Vaisala TERMBOX-9000 User manual

USER'S GUIDE
Termination Box
TERMBOX-9000, -1200, -1212
M210310EN-B

PUBLISHED BY
Vaisala Oyj Phone (int.): [phone]
P.O. Box 26 Fax: [phone]
FI-00421 Helsinki
Finland
Visit our Internet pages at www.vaisala.com.
© Vaisala 2012
No part of this manual may be reproduced, published or publicly displayed in any form
or by any means, electronic or mechanical (including photocopying), nor may its
contents be modified, translated, adapted, sold or disclosed to a third party without prior
written permission of the copyright holder. Translated manuals and translated portions
of multilingual documents are based on the original English versions. In ambiguous
cases, the English versions are applicable, not the translations.
The contents of this manual are subject to change without prior notice.
This manual does not create any legally binding obligations for Vaisala towards
customers or end users. All legally binding obligations and agreements are included
exclusively in the applicable supply contract or the General Conditions of Sale and
General Conditions of Service of Vaisala.

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VAISALA ________________________________________________________________________ 1
Table of Contents
CHAPTER 1
GENERAL INFORMATION............................................................................ 3
About This Manual ................................................................... 3
Contents of This Manual ....................................................... 3
Version Information ............................................................... 3
Documentation Conventions ................................................. 4
Safety......................................................................................... 4
Recycling .................................................................................. 5
Warranty.................................................................................... 5
CHAPTER 2
PRODUCT OVERVIEW.................................................................................. 7
Introduction to TERMBOX....................................................... 7
TERMBOX Models .................................................................... 8
CHAPTER 3
INSTALLATION.............................................................................................. 9
Installation to Pole ................................................................... 9
Equipment Grounding ........................................................... 11
Connections............................................................................ 13
Signal Cable Grounding ........................................................ 15
CHAPTER 4
MAINTENANCE ........................................................................................... 17
Fuse Replacement.................................................................. 17
Parts List for Consumables .................................................. 17
Return Instructions ................................................................ 18
Getting Help ............................................................................ 18
CHAPTER 5
TECHNICAL DATA ...................................................................................... 19
Specifications ......................................................................... 19
APPENDIX A
TERMBOX-9000........................................................................................... 21
APPENDIX B
TERMBOX-1200........................................................................................... 25
APPENDIX C
TERMBOX-1212........................................................................................... 27

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List of Figures
Figure 1 Inside TERMBOX 1212 ..............................................................8
Figure 2 Installation to ∅104, ∅132, and ∅168 mm Poles ....................10
Figure 3 Installation to ∅75 mm Pole .....................................................11
Figure 4 TERMBOX Grounding ..............................................................12
Figure 5 Cable Glands............................................................................14
Figure 6 Front View AC Power Connections ..........................................14
Figure 7 Signal Cable Grounding ...........................................................15
Figure 8 TERMBOX 9000.......................................................................21
Figure 9 TERMBOX-9000 Signal Connector Block ................................22
Figure 10 TERMBOX-9000 General Wiring Diagram...............................22
Figure 11 Power and Signal Cabling of Mitras Signals Baseline .............23
Figure 12 Power and Signal Cabling of Mitras Double Baseline..............24
Figure 13 TERMBOX-1200.......................................................................25
Figure 14 TERMBOX-1200 Signal Line Protector ....................................26
Figure 15 TERMBOX-1200 General Wiring Diagram...............................26
Figure 16 TERMBOX-1212.......................................................................27
Figure 17 TERMBOX-1212 Signal Line Protectors ..................................28
Figure 18 TERMBOX-1212 General Wiring Diagram...............................28
List of Tables
Table 1 TERMBOX Models .....................................................................8
Table 2 Cable Gland Specifications ......................................................14
Table 3 Spare Parts and Consumables.................................................17
Table 4 TERMBOX General Specifications...........................................19
Table 5 TERMBOX Connection Specifications .....................................19
Table 6 TERMBOX Enclosure Specifications .......................................20
Table 7 TERMBOX AC Power Protection Specifications ......................20
Table 8 RS-485, LON, and Modem Line (Leased) Protection
Specifications............................................................................20

Chapter 1 ________________________________________________________ General Information
VAISALA ________________________________________________________________________ 3
CHAPTER 1
GENERAL INFORMATION
About This Manual
This manual provides information for installing, operating, and
maintaining the TERMBOX.
Contents of This Manual
This manual consists of the following chapters:
- Chapter 1, General Information, provides information for installing,
operating, and maintaining the TERMBOX.
- Chapter 2, Product Overview, introduces the TERMBOX features,
advantages, and the product nomenclature.
- Chapter 3, Installation, provides you with information that is intended
to help you install this product.
- Chapter 4, Maintenance, contains basic maintenance information on
the TERMBOX.
- Chapter 5, Technical Data, provides the technical data of the
TERMBOX.
- Appendix A, TERMBOX-9000, details and illustration.
- Appendix B, TERMBOX-1200, details and illustration.
- Appendix C, TERMBOX-1212, details and illustration.
Version Information
Manual Code Description
M210310EN-B June 2012. This version. Wiring diagrams corrected
in Appendix B and C.
M210310EN-A Previous version.

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Documentation Conventions
Throughout the manual, important safety considerations are highlighted
as follows:
WARNING Warning alerts you to a serious hazard. If you do not read and follow
instructions very carefully at this point, there is a risk of injury or even
death.
CAUTION Caution warns you of a potential hazard. If you do not read and follow
instructions carefully at this point, the product could be damaged or
important data could be lost.
NOTE Note highlights important information on using the product.
Safety
The TERMBOX delivered to you has been tested for safety and approved
as shipped from the factory. Note the following precautions:
WARNING Ground the product and verify outdoor installation grounding
periodically to minimize shock hazard.
CAUTION Do not modify the unit. Improper modification can damage the product
or lead to malfunction.

Chapter 1 ________________________________________________________ General Information
VAISALA ________________________________________________________________________ 5
Recycling
Recycle all applicable material.
Dispose of batteries and the unit according to statutory regulations. Do
not dispose of with regular household refuse.
Warranty
Visit our Internet pages for standard warranty terms and conditions:
www.vaisala.com/warranty.
Please observe that any such warranty may not be valid in case of
damage due to normal wear and tear, exceptional operating conditions,
negligent handling or installation, or unauthorized modifications. Please
see the applicable supply contract or Conditions of Sale for details of the
warranty for each product.

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Chapter 2 __________________________________________________________ Product Overview
VAISALA ________________________________________________________________________ 7
CHAPTER 2
PRODUCT OVERVIEW
This chapter introduces the TERMBOX features, advantages, and the
product nomenclature.
Introduction to TERMBOX
TERMBOX acts as the connection point and surge protector device for
mains power and signal line cables. A mains power cable of a maximum
of 25 mm in diameter can be taken inside the termination box. The
connector contacts are proper for cable leads up to 10 mm2.
TERMBOX offers connection points and surge protectors for up to two
signal lines. Surge protectors are available for the following signal line
types: leased-line modem, RS-485, and LON.
TERMBOX is adaptable for different needs. The number of signal line
protectors can vary up to 2 units and the number of cable glands can also
vary by replacing them with blocking plugs. The actual versions
available are discussed in detail in the appendices.

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0210-014
Figure 1 Inside TERMBOX-1212
The following numbers refer to Figure 1 above:
1 = Cover screws
2 = AC power overvoltage protector
3 = Fuse
4 = AC power connections
5 = Signal line connections/protectors
6 = Mounting screws (located at the bottom)
TERMBOX Models
There are three TERMBOX models available. The AC block is the same
in each TERMBOX model, however the signal line connections differ.
For details on the different TERMBOX models, see Table 1 below.
Table 1 TERMBOX Models
Code Signal Connection
TERMBOX-9000 Connector block with 90 V gas tube arresters
TERMBOX-1200 One signal line protector, 12 V
TERMBOX-1212 Two signal line protectors, 12 V

Chapter 3 _______________________________________________________________ Installation
VAISALA ________________________________________________________________________ 9
CHAPTER 3
INSTALLATION
This chapter provides you with information that is intended to help you
install this product.
Installation to Pole
The TERMBOX is connected to the pole with the use of the
TERMBOXFIXSET mounting set.
1. Connect the back plate to the TERMBOX using the four mounting
screws. Tighten all four screws to ensure the plate is firmly in
place.
2. With ∅104 mm, ∅132 mm, or ∅168 mm poles, select two
appropriate-sized angle clips from the TERMBOXFIXSET
mounting set and fasten the TERMBOX with the two angle clips
and four M8 nuts and washers to the pole. See Figure 2 on page 10
for details.
3. In case of a ∅75 mm pole, select the two angle clips shown in Figure
3 on page 11. Fasten the TERMBOX with the two angle clips and four
M6 screws, nuts, and washers to the pole. For details, refer to Figure 3 on
page 11.

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0210-015
Figure 2 Installation to ∅104, ∅132, and ∅168 mm Poles
The following numbers refer to Figure 2 above:
1 = Back plate
2 = TERMBOX
3 = Angle clips
4 = Mounting screws
5 = M8 nuts and washers
6 = ∅104, ∅132, and ∅168 mm pole (for example, Mitras or
Wind Mast)

Chapter 3 _______________________________________________________________ Installation
VAISALA _______________________________________________________________________ 11
0210-016
Figure 3 Installation to ∅75 mm Pole
The following numbers refer to: Figure 3 above
1 = Back plate
2 = TERMBOX
3 = Mounting screws
4 = Angle clips
5 = ∅75 pole (for example, FD12(P) or Wind Mast)
6 = M6 screws, nuts, and washers
Equipment Grounding
It is essential to appropriately ground the TERMBOX. This will ensure
proper operation of the unit. Ground the TERMBOX by using a jacketed
grounding cable and a conductive grounding rod, as shown in Figure 4 on
page 12.

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0210-017
Figure 4 TERMBOX Grounding
The following numbers refer to Figure 4 above.
1 = Cable clamp
2 = 16mm2 jacketed grounding cable
3 = Equipment grounding
4 = Alternative equipment grounding
The jacketed 16 mm2grounding cable is fastened to a special clamp on
the bottom of the TERMBOX. The grounding principles are:
- By default, the grounding cable is connected to the equipment
grounding rod used for grounding the pole and other electrical
equipment attached to the pole. Install the grounding rod as close to
the pole as possible in order to minimize the length of the grounding
cable. The grounding rod can also be cast inside the concrete base.
- Grounding rod length depends on the local ground water level. The
lower end of the grounding rod should continuously touch moist soil.

Chapter 3 _______________________________________________________________ Installation
VAISALA _______________________________________________________________________ 13
Connections
The mains cable is lead into the TERMBOX through cable gland number
1 (CG1). The connection points are the five leftmost in the terminal
connector block: PE, N, L1, L2, and L3. N and L1 are internally wired to
the Surge Protector board. Phases L2 and L3 are not wired ahead - the L2
and L3 connectors are just connection points for unusable wires.
The mains connection after the surge protector board can be taken out
from the TERMBOX through CG2, CG3 and CG4 cable glands. CG2 is
reserved for a thick outgoing cable. Mains output for the instrument is
taken out through CG3, and CG4 is for an auxiliary mains output. The
connection points for the outgoing wires are the five rightmost in the
terminal connector block: L2, L3, L, N, and PE. The L2 and L3
connectors are just connection points for unusable wires.
The cable glands number 5 - 8 (CG5 - 8) are reserved for signal cables.
The lowest ones (CG5 and CG7) are for the incoming cables. CG6 and
CG8 are for the outgoing signal cables. The signal cables are connected
directly to the screw terminals of the connector block or the protection
component depending on the TERMBOX model used.
For details, see Figure 5 on page 14, and Chapter 5, section
Specifications on page 19 for more details about the connection and
protection specifications.
The signal line connections of each TERMBOX model are illustrated in
detail in the appendices. For TERMBOX-9000, see Appendix A on page
21. For TERMBOX-1200, see Appendix B on page 25. For TERMBOX-
1212 , see Appendix C on page 27.

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Table 2 Cable Gland Specifications
Cable Diameter Wrench Size
CG1 Mains in 18 - 25 mm 32 mm
CG2 Mains out 18 - 25 mm 32 mm
CG3 Mains out for instrument 7 - 12 mm 20 mm
CG4 Auxiliary power out 7 - 12 mm 20 mm
CG5 Signal line 1 in 7 - 12 mm 20 mm
CG6 Signal line 1 out 5 - 10 mm 16 mm
CG7 Signal line 2 in 7 - 12 mm 20 mm
CG8 Signal line 2 out 5 - 10 mm 16 mm
0210-018
Figure 5 Cable Glands
0210-019
Figure 6 Front View AC Power Connections

Chapter 3 _______________________________________________________________ Installation
VAISALA _______________________________________________________________________ 15
Signal Cable Grounding
The cable shield can be grounded to ∅5-10 mm and ∅7-12 mm cable
glands (CG3 - 8). ∅18-25 mm cable glands (CG1 - 2) are not groundable
types.
In case cable glands numbers 3 to 8 (CG3 - 8) are used, fold the cable
shield back over the O-ring of the plastic portion and mount the metal
cable gland parts as shown in Figure 7 below.
0210-020
Figure 7 Signal Cable Grounding
NOTE Tighten the cable glands and make sure that no cable shield mesh gets
on the circuit board.

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Chapter 4 ______________________________________________________________ Maintenance
VAISALA _______________________________________________________________________ 17
CHAPTER 4
MAINTENANCE
This chapter contains basic maintenance information on the TERMBOX.
Fuse Replacement
If the fuse needs to be replaced, follow the steps below.
1. Open the cover by unscrewing the four cover screws.
2. Remove the fuse plug from the fuse terminal block located in the
AC Power connector block by twisting and pulling the plug out.
3. Open the fuse clip cover.
4. Press the clip located on the bottom of the fuse plug to remove the
old fuse.
5. Check that the new fuse is of the correct type, refer to Table 3
below for details. Insert the new fuse.
6. Place the fuse plug back into the fuse terminal block in the AC
Power connector block.
7. Close the cover carefully with the four cover screws.
Parts List for Consumables
A list of consumables and parts is provided in Table 3 below.
Table 3 Spare Parts and Consumables
Spare Part Description
Fuse Bussman S506-10-C, 5 x 20 mm 10 A (slow)
Surge protector board FPS111
RS-485, leased modem line,
and LON protector
Phoenix Contact PT 1x2-BE base element
(rail-mountable)
Phoenix Contact PT 3-HF-12DC-ST plug
Gas tube arrester Sankosha YO8U - 90B

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Return Instructions
If the product needs repair, please follow the instructions below to speed
up the process and avoid extra costs.
1. Read the warranty information.
2. Write a Problem Report with the name and contact information of a
technically competent person who can provide further information
on the problem.
3. On the Problem Report, please explain:
- What failed (what worked / did not work)?
- Where did it fail (location and environment)?
- When did it fail (date, immediately / after a while / periodically /
randomly)?
- How many failed (only one defect / other same or similar
defects / several failures in one unit)?
- What was connected to the product and to which connectors?
- Input power source type, voltage and list of other items
(lighting, heaters, motors etc.) that were connected to the same
power output.
- What was done when the failure was noticed?
4. Include a detailed return address with your preferred shipping
method on the Problem Report.
5. Pack the faulty product using an ESD protection bag of good
quality with proper cushioning material in a strong box of adequate
size. Please include the Problem Report in the same box.
6. Send the box to:
Vaisala Oyj
SWD Service
Vanha Nurmijärventie 21
FIN-01670 Vantaa
Finland
Getting Help
For technical questions or for comments on the manuals, contact the
Vaisala technical support:
E-mail [email protected]
Telephone [phone]
Fax [phone]