installation instructions and operator manual for the ... · roxtec cable management system...

Appleton • 1.800.621.1506 • www.appletonelec.com 504543-000 Rev. C 1/3/2020 • of 19

504543-000 INSTRUCTION SHEET

Installation Instructions and Operator Manual for the Appleton™ PlexPower™ Fiber Panelboard

FOR PROPER AND SAFE INSTALLATION OF THIS PRODUCT, PLEASE READ AND RETAIN THE FOLLOWING INSTRUCTIONS.

ApplicationsThe PlexPower™ Fiber Panelboard provides control of electrical circuits and communications patch panels in hazardous environments such as:

• Petroleum plants

• Chemical plants

• Refineries

• Wastewater treatment plants

• Paper and pulp industries

• Other process facilities

Product SafetyPlexPower Fiber Panelboard with Belden Fiber Patch Panel.

Signal Words Defined

DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE: Is used to address practices not related to physical injury.

Safety Instructions

WARNING: Before replacing any part or accessory of the panel, ensure that the power to panel Mains is Switched OFF.

CAUTION: Live parts behind the cover; only authorized person to open.

NOTICE: For Internally Actuated Panel, a Dead Front Plate is supplied to ensure safe operation which will protect operators from electrocution.

504543-000 Rev. C 1/3/2020 • of 19Appleton • 1.800.621.1506 • www.appletonelec.com

Installation

3

3.0 Panel Arrangement / Configuration:

PlexPower Fiber Patch Panel with Roxtec Cable Management System

PlexPower Fiber Patch Panel with Gland Plate & Heater

FRONT VIEW

VIEW WITH ENCLOSURE DOOR CLOSED FRONT VIEW

SIDE VIEW VIEW WITH ENCLOSURE DOOR HIDDEN

Fig.1

VIEW WITH ENCLOSURE DOOR CLOSEDFRONT VIEW

SIDE VIEW VIEW WITH ENCLOSUREDOOR HIDDEN

NOTE: The Given Figures are Representation for All Panel.

ROXTEC CABLE MANAGEMENT

SYSTEM

FIGURE 1 - PlexPower Fiber Patch Panel With Roxtec Cable Management*

3

3.0 Panel Arrangement / Configuration:

PlexPower Fiber Patch Panel with Roxtec Cable Management System

PlexPower Fiber Patch Panel with Gland Plate & Heater

FRONT VIEW

VIEW WITH ENCLOSURE DOOR CLOSEDFRONT VIEW

SIDE VIEW VIEW WITH ENCLOSUREDOOR HIDDEN

Fig.1

VIEW WITH ENCLOSURE DOOR CLOSED FRONT VIEW

SIDE VIEW VIEW WITH ENCLOSURE DOOR HIDDEN

NOTE: The Given Figures are Representation for All Panel.

ROXTEC CABLEMANAGEMENT

SYSTEM

FIGURE 2 - PlexPower Fiber Patch Panel With Gland Plate and Heater*

*NOTE: These figures are representative of all panels.


Owner’s Responsibility:• All installation instructions need to be followed.

• Users need to follow latest edition of the National Electrical Code® or the Canadian Electrical Code for installation guidelines.

• Inspect the panelboard thoroughly before operating.

• Understand how to operate all standard and accessory equipment.

• Ensure that anyone operating or maintaining the panelboard is qualified.

• Retain these instructions for reference during future inspections and maintenance.

Lifting & Moving Panel by Using an Eye BoltTo lift the the panelboard, use M10 Eye Bolt and fix it into both top mounting foot of panelboard enclosure and fasten it with nut. Lift panelboard vertically with the help of a crane, wire rope, chain, sling belt etc. to enable movement/transfer of panel to mounting location.

FIGURE 3 - PlexPower Fiber Panelboard

504543-000 Rev. C 1/3/2020• of 19Appleton • 1.800.621.1506 • www.appletonelec.com

Lifting & Moving Panel by Using Forklift TruckFollow the instructions/procedure below to transfer the panel from one location to another by using forklift.

• Keep the panelboard vertical on a stand/pallet from which we can lift it and transfer to desired location. Transfer of panel withforklift without using any pallet or stand could damage Gland plate provided on panel bottom.

• Ensure that Panelboard mounting location is at front of forklift truck.

• For additional safety during transfer, it is necessary to secure Panelboard to forklift truck with belt/wire rope/chain.

• Actuation components should not get damaged during transfer.

5

3.3 Lifting & Transfer by Forklift Truck:1. To transfer panel from one location to another by use of fork lift some additional

care to be taken.2. Keep Panel board vertical on a stand/pallet etc. from which we can lift panel board

to transfer to desired location. Transfer of panel with forklift without using anypallet or stand could damage Gland plate provided on bottom side.

3. Ensure that panel board mounting location side is at front face of forklift truck.4. For additional safety during transfer using forklift, it is necessary to secure panel

board to forklift truck with belt/wire rope/chain.5. Ensure that operators will not get damaged during transfer.

Anchor Belt for Additional Safety

Mounting Foot

Pallet to avoid any damage to panel board gland plate

Fig.3

Note: In-case of PlexPower Fiber Patch with Roxtec cable Management System Panel Transfer make sure there is no damage to Roxtec Cable System and frame.

FIGURE 4

Note: If you purchased a PlexPower Fiber Patch with Roxtec Cable Management System, make sure there is no damage to the Roxtec Cable Management System during transit.


Mounting:• Ensure mounting studs/bolts are in place on mounting frame, mounting strut, wall etc.

• The panelboard is intended to be mounted vertically. Use mounting feet U-Slot for positioning and fastening panelboard.

• Since upper mounting locations are tied with panel lifting accessories, use bottom mounting feet first for securing panelboardusing M10 Bolt.

• Once the bottom mounting locations are fastened, release lifting accessories and fasten upper mounting locations withwall or frame.

• All mounting locations must be secured properly to avoid any damage.

• If you find any damaged mounting feet, consult tech support.

6

3.4 Mounting:1. Ensure mounting studs /bolts are in place on mounting frame, mounting strut,

wall etc. according to dimensions specified on drawings included in Installationsection.

2. The panel board enclosure is intended to be mounted vertically. Use mountingfoot U-Slot for positioning and fastening panelboard.

3. Since upper mounting locations are tied with panel lifting accessories, usebottom mounting locations first for securing panelboard.

4. Once the bottom mounting locations are securely fastened then release liftingaccessories and fasten upper mounting locations with wall or frame etc.

5. All mounting locations must be secured properly to avoid any damage.6. If you find mounting foot damaged, then consult factory.

Mounting Foot

U-Slot

PlexPower Fiber Patch Panel

Fig.4FIGURE 5 - PlexPower Fiber Panelboard


Mounting Procedure:• After both bottom and middle mounting feet are fixed, remove the eye bolt from top mounting foot and fix it with M10 bolt.

• Make sure that all the bolts are fully tight.

• The number of bolts required to mount the panel should be equal to the number of mounting feet of panel.

• Keep a 20" clearance to the left of the panel to facilitate the 120˚ door swing.

• Clearance between the floor and panelboard bottom is to be at least 1 foot.

FIGURE 6


Electrical Connections:1) To open the panelboard's cover for wiring, unlock the latches on the panelboard using a screwdriver.

2) Incoming supply can be wired to the main lug connector (Figure 7).

3) Load side connections are wired directly to the breaker modules by the customer. If the terminal block option is purchased, then the load side connections will be wired to the terminal blocks located at the bottom of the panel in the factory.

4) Main ground lug is provided for system ground.

FIGURE 7 - PlexPower Fiber Panel Assembly


Wiring Connections for Customer Input and OutputIncoming and outgoing connection to panel:• To facilitate cable connections to line of panel and to take out cables towards load from power terminal blocks, the user needs to

drill holes into the enclosure. A gland plate is provided on the bottom of the enclosure to make this drilling easier. Additional glandplates can be provided as options when ordering.

• User needs to take into consideration the required cable size according to panel specifications.• User needs to install certified cable gland from which incoming and outgoing wires can be routed.• Appleton recommends using Appleton TC cable gland series.

10

(Above picture refers to Bottom in Bottom Out Connection)

PlexPower Fiber Patch with Gland Plate

Incoming Cable

Outgoing Cable

4.1.2 Incoming and outgoing connection for PlexPower Fiber Patch Panel with Heater:

To facilitate cable connection to line side of panel and to take out cables towardload from power terminal blocks, Customer needs to drill hole on gland plateprovided on bottom side of enclosure.

Customer needs to take into consideration required cable size according to panelspecifications.

Also, customer needs to install cable gland from which incoming and outgoingwires can be routed.

Consult Appleton group for required Cable gland size and information regardingdrilling hole specifications.

Fig.8

FIGURE 8


Incoming and Outgoing Connection for PlexPower Fiber Patch Panel with Roxtec Cable Management:• To facilitate cable connection to line side of panel and to take out cables toward load from power terminal blocks, Customer needs

to open Module in ROXTEC Cable provided on bottom side of enclosure.• Customer needs to take into consideration required cable size according to panel specifications.• Appleton uses the CF16 Roxtec Cable management system installation.

9

4.1 Wiring Connections for Customer Input & Output

Roxtec cable System for Incoming Cable

4.1.1 Incoming and outgoing connection for PlexPower Fiber Patch Panel with RoxtecCable Management:

❑ To facilitate cable connection to line side of panel and to take out cables towardload from power terminal blocks, Customer needs to open Module in ROXTECCable provided on bottom side of enclosure.

❑ Customer needs to take into consideration required cable size according to panel specifications.

❑ Consult Appleton group for required Cable size and information regardingRoxtec Cable management system installation.

Roxtec cable System for Outgoing Cable

PlexPower Fiber Patch with Roxtec Cable Management

Insert the back plate from the installation side.

Place the compression rubber from the installation side.

Fix the back plate with the two cross-slotted screws.

Thoroughly lubricate all surfaces of the compression rubber with

Roxtec Lubricant.

Fix the front plate parts loosely over the compression rubber with the torx screws.

Fig.7FIGURE 9


Wiring DiagramTo connect cables from load to panelboard power terminal blocks, refer below wiring diagram and terminal block marking.

11

4.2.1 Wiring Connection for QC Switch/QC Breaker

4.2 Wiring Diagram

1. In-case of QC Switch connect the cables from load side to Fuse, refer belowwiring diagram.

2. To connect cables from load side QC Breaker to panel board with help of powerterminal blocks, refer below wiring diagram by replacing fuse with TerminalBlock.

3. When Assembly comes with USCC1 Fuse Block with Fuses assembly then LEDIndicator connection should be connect with output wire of USCC1 Fuse

Note: Cable routing through panel1. All cables must be routed in such a way that it will not mess with one another.2. All cable should be tied with cable tie and routed through cable spirals.3. All cables must be tagged appropriately for easy identification4. Cable colour coding must be followed as per wiring diagram provided.5. Secure cables firmly by applying required torque on pressure screw.6. Special care to be taken while connecting cables to line side and load side, also for

cables routed nearby heater.7. Don’t use Electric Connectors or Lug for the Load Wire Connection to USCC Fuse

Holder

Fig.9FIGURE 10*

*NOTE: When the assembly comes with a USCC 1 Fuse Block with Fuses Assembly, the LED indicator connection should beconnected with the Output wire of the USCC 1 fuse.


Wiring Connection for Heater and ThermostatAfter installing the new Heater and Thermostat in the Panel, make wiring connections as per the diagram below. Once the connections are complete, verify that all wires are secured in their designated places as per the wiring diagram.

18

5.4 Wiring connection for Heater and Thermostat:

After installing new Heater and Thermostat in Panel, do wiring connections as per belowdiagram. Once Connections are done, verify all wires are secured in its designated placeas per wiring diagram.

Fig.13FIGURE 11


22

Fig.15

Note- Do not Route any wire connection around the 32 mm of Heaters.

This Label Must be at front facing orientation

FIGURE 12


Wire Sizing Chart For Breaker- Reference - CSA C22.2, NO. 5-02, Table 6.1.4.2.1, UL 489.

13

Current (AMPS) Requires Wire Size

15 A OR LESS 14 AWG

20A 12 AWG

25A-30A 10 AWG

40A 8 AWG

50A 6 AWG

60A-70A 4 AWG

80A 3 AWG

90A-100A 2 AWG

110A 1 AWG

125A 0 AWG

150A 1/0 AWG

Purpose Conductor Size (UL/CSA) MaxAmps

PressureScrew Torque

Power Terminal Block

12 AWG 15

10 in-lbs

10 AWG 2010 AWG 258 AWG 306 AWG 504 AWG 60

Main Lug 1/0 AWG 150 275 in-lbsGround Lug 1/0 AWG 150 275 in-lbsUSSC FUSE 8 AWG 30 14.75 in-lbs

4.3 Wire Information as per Ampacity

Table 1

Table 2

4.4 Terminals-Connection DevicesTerminals - Incoming Line Connection

13

Current (AMPS) Requires Wire Size

15 A OR LESS 14 AWG

20A 12 AWG

25A-30A 10 AWG

40A 8 AWG

50A 6 AWG

60A-70A 4 AWG

80A 3 AWG

90A-100A 2 AWG

110A 1 AWG

125A 0 AWG

150A 1/0 AWG

Purpose Conductor Size (UL/CSA) Max

Amps Pressure

Screw Torque

Power Terminal Block

12 AWG 15

10 in-lbs

10 AWG 20 10 AWG 25 8 AWG 30 6 AWG 50 4 AWG 60

Main Lug 1/0 AWG 150 275 in-lbs Ground Lug 1/0 AWG 150 275 in-lbs USSC FUSE 8 AWG 30 14.75 in-lbs

4.3 Wire Information as per Ampacity

Table 1

Table 2

4.4 Terminals-Connection Devices


Electrical TestingAll wiring must be checked and tested to ensure all circuits are according to plan and there are no unwanted opens, shorts or grounds. Do not power the panel until the following steps are completed:

• Test each circuit to verify correct phasing and ground connections.

• Test each circuit for insulation resistance by merge ring, high voltage or hi-pot test; Be sure the system does not have any shortcircuits or unwanted grounds.

• If any circuit displays a resistance to another circuit or to ground of One Mega ohm or less, that circuit must be analyzed, correctedand tested to more than One Mega ohm before applying power.

• Perform these tests with circuit breakers in both the “ON” and “OFF” conditions.

• Once it has been determined that all Load and Line circuits are satisfactory, the next steps of installation may be completed.

• Check the terminals and connectors for looseness or signs of overheating.

• Overheating will show as discoloration, melting, or blistering of conductor/connector insulation, or as pitting or melting ofconductor surfaces due to arcing.

• If there is evidence of overheating, terminations should be cleaned or replaced.

• Before re-energizing the panel, all terminations and cables should be refurbished to the condition when originally installed.


OperationBranch Breaker

The Status of the branch breaker is determined by position of knob as indicated by the label. Operation is as simple as twisting the handle to the desired position.

23

Electrical Components*

1. Breaker Part Number

AMPERAGE 1 POLE (120/240 VAC) 2 POLE (120/240 VAC) 3 POLE (120/240 VAC) 15A QC1015 QC2015 QC3015H 20A QC1020 QC2020 QC3020H 25A QC1025 QC2025 QC3025H 30A QC1030 QC2030 QC3030H 35A QC1035 QC2035 QC3035H 40A QC1040 QC2040 QC3040H 50A QC1050 - - 50A QC1050N - - 60A QC1060 - -

2. Switch Part Number

AMPERAGE 1 POLE (120/240 VAC) 2 POLE (120/240 VAC) 3 POLE (120/240 VAC) 50A QC1050N

*#- For other related configuration refer product catalogue nomenclatureor consult factory

Table No.5

Table No.6

FIGURE 13


Dead Front (Installed on the Power Section Only):

By using a split type dead front arrangement a user can access power and data transmission parts separately inside a panel.

FIGURE 14


General MaintenanceMaintenance:

1. Before carrying out any work on equipment, cited safety instructions must be very carefully observed (DO NOT OPEN WITHPOWER “ON”).

2. Incoming power should be locked and tagged out for safety while in maintenance.

3. The hardware installed shall be inspected on regular schedule.

4. It is user’s responsibility to ensure these inspections are implemented according to the protection modes of equipmenthardware installed.

5. To ensure that breaker housing remain explosion-proof, before use of product, confirm cover attaching screws and cable inputs areappropriately torqued.

6. The flameproof function for product must be maintained for complete duration of service life therefore joints must be maintained ingood condition.

7. No scratches, marks or modification is allowed on parts which are important for flame path (e.g. Body, Cover).

8. External lug assembly and connecting wires from other devices should be checked at regular intervals, for appropriate secureness,electrical safety etc.

9. Any appliance found to be defective should be replaced immediately.

10. Perform visual, electrical, and mechanical checks on all components on regular intervals.

• Carry out Visual checks for undue heating events such as discoloration of wires or other components, damaged orworn parts, or leakage evidence such as ingress of water or corrosion of interior.

• Conduct Electrical inspection to ensure that all connections are clean and tight.

• Conduct Mechanical inspection to ensure all parts are properly assembled, and operating mechanismsare moving freely.

11. Contact service personnel if product does not function as desired.

12. Maintenance should be done by skilled and authorized personnel who have complete knowledge and understanding aboutproduct service and application.

WARNING

• Electrical Power must be turned OFF before and during Maintenance.

• Modification of this panel or substitution of parts with non-standard parts may result in Serious/Fatal Personnel injurydue to Electrocution.


Replacement Of Fiber Module:

• Remove all Fiber optics cable from Fiber Module.• Remove Fiber module from the Din Rail.• Replace module with (LC, SC or ST type) as per requirement.• Reinstall Fiber Module in Din Rail.

FIGURE 15 - ST Type Fiber Module

Replacement Of Fuses

1. Check continuity of fuse, if it is damaged, replace fuse.2. Open fuse holder cap as shown in below sequence of images.3. Then remove Fuse from Fuse holder body.4. Install new Fuse into the Fuse Holder5. Fix Fuse holder cap on body till it is securely fastened.

FIGURE 16

504543-000 Rev. C 1/3/2020 • of 19

Except as expressly provided by Appleton Grp, LLC (Appleton), Appleton products are intended for ultimate purchase by industrial users and for operation by persons trained and experienced in the use and maintenance of this equipment

and not for consumers or consumer use. Appleton warranties DO NOT extend to, and no reseller is authorized to extend Appleton’s warranties to any consumer.

While every precaution has been taken to ensure accuracy and completeness in this manual, Appleton Grp, LLC. assumes no responsibility, and disclaims all liability for damages resulting from use of this information or for any errors or

omissions. Specifications are subject to change without notice. The Appleton and Emerson logos are registered in the U.S. Patent and Trademark Office. All other product or service names are the property of their registered owners.

©2019 Appleton Grp, LLC. All rights reserved.

Replacement Part Numbers

PART NUMBER DESCRIPTION

59504771014 or 59504771024 250W HEATER CPA or DPA BI 120V CSA CERTIFIED - INTERTEC

59504790003 TAE -15 250V MAXIMUM THERMOSTAT INTERTEC

59351106000 PlexPower™ LED Indicator

59504450005 BELDEN MIPP TWO DOUBLE CASSETTES - CONNECTOR TYPE ST

59504450006 BELDEN MIPP ONE DOUBLE CASSETTE - CONNECTOR TYPE ST

59504460005 BELDEN MIPP TWO DOUBLE CASSETTES - CONNECTOR TYPE SC

59504460006 BELDEN MIPP ONE DOUBLE CASSETTE - CONNECTOR TYPE SC

59504461005 BELDEN MIPP TWO DOUBLE CASSETTES - CONNECTOR TYPE LC

59504461006 BELDEN MIPP ONE DOUBLE CASSETTE - CONNECTOR TYPE LC

ZF6353208 COVER BOLTS 1/4-20 X 3/4" HEX, SS

ATMR4 Mersen Fuse - 4A 600V REJECTION GOULD

ATMR1 Mersen Fuse - 1A 600V REJECTION GOULD

ATQR2 Mersen Fuse - 2 AMP TIME DELAY

ATQR1 Mersen Fuse - 1 AMP TIME DELAY

USCC1 FUSE HOLDER 1P, 30A MAX, FERRAZ SHAWMUT

CF16AISI304 ROXTEC CF16 FRAME - AISI 304

CM20W40 CM 20w40 MODULE - DOUBLE INCOMING CABLE

CM401032 C CM 40 10-32 MODULE - SINGLE INCOMING CABLE

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