User Manual and Installation Guide
Contents
1. 20 27 W x 12 91 D 38 90 H x 20 27 W x 11 64 D 38 90 H x 20 27 W x 12 91 D Approximate Weight 130 Ibs 123 Ibs 123 Ibs NOTE For 5 Wire replace 6 with 5 in catalog number Company Switch with IEC 60309 Pin amp Sleeve Receptacle Ordering Information 100 AMP CS 100F D5PS1 60 AMP CS 60F D5PS1 Catalog Number Rating 100 Amp 3 Phase H H H N G 120 208Y VAC 60 Amp 3 Phase H H H N G 120 208Y VAC Overcurrent Protection 65 000 AIC Main Breaker100 Rated 65 000 AIC Main Breaker 100 Rated Output 1 100 Amp 3 Phase 4 Pole 5 Wire 120 208Y IEC 60309 pin amp sleeve receptacle 5 Lugs for bare wire connection in parallel with pin amp sleeve receptacle 1 60 Amp 3 Phase 4 Pole 5 Wire 120 208Y IEC 60309 pin amp sleeve receptacle 5 Lugs for bare wire connection in parallel with pin amp sleeve receptacle Cabinet Finish Color Beige or matte black powder coat For black finish add suffix BLK to catalog number Beige or matte black powder coat For black finish add suffix BLK to catalog number Dimensions 38 90 H x 20 27 W x 11 64 D 38 90 H x 20 27 W x 11 64 D LEX We Deliver the Power Lex Products Corporation Lex West www lexproducts com 15 Progress Drive 11847 Sheldon Street info lexproducts com shelton CT 06484 sun Valley CA 91352 800 643 4460 203 363 3738 818 768 4474 203 363 37422. follows The chassis ground C G termination is located next to the main ground cable see Figure 16 To isolate this ground 1 Remove the nut holding the chassis ground lug to the threaded stud 2 Wrap the chassis ground mounting lug with listed electrical tape or shrink wrap If available 3 Using a plastic wire tie secure the chassis ground to the main ground cable 4 Check to make sure that the chassis ground is secure and that it cannot come into contact with any metal surfaces of the cabinet See Figure 16A Figure 16 GROUND NEUTRAL Step 5 Review Pre Operation Checklist under Appendix A prior to operation page 12 Step 6 Once Pre Operation Checklist is complete finish assembly of panel 1 Fasten the upper front panel by securing the twenty 20 Phillips headed 10 32 x 1 2 screws securing it See Figure 8 and 9 Step 7 Powering Up 1 Turn the power lever to the ON position A LEDs for each phase as well as the ground continuity should be lit Figure 16A Contact Lex Products 800 643 4460 info lexproducts com 9 PowerGATE Company Switch Set up ZN WARNING Ensure the circuit breaker is OFF and locked out from utility power prior to connection Step 8A Making Lug Connections 1 Unsecure keylock on lower chamber and open chamber door NOTE As a safety feature of the PowerGATE Company Switch the power will be tripped off when the door is opened 2 Feed Ground green cable throug
3. operation of the Lex Products PowerGATE Company Switch All concepts and ideas are the sole property of Lex Products and are not to be duplicated or utilized in any manner without written permission PowerGATE Company Switch Prior to Installation Site Preparation Prepare installation site according to local codes The PowerGATE Company Switch is to be secured to a structure using appropriate 3 8 fasteners See Figures 11 through 14 The surface where the PowerGATE Company Switch is to be secured must be capable of supporting the weight of the device as well as the cable attached to It The following should be taken into consideration when locating the PowerGATE Company Switch The PowerGATE Company Switch is available in both and interior Type 1 and exterior Type 3R configurations Be certain to select the appropriate device for the given install location Identify and meet local codes and local Authority Having Jurisdiction AHJ The mounting location is to be carefully selected to allow convenient connection between the PowerGATE Company Switch and those devices that are to draw power from it Proper clearance must be allowed in front of the PowerGATE Company Switch to allow for operation of access doors and attachment of externally connected cables The clearance should be no less than six 6 feet from the face of the panel and no less than two 2 feet beneath the panel While keylock p
4. 00F C6DG3 CS 400F C6DG3 CS 60F C6DS3 CS 100F C6DS3 CS 200F C6DS3 CS 400F C6DS3 Model Number Key CS Company Switch Number F Amperage Rating with Female Connectors C Number D Letter 3 Series 16 Cams Quantity of Cams Direct Wire Cam Configuration Type 3 Device Cam Configuration B Reverse Both Neutral and Ground G Reverse Ground Only Appendix E S Straight All Female Connectors Represented Model Numbers of PowerGATE Pin and Sleeve Company Switches CS 60F D5PS1 CS 100F D5PS1 Model Number Key CS Number F Company Switch Amperage Rating with Female Connectors D5PS1 Direct Wire 5 Pin Pin and Sleeve Type 1 Device 14 Contact Lex Products 800 643 4460 info lexproducts com Labels for Replacement 12 PowerGATE We Deliver the Power 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 lectrique Le raccordement devrait tre effectu dans l ordre qui suit 1 Conducteur de mise la terre de l appareillage 2 Conducteur du circuit mis la terre 3 Conducteurs non mis la terre La mise hors tension doit se faire dans l ordre inverse 400 Company Switch US Pat No 7 136 278 B2 FOR USE IN AREAS NOT READILY ACCESSIBLE BY THE GENERAL PUBLIC Gr
5. 60F C5DB1 BLK CS 100F C5DB1 BLK CS 200F C5DB1 BLK CS 400F C5DB1 BLK CS 60F C5DG1 CS 100F C5DG1 CS 200F C5DG1 CS 400F C5DG1 CS 60F C5DG1 BLK CS 100F C5DG1 BLK CS 200F C5DG1 BLK CS 400F C5DG1 BLK CS 60F C5DS1 CS 100F C5DS1 CS 200F C5DS1 CS 400F C5DS1 CS 60F C5DS1 BLK CS 100F C5DS1 BLK CS 200F C5DS1 BLK CS 400F C5DS1 BLK CS 60F C6DB1 CS 100F C6DB1 CS 200F C6DB1 CS 400F C6DB1 CS 60F C6DB1 BLK CS 100F C6DB1 BLK CS 200F C6DB1 BLK CS 400F C6DB1 BLK CS 60F C6DG1 CS 100F C6DG1 CS 200F C6DG1 CS 400F C6DG1 CS 60F C6DG1 BLK CS 100F C6DG1 BLK CS 200F C6DG1 BLK CS 400F C6DG1 BLK CS 60F C6DS1 CS 100F C6DS1 CS 200F C6DS1 CS 400F C6DS1 CS 60F C6DS1 BLK CS 100F C6DS1 BLK CS 200F C6DS1 BLK CS 400F C6DS1 BLK Model Number Key CS Company Switch Number F Amperage Rating with Female Connectors C Number D Letter 1 Series 16 Cams Quantity of Cams Direct Wire Cam Configuration Type 1 Device Cam Configuration B Reverse Both Neutral and Ground G Reverse Ground Only S Straight All Female Connectors Color No Entry Tan BLK Black Appendix D Represented Model Numbers of PowerGate Outdoor Company Switches CS 60F C5DB3 CS 100F C5DB3 CS 200F C5DB3 CS 400F C5DB3 CS 60F C5DG3 CS 100F C5DG3 CS 200F C5DG3 CS 400F C5DG3 CS 60F C5DS3 CS 100F C5DS3 CS 200F C5DS3 CS 400F C5DS3 CS 60FC6DB3 CS 100F C6DB3 CS 200F C6DB3 CS 400F C6DB3 CS 60F C6DG3 CS 100F C6DG3 CS 2
6. Fax 818 768 4040 Fax Copyright Lex Products 2014 Produced in the United States of America 05 30 All Rights Reserved Lex Products logo and lexproducts com are trademarks or registered trademarks of Lex Products in the United States other countries or both
7. PowerGATE Switches amp Panels PowerGATE Company Switch Installation Instructions amp User Manual US Patent No 7 136 278 B2 Specifically designed for safe power access in the following locations Theaters Convention Centers Studios Theme Parks Recreational Facilities C US LISTED LEX PowerGATE 400 A Company Switch US Pat to 7 136 278 82 FOR UIE AREAS NOT Reson ACCEL Or Th Cones me LEX PowerGATE Detver he Power 400 A Company Switch PO LEE ANS NET READ ACODER THE GENERA PLS LM CS 000 PowerGATE Company Switch Contents Contents Prior to Installation shipment Unpacking and Inspection Product Features O gt JES oO oO NO I I CO O1 Installation 10 Set Up Making Lug Connections 10 11 Set Up Making Cam Connections 1 Disconnection Disconnecting Connections 12 Changing the Trip Current 12 Troubleshooting 12 Limited Warranty 12 Maintenance 12 Technical Support Appendices 12 Pre Operation and Maintenance Checklist 1 Parts Dimensions 14 Represented Model Numbers 15 Labels for Replacement 2 Contact Lex Products 800 643 4460 info lexproducts com Important This manual contains information critical to the proper installation and operation of the Lex Products PowerGATE Company Switch Be certain to read and understand all instructions prior to installation and operation This manual is furnished exclusively to support installation and
8. act Lex Products Technical Services for instructions on adjusting the trip delay time Limited Warranty When this PowerGATE Company Switch is installed and operated according to the manuals 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 Company Switch 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 1 855 LEX 1002 or emailing support LexProducts com For any other information please call Lex Products at 1 800 643 4460 or e mail info LexProducts com 12 Contact Lex Products 800 643 4460 info lexproducts com Appendix A Pre Operation and Maintenance Checklist 1 Visual inspection of enclosure Ensure the PowerGATE Company Switch is firmly secured to the building Review conduit connection for signs of loosening or leakage Ensure enclosure is intact with no signs of fatigue or rusting 2 Open the lower chamber door Ensure the chamber is dry and free of debris Ensure that gaskets are pliable and no cracking exists Ensure that doo
9. h appropriate port in bottom of the unit 3 Complete the connection A Cut the cable end square B Strip the wire 1 1 2 Do not nick any strands C Insert the bare end into the lug and torque per the label on the lug cover 4 Complete the Neutral white connection A Cut the cable end square B Strip the wire 1 1 2 Do not nick any strands C Insert the bare end into the lug and torque per the label on the lug cover 5 Complete the Phase hot connections A Cut the cable end square B Strip the wire 1 1 2 Do not nick any strands C Insert the bare end into the lug and torque per the label on the lug cover 6 Make sure all connections are right and secure 7 Tighten thubscrews on strain relief until the cables are held firmly A Be certain to leave a little slack in the cable so there is no strain on the lug connection Step 9A Close chamber door secure the keylock allowing cables to exit cable ports at bottom 10 Contact Lex Products 800 643 4460 info lexproducts com WARNING Ensure the circuit breaker is OFF and locked out from utility power prior to connection Step 8B Making Cam Connections 1 Unsecure keylock on lower chamber and open chamber door NOTE As a safety feature of the PowerGATE Company Switch the power will be tripped off when the door is opened 2 Feed Ground green cable through appropriate port in bottom 3 Complete the connection Proper connection See Figure 17 A Grasp pl
10. itch Figure 14 3 Cable installation notes A See chart Figure 15 for proper strip length and torque B Fine stranded cable MUST be sleeved in copper shim stock before inserting into lugs or strands may interfere with threads of the binding screw resulting in false torque indication C The use of 600 kcmil cable will require different lugs and or reducers These are not supplied by Lex Products but are readily available from most electrical suppliers 4 Tighten individual terminal screws to the torque indicated on the chart using a 3 8 Allen wrench 5 Continue to connect the Neutral and then the Phases hots 6 Vacuum entire upper chamber to ensure no metal shavings are left behind O NEUTRAL NEUTRAL EE Phase A x Black Neutral oo Phase B Red Ground Phase C Blue We mg FES ael aerial S eae C Figure 15 Recommended Torque Torque Strip Length Strip Length Circuit Breaker Min Wire Guage Wire Guage Range Ib in kg cm in cm 60 Amp 2 AWG 350 kcmil 6 AWG 115 317 1 1 8 29 100 Amp 2 AWG 350 kcmil 6 AWG 215 317 11 8 2 9 200 Amp 4 0 AWG 350 kcmil 6 AWG rake 317 1 1 8 2 9 500 kemil 250 kcmil 380 52 PR ON 250 kcmil 3 0 kcmil 275 317 rue Ground amp Neutral Lugs 350 kcmil 6 AWG 275 275 116 2 9 8 Contact Lex Products 800 643 4460 info lexproducts com Step 4 Isolating the Chassis Ground If you need to isolate the chassis from ground proceed as
11. n the upper front panel by removing the twenty 20 Phillips headed 10 32 x 1 2 screws securing it See Figure 7 and 8 Allow 1 2 Conduit to be sized according to cabling rating minumum from all edges 3 The completed conduit when connected to the box must be a minumum of one inch 1 from any of the top edges of the enclosure to ensure proper clearance see Figure 9 6 Contact Lex Products 800 643 4460 info lexproducts com PowerGATE Company Switch Figure 10 Figure 11 CS 60F CxDx1 CS 100F CxDx1 CS 200F CxDx1 CS 60F D5PS1 CS 400F CxDx1 CS 100F D5PS1 Finnra 12 Figure 12 CS 60F CxDx3 CS 100F CxDx3 CS 200F CxDx3 CS 400F CxDx3 NOTE All measurements in inches Contact Lex Products 800 643 4460 info lexproducts com 7 PowerGATE Company Switch Installation Continued Step 3 Wiring the Lug Terminals WARNING Ensure circuit breakers are OFF and locked out from utility power prior to connection The PowerGATE Company Switch is for the connection of portable power devices to utility power It is available in four 4 standard amperage types 60 Amp 100 Amp 200 Amp and 400 Amp 1 Pull the cables from the utility source to the PowerGATE Company Switch Panel 2 Beginning with the Ground strip and install the cables in the appropriate compression terminals See Figure 14 NOTE Conduit shall NOT be relied upon to provide grounding protection to PowerGATE Company Sw
12. og Number CS 400F C6DS1 CS 200F C6DS1 CS 100F C6DS1 NEMA 1 Indoor CS 400F C6DB1 reverse ground neutral CS 200F C6DB1 reverse ground neutral CS 100F C6DB1 reverse ground neutral Catalog Number CS 400F C6DS3 CS 200F C6DS3 CS 100F C6DS3 NEMA 3R Weather Resistant Rating CS 400F C6DB3 reverse ground neutral 400 Amp 3 Phase 120 208Y VAC CS 200F C6DB3 reverse ground neutral 200 Amp 3 Phase 120 208Y VAC CS 100F C6DB3 reverse ground neutral 100 Amp 3 Phase 120 208Y VAC Overcurrent Protection 65 000 AIC Main Breaker 100 Rated 65 000 AIC Main Breaker 100 Rated 65 000 AIC Main Breaker 100 Rated Output 6 16 Series Cam type devices Black Hot Blue Hot Red Hot 2 White Neutral Green Ground 6 16 Series Cam type devices Black Hot Blue Hot Red Hot 2 White Neutral Green Ground 6 16 Series Cam type devices Black Hot Blue Hot Red Hot 2 White Neutral Green Ground Cabinet Finish Color Beige or matte black powder coat For black finish add suffix BLK to catalog number Beige or matte black powder coat For black finish add suffix BLK to catalog number Beige or matte black powder coat For black finish add suffix BLK to catalog number Dimensions Indoor Dimensions Outdoor 46 50 H x 20 27 W x 11 64 D 46 50 H x 20 27 W x 12 91 D 38 90 H x 20 27 W x 11 64 D 38 90 H x
13. ound LBL PGIP W1 FOR USE BY QUALIFIED PERSONNEL ONLY POUR EMPLOI PAR UN TECHNICIEN QUALIFIE EXCLUSIVEMENT FOR USE IN AREAS NOT READILY ACCESSIBLE BY THE GENERAL PUBLIC FOR BRANCH CIRCUIT USE ONLY POUR EMPLOI DANS DES ENDROITS QUI NE SONT PAS FACILEMENT WIRE RANGE 4 AWG 500 KCM POUR EMPLOI SUR UN CIRCUIT DE ACCESSIBLES A L ENSEMBLE DU PUBLIC DERIVATION EXCLUSIVEMENT TEMPERATURE 75 C MIN THE ROUTING OF PORTABLE SUPPLY CONDUCTORS THE MAKING AND BREAKING DO NOT DISCONNECT UNDER LOAD OF SUPPLY CONNECTORS AND THE ENERGIZATION AND DE ENERGIZATION OF TORQUE 500 IN LBS NE PAS DECONNECTER PENDANT QUE SUPPLY SERVICES SHALL BE PERFORMED BY QUALIFIED PERSONNEL ONLY L EQUIPEMENT EST SOUS TENSION LBL 0002 REV 001 LBL CSTQ R 001 L ACHEMINEMENT DE CONDUCTEURS D ALIMENTATION PORTATIFS LA CONNEXION ET LA D CONNEXION DE CONNECTEURS D ALIMENTATION ET L ACTIVATION ET LA DESACTIVATION DE SERVICES D ALIMENTATION NE DEVRONT ETRE EFFECTUES QUE PAR UN TECHNICIEN QUALIFIE LBL CSPQ REV 001 Figure 22 Figure 23 LEXC PowerGATE 400 A Company Switch PowerGATE 400 A Company Switch US Pat No 7 136 278 82 POR URE I AREAS MOT READILY ACCERSBLE OY THE CENTRAL PUBLIC Contact Lex Products 800 643 4460 info lexproducts com 15 PowerGATE Company Switch User Manual PowerGATE Switches amp Panels c US LISTED Company Switch with Cam Type Outlets Ordering Information 400 AMP 200 AMP 100 AMP Catal
14. owerGATE Company Switch the power will be tripped off when the door is opened 2 Loosen thubscrews on strain relief until the cables may move freely if using bare wire 3 Disconnect the Phase hot connections beginning with the furthest to the right 4 Complete disconnect of ALL Phase connections and set aside prior to proceeding 5 Disconnect the Neutral white connection 6 Complete disconnect of ALL Neutral connections and set aside prior to proceeding 7 Disconnect the Ground green connection 8 Complete disconnect of the Ground connection and set aside prior to proceeding Step 11 Close chamber door secure keylock Contact Lex Products 800 643 4460 info lexproducts com 11 PowerGATE Company Switch Changing the Trip Current The trip current of the PowerGATE Company Switch may be adjusted in the field Contact Lex Products Technical Services for instructions on adjusting the trip current NOTE The revised trip current rating will NOT be reflected on the label Lex Products Part Number LBL CS Amperage on the face of the device Troubleshooting If the unit immediately trips off on power up check to make sure the lower panel door Is closed and secured lf any or all LEDs do not light and there is power to the unit turn main power switch off and check the fuses located to the left of the LEDs f the breaker appears to be tripping too quickly possibly due to inrush current cont
15. r hinges are secure and lubricated Ensure that the keylock is intact and operational Z WARNING Ensure the circuit breaker is OFF and locked out from utility power prior to proceeding 3 Remove dead front panel Ensure that all load terminals are securely fastened and that the set screws are set at the torque rating as detailed in Figure 16 Ensure electrical connections are intact with no signs of corrosion or cracking Ensure there is no debris left over from drilling and that no tools are left in cabinet 4 Review all safety labels and ensure that they are present and legible See Appendix F for label nomenclature and location Replace as needed 5 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 PowerGATE Company Switch Appendix B Parts Dimensions Figure 18 Figure 19 CS 60F CxDx1 CS 100F CxDx1 CS 200F CxDx1 CS 60F D5PS1 CS 400F CxDx1 CS 100F D5PS1 Figure 21 12 91 9 07 Figure 20 CS 60F CxDx3 CS 100F CxDx3 CS 200F CxDx3 CS 400F CxDx3 NOTE All measurements in inches Contact Lex Products 800 643 4460 info lexproducts com 13 PowerGATE Company Switch Appendix C Represented Model Numbers of PowerGate Indoor Company Switches CS 60F C5DB1 CS 100F C5DB1 CS 200F C5DB1 CS 400F C5DB1 CS
16. rotection is provided 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 object when cutting packaging as damage to the outer coating may result Perform a visual inspection to ensure the keylocks and doors are in functioning condition and that the panel integrity is intact Contact Lex Products 800 643 4460 info lexproducts com 3 Product Features Figure 1 Figure 2 LEX PowerGATE ABB SACE Tmax 400 A Company Switch US Pat No 7 136 278 B2 FO SE IN AREAS NOT READILY ACCESSIBLE BY THE GENERAL PUBLIC 100 Rated Electronic Circuit Breaker cULus Listed Cam type and lug connections Lock Figure 3 Cable entry holes e O OOS O OO 4 Contact Lex Products 800 643 4460 info lexproducts com Product Features Cam Lug Connection Chamber Figure 4 Figure 5 SIDE VIEW Indicator lights HAN MAW LUG OPENING FOR BARE END CABLE Du CAM TYPE FEMALE Ground CONNECTOR Stainless Steel Handles Cam type receptacle and lug Figure 6 Auto Shut Off Automatic chamber light Strain relief Contact Lex Products 800 643 4460 info lexproducts com PowerGATE Company Switch Installation The installation of the PowerGATE Company Switch should 4 Itis recommended that a knockout punch be used to cut hole for be ca
17. rried out by qualified personnel in accordance with conduit local electrical codes A Cover the main switch to prevent metal shaving intrusion B Place the punch on the inside of the enclosure and draw the Step 1 Fasten the PowerGATE Company Switch to punch through to the die on the outside secure location 5 Vacuum entire upper chamber to ensure no shavings are left NOTE The PowerGATE Company Switch can weigh as much behind as 130 Ibs without cables attached 1 The panel should be located so there is adequate room for the externally connected cables to hang below the panel A Typically allow a minimum of 24 clearance from the bottom of Figure 7 Figure 8 the panel to finished ground level B A mounting height of 44 A F F is recommended wherever conditions allow 2 Installation must be level and plumb 3 Fastening onto a wall using 3 8 fasteners must be completed prior to proceeding with any terminations See Figures 10 through 13 for hole spacing Step 2 Installing the Conduit NOTE Conduit to enter through the top of the device See Figure 9 NOTE To maintain TYPE 3R Rating compliance for the relevant enclosure proper sealing procedures must be followed This is to include but not limited to the use of proper gaskets NOTE In order to prevent enclosure damage and to maintain the enclosure requirements the conduit must be aligned to prevent unnecessary stress on the enclosure walls Figure 9 1 Unfaste
18. ug jacket and firmly insert cam connector into cam receptacle B Push on cam plug jacket until connector fully seats in cam receptacle C Rotate plug connector jacket counterclockwise until it stops 4 Feed Neutral white cable s through appropriate port s in bottom 5 Complete the Neutral white connection s Proper connection See Figure 17 A Grasp plug jacket and firmly insert cam connector into cam receptacle B Push on cam plug jacket until connector fully seats in cam receptacle C Rotate plug connector jacket counterclockwise until it stops Figure 17 PowerGATE Company Switch Set up Continued Step 8B Making Cam Connections continued 6 Feed Phase black red and blue cables through appropriate ports in bottom 7 Complete the Phase hot connections Proper connection See Figure 17 A Grasp plug jacket and firmly insert cam connector into cam receptacle B Push on cam plug jacket until connector fully seats in cam receptacle C Rotate plug connector jacket counterclockwise until it stops 8 Make sure all connections are right and secure Step 9B Close chamber door secure the keylock allowing cables to exit cable ports at bottom Disconnection Step 10 Disconnecting Circuits Z WARNING Ensure the circuit breaker is OFF and locked out from utility power prior to connection 1 Unsecure keylock on lower chamber and open chamber door NOTE As a safety feature of the P
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