PowerGATE™ Power Input Panel
Contents
1. PowerGATE Power Input Panel User Manual for 1200 and 1600 Amp Models We Deliver the Power A safe reliable and convenient means of connecting temporary power for disaster relief applications PowerGATE Power Input Panel Contents Important 2 Table of Contents This manual contains information critical to the proper installation ct and operation of the Lex Products PowerGATE Power Input Panel Be certain to read and understand all instructions prior to installation 3 Shipment and Inspection and operation 4 Product Features NOTE Must be installed in conjunction with transfer switch 5 6 Installation Transfer Switch to be provided by a source other than Lex Products 7 8 Set up 8 9 Disconnection 9 Limited Warranty 9 Maintenance 9 Technical Support Appendices 10 Pre Operation and Maintenance Checklist 10 Parts Dimensions 10 Represented Model Numbers and Ratings 11 Warning Labels 2 Contact Lex Products 800 643 4460 info lexproducts com PowerGATE Power Input Panel Prior to Installation Site Preparation Prepare installation site according to local codes The PowerGATE Power Input Panel is 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 Power Input Panel is to be secured must be capable of supporting the weight of the cabinet as well as the cable attached to it The follo2. Power Input Panel Hot A B B A C C Contact Lex Products 800 643 4460 info lexproducts com 7 PowerGATE Power Input Panel Set up Continued Proper connection See Figure 8 A Grasp connector jacket and firmly 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 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 right and secure Step 6 Close and lock lower chamber door allowing cables to exit through smaller cable door See Figure 9 Figure 9 8 Contact Lex Products 800 643 4460 info lexproducts com Disconnection Step 7 Powering Up Z 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 Step 8 Disconnecting Circuits Z 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 dis
3. 0 All Rights Reserved li 203 363 3738 818 768 4474 We Deliver the Power 203 363 3742 Fax 818 768 4040 Fax Lex Products logo and lexproducts com are trademarks or registered trademarks of Lex Products in the United States other countries or both
4. Series Cam type color coded panel mount inlets panel mount inlets Output Copper Bus Bar with 1 2 Holes Copper Bus Bar with 1 2 Holes Enclosure Powder Coated 12 Gauge Galvanized Steel Powder Coated 12 Gauge Galvanized Steel Dimensions 56 H x 30 D x 35 W 56 H x 30 D x 35 W Approximate Weight 485 lbs 505 Ibs Part Number PGIP1200 CRG12DI S3 PGIP1600 CRG16DI S3 Rating 1200 Amp 3 Phase H H H G 3 Pole 3 Wire 1600 Amp 3 Phase H H H G 3 Pole 3 Wire 600 VAC Maximum 600 VAC Maximum Environmental Rating TYPE 3R Rainproof TYPE 3R Rainproof Input 3 Set of 4 16 Series Cam type color coded 4 Set of 4 16 Series Cam type color coded panel mount inlets panel mount inlets Output Copper Bus Bar with 1 2 Holes Copper Bus Bar with 1 2 Holes Enclosure Powder Coated 12 Gauge Galvanized Steel Powder Coated 12 Gauge Galvanized Steel Dimensions 56 H x 30 D x 35 W 56 H x 30 D x 35 W Approximate Weight 475 lbs 495 Ibs BRB Black Red Blue BOY Brown Orange Yellow BBB Black Black Black and RGN Reverse Ground Neutral Cam options available Contact a Lex Products sales representative for more information LEX Lex Products Corporation Lex West 15 Progress Drive www lexproducts com 11847 Sheldon Street info lexproducts com Copyright Lex Products 2012 Produced in the United States of America Shelton CT 06484 Sun Valley CA 91352 800 643 446
5. connection See Figure 10 A Grasp connector jacket firmly and rotate cam connector 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 Figure 10 PowerGATE Power Input Panel 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 10 A Grasp connector jacket firmly and rotate cam connector 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 8 Disconnect the Ground green connections beginning with the closest to the front door Proper disconnection See Figure 10 A Grasp connector jacket firmly and rotate cam connector clockwise until it stops 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 9 Secure the three 3 keylocks to complete procedure Limite
6. d Warranty When this PowerGATE Power Input 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 Power Input 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 Service department is available 24 7 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 Contact Lex Products 800 643 4460 info lexproducts com 9 PowerGATE Power Input Panel Appendix A Pre Operation Checklist 1 Visual inspection of enclosure Ensure the PowerGATE Power Input Panel is firmly 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 i
7. e d brancher les connecteurs 3 3 Conducteurs non mis la terre 3 a La mise hors tension doit se faire dans l ordre inverse 3 Lex Products Part Number LBL PGIP D1 Lex Products Part Number LBL PGIP D2 Lex Products Part Number LBL PGIP W1 cAc Be Lex Products Part Number LBL A Lex Products Part Number LBL B Lex Products Part Number LBL C o G gt LBL G Lex Products Part Number LBL N Lex Products Part Number LBL G A DANGER HIGH VOLTAGE KEEP OUT HAUTE TENSION NE PAS TOUCHER 1 i 1 LBL PGIP D1 e a H nun uun uuy uuy uuy A DANGER At LBL PGIP D2 C C LBL PGIP LBL PGIP W1 Contact Lex Products 800 643 4460 info lexproducts com 11 PowerGATE Power Input Panel User Manual for 1200 and 1600 Amp Models Switches amp Panels PowerGATE Gi c us Ordering information cETLus Listed 1200 Amp 1600 Amp Part Number PGIP1200 CRG15EI S3 PGIP1600 CRG20EI S3 Rating 1200 Amp 3 Phase H H H N G 4 Pole 5 Wire 1600 Amp 3 Phase H H H N G 4 Pole 5 Wire 600 VAC Maximum 600 VAC Maximum Environmental Rating TYPE 3R Rainproof TYPE 3R Rainproof Input 3 Sets of 5 16 Series Cam type color coded 4 Sets of 5 16
8. elta 208Y 120V operation PGIP1600 CRG15EI S3 PGIP1600 CRG15EI S3 BOY PGIP1600 CRG15EI S3 BBB Specific model numbers for 1200A Wye 240V operation PGIP1200 CRG12DI S3 PGIP1200 CRG12DI S3 BOY PGIP1200 CRG12DI S3 BBB Specific model numbers for 1600A Wye 240V operation PGIP1600 CRG12DI S3 PGIP1600 CRG12DI S3 BOY PGIP1600 CRG12DI S3 BBB PowerGATE Power Input Panel Appendix D Labels for Replacement Moy Veja Pi e 2 Risk of Electric Shock Do not start the generator until all connectors are connected Plug connection should be in the following order H G H VO LTAG E or made to be inaccessible Any terminal may be energized 1 Equipment grounding conductor connectors when any cable is connected De energize cables at the 2 Grounded circuit conductor connectors and KE E P O UT generator prior to connecting or removing any connectors 3 Ungrounded conductor connectors Disconnection should be in the reverse order Ne pas mettre la g n ratrice en marche avant que tous les Risque de choc lectrique H AUTE TE N S O N connecteurs soient connect s ou rendus inaccessibles Le raccordement devrait tre effectu dans l ordre qui suit 5 N importe quelle borne peut tre mise sous tension siun 1 Conducteur de mise a la terre de l appareillage z N E PAS TO U C H E R cable est raccord D brancher les c bles la g n ratrice 2 Conducteur du circuit mis la terre a a avant de brancher ou d
9. ested to current code Keylocked access doors for ease of inspection termination and prevention of unauthorized access Large copper bus bars with numerous locations for securing load wiring Large upper termination chamber to ease cable routing and installation Cable access door for mechanical strain reduction and theft deterrence Figure 3 Industry standard Series 16 single pole cam inputs for rapid termination during an emergency 4 Contact Lex Products 800 643 4460 info lexproducts com PowerGATE Power Input Panel Installation Z WARNING The PowerGATE Power Input Panel is top heavy and therefore Care must be taken to secure the device when it is lifted and moved Please note that the 1200 Amp versions weigh approximately 485 pounds and the 1600 Amp versions weigh approximately 505 pounds the center of gravity is well above the forklift slots See Figure 4 Figure 4 Forklift ports The installation of the PowerGATE Power Input Panel should be carried out by qualified personnel in accordance with local electrical codes Step 1 Fasten the PowerGATE Power Input Panel to secure base 1 Base must be level and plumb to allow for proper drainage from the PowerGATE Power Input Panel weep holes 2 Fastening onto an external pad using 3 8 fasteners must be completed prior
10. ether the building is wired clockwise or counter clockwise B Apply the provided label Figure 6 to the inside of the PowerGATE Input Panel on the inside of the cam connection chamber door Figure 7 Figure 6 3 Power Counter 39 Power Clockwise Clockwise Apply 1 to inside door of Input Panel Connection Chamber Lex Products Part Number LBL PGIP ROTATION Figure 7 Place rotation label here Step 5 Conduct a safety test to ensure proper installation Do not attempt to use the PowerGATE Power Input Panel prior to installation and completing the Pre Operation and Maintenance Checklist under Appendix A PowerGATE Power Input Panel Set up A Review Pre Operation Checklist under Appendices A prior to operation page 10 Z 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 B 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 C Making Cam Connections 1 Open lower chamber door 2 Complete the Ground green connections beginning with the furthes
11. m 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 Z 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 6 Contact Lex Products 800 643 4460 info lexproducts com 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 wh
12. ntact 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 203 363 3738 or e mail support LexProducts com 10 Contact Lex Products 800 643 4460 info lexproducts com Appendix B Parts Dimensions 1 Table with leader letters part number and part description Figure 11 a 35 80 gt i 31 00 l l A H L 58 91 mi s DAO Appendix C Represented Model Numbers and Ratings of Multi Row Input Panels Specific model numbers for 1200A Delta 208Y 120V operation PGIP1200 CRG15EI S3 PGIP1200 CRG15EI S3 BOY PGIP1200 CRG15EI S3 BBB Specific model numbers for 1600A D
13. t from the front door to the left Proper connection See Figure 8 A Grasp connector jacket and firmly 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 8 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 8 A Grasp connector jacket and firmly 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 connections A Should the phase rotation of the generator as determined in Step 5 B 3 above 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 5 B 3 above 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
14. to proceeding with any terminations See Figure 1 for hole spacing Step 2 Installing the Conduit NOTE Conduit to enter through the top or top rear of the device See Figure 5 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 5 Contact Lex Products 800 643 4460 info lexproducts com 5 PowerGATE Power Input Panel Installation Continued Step 3 Wiring the Bus Bars Z 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 Power Input Panel and endanger generator personnel The PowerGATE Power 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 fro
15. wing should be taken into consideration when locating the PowerGATE power Input Panel The PowerGATE Power Input Panel is designed for exterior operation ONLY Identify and meet local codes and local Authority Having Jurisdiction AHJ To prevent carbon monoxide poisoning from improperly ventilated generator emissions the Power Input Panel must be mounted outdoors only The mounting location is to be carefully selected to allow convenient connection to a generator and located a suitable distance away from any building openings or HVAC inlets Figure 1 33 14 27 44 Proper clearance must be allowed in front of the PowerGATE Power Input 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 keylock protection 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 scratching of outer coating may result in rusting Perform a visual inspection to ensure all keylocks and doors are in functioning condition and that the panel integrity is intact Contact Lex Products 800 643 4460 info lexproducts com 3 PowerGATE Power Input Panel Product Features Purpose built Type 3R cabinet independently t
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