconnectorunlitseparatesfromtheplug
C. Set aside
Step 12: Close chamber door and replace padlock.
Disconnecng Circuits
WARNING
DONOTATTEMPTDISCONNECTINGWHILECIRCUITSARE
LIVE
Phase Rotaon 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.
Product Feature Instrucons
Cable Entry Plate
RemovecableentryplatetoallowconneconofCAMfeeder
cables.Onceallcablesareconnectedinsertthecableentry
plate into the white tracks within cabinet and slide into place
RemovecableentryplatebeforedisconnecngCAMfeeder
cables.
–Returnplateintoposiononcecablesareremoved