Appleton PlexPower Fiber Panelboard Installation and Operation, 504483-000 Instruction Sheet
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.
Applications
The PlexPower™ Fiber Panelboard provides control
of electrical circuits and communications patch panels
in hazardous environments such as:
• Petroleum plants
• Chemical plants
• Reneries
• Wastewater treatment plants
• Paper and pulp industries
• Other process facilities
Product Safety
PlexPower 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.
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.
CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or
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504543-000 Rev. C 1/3/2020 • Page 1 of 19
Installation
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
SIDE VIEW
VIEW WITH ENCLOSURE
DOOR HIDDEN
ROXTEC CABLE
SYSTEM
FRONT VIEW
VIEW WITH ENCLOSURE DOOR CLOSED
FRONT VIEW
SIDE VIEW
VIEW WITH ENCLOSURE
DOOR HIDDEN
VIEW WITH ENCLOSURE DOOR CLOSED
SIDE VIEW
VIEW WITH ENCLOSURE
ROXTEC CABLE
MANAGEMENT
SYSTEM
FRONT VIEW
MANAGEMENT
FIGURE 1 - PlexPower Fiber Patch Panel With Roxtec Cable Management*
FRONT VIEW
FIGURE 2 - PlexPower Fiber Patch Panel With Gland Plate and Heater*
*NOTE: These figures are representative of all panels.
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DOOR HIDDEN
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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 qualied.
• Retain these instructions for reference during future inspections and maintenance.
Lifting & Moving Panel by Using an Eye Bolt
To lift the the panelboard, use M10 Eye Bolt and x 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
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Lifting & Moving Panel by Using 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 any
pallet 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
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.
Follow 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 with
• 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.
forklift without using any pallet or stand could damage Gland plate provided on panel bottom.
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.
FIGURE 4
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Mounting:
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 Installation
section.
2. The panel board enclosure is intended to be mounted vertically. Use mounting
foot U-Slot for positioning and fastening panelboard.
3. Since upper mounting locations are tied with panel lifting accessories, use
bottom mounting locations first for securing panelboard.
4. Once the bottom mounting locations are securely fastened then release lifting
accessories 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
• 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 rst for securing panelboard
• Once the bottom mounting locations are fastened, release lifting accessories and fasten upper mounting locations with
• All mounting locations must be secured properly to avoid any damage.
• If you nd any damaged mounting feet, consult tech support.
using M10 Bolt.
wall or frame.
FIGURE 5 - PlexPower Fiber Panelboard
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504543-000 Rev. C 1/3/2020 • Page 5 of 19
Mounting Procedure:
• After both bottom and middle mounting feet are xed, remove the eye bolt from top mounting foot and x 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 oor and panelboard bottom is to be at least 1 foot.
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FIGURE 6
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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
4) Main ground lug is provided for system ground.
side connections will be wired to the terminal blocks located at the bottom of the panel in the factory.
FIGURE 7 - PlexPower Fiber Panel Assembly
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Wiring Connections for Customer Input and Output
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 toward
load from power terminal blocks, Customer needs to drill hole on gland plate
provided on bottom side of enclosure.
Customer needs to take into consideration required cable size according to panel
specifications.
Also, customer needs to install cable gland from which incoming and outgoing
wires can be routed.
Consult Appleton group for required Cable gland size and information regarding
drilling hole specifications.
Incoming 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
• User needs to take into consideration the required cable size according to panel specications.
• User needs to install certied cable gland from which incoming and outgoing wires can be routed.
• Appleton recommends using Appleton TC cable gland series.
drill holes into the enclosure. A gland plate is provided on the bottom of the enclosure to make this drilling easier. Additional gland
plates can be provided as options when ordering.
FIGURE 8
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504543-000 Rev. C 1/3/2020 • Page 8 of 19
Incoming and Outgoing Connection for PlexPower Fiber Patch Panel with Roxtec Cable Management:
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 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.
❑ Consult Appleton group for required Cable size and information regarding
Roxtec Cable management system installation.
Roxtec cable System
for Outgoing Cable
PlexPower Fiber Patch with Roxtec Cable Management
Insert the back plate from
Place the compression rubber
Fix the back plate with the
Thoroughly lubricate all surfaces of
Fix the front plate parts loosely over the
• To facilitate cable connection to line side of panel and to take out cables toward load from power terminal blocks, Customer needs
• Customer needs to take into consideration required cable size according to panel specications.
• Appleton uses the CF16 Roxtec Cable management system installation.
to open Module in ROXTEC Cable provided on bottom side of enclosure.
the installation side.
two cross-slotted screws.
the compression rubber with
Roxtec Lubricant.
from the installation side.
compression rubber with the torx screws.
FIGURE 9
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Wiring Diagram
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 below
wiring diagram.
2. To connect cables from load side QC Breaker to panel board with help of power
terminal blocks, refer below wiring diagram by replacing fuse with Terminal
Block.
3. When Assembly comes with USCC1 Fuse Block with Fuses assembly then LED
Indicator connection should be connect with output wire of USCC1 Fuse
To connect cables from load to panelboard power terminal blocks, refer below wiring diagram and terminal block marking.
*NOTE: When the assembly comes with a USCC 1 Fuse Block with Fuses Assembly, the LED indicator connection should be
connected with the Output wire of the USCC 1 fuse.
FIGURE 10*
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Wiring Connection for Heater and Thermostat
After 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.
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FIGURE 11
504543-000 Rev. C 1/3/2020 • Page 11 of 19
Note- Do not Route any wire connection
This Label Must be at front
facing orientation
around the 32 mm of Heaters.
FIGURE 12
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Wire Sizing Chart For Breaker- Reference - CSA C22.2, NO. 5-02,
4.3 Wire Information as per Ampacity
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
12 AWG
15
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
4.4 Terminals-Connection Devices
Table 6.1.4.2.1, UL 489.
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
Terminals - Incoming Line Connection
Purpose Co
Power Terminal Block
nductor Size (UL/CSA)
Max
Amps
Pressure
Screw Torque
10 in-lbs
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Electrical Testing
All 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 short
• If any circuit displays a resistance to another circuit or to ground of One Mega ohm or less, that circuit must be analyzed, corrected
• 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 of
• 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.
circuits or unwanted grounds.
and tested to more than One Mega ohm before applying power.
conductor surfaces due to arcing.
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Operation
Electrical Components*
1. Breaker Part Number
AMPERAGE
1 POLE (120/240 VAC)
2 POLE (120/240 VAC)
3 POLE (120/240 VAC)
20A
QC1020
QC2020
QC3020H
25A
QC1025
QC2025
QC3025H
30A
QC1030
QC2030
QC3030H
40A
QC1040
QC2040
QC3040H
50A
QC1050 - -
60A
QC1060 - -
AMPERAGE
1 POLE (120/240 VAC)
2 POLE (120/240 VAC)
3 POLE (120/240 VAC)
50A
QC1050N
Table No.5
Table No.6
Branch 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.
15A QC1015 QC2015 QC3015H
35A QC1035 QC2035 QC3035H
50A QC1050N - -
2. Switch Part Number
FIGURE 13
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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.
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FIGURE 14
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General Maintenance
Maintenance:
1. Before carrying out any work on equipment, cited safety instructions must be very carefully observed (DO NOT OPEN WITH
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 equipment
5. To ensure that breaker housing remain explosion-proof, before use of product, conrm cover attaching screws and cable inputs are
6. The ameproof function for product must be maintained for complete duration of service life therefore joints must be maintained in
7. No scratches, marks or modication is allowed on parts which are important for ame path (e.g. Body, Cover).
8. External lug assembly and connecting wires from other devices should be checked at regular intervals, for appropriate secureness,
9. Any appliance found to be defective should be replaced immediately.
10. Perform visual, electrical, and mechanical checks on all components on regular intervals.
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 about
POWER “ON”).
hardware installed.
appropriately torqued.
good condition.
electrical safety etc.
• Carry out Visual checks for undue heating events such as discoloration of wires or other components, damaged or
worn 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 mechanisms
are moving freely.
product service and application.
WARNING
• Electrical Power must be turned OFF before and during Maintenance.
• Modication of this panel or substitution of parts with non-standard parts may result in Serious/Fatal Personnel injury
due to Electrocution.
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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 Holder
5. Fix Fuse holder cap on body till it is securely fastened.
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FIGURE 16
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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
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. Specications are subject to change without notice. The Appleton and Emerson logos are registered in the U.S. Patent and Trademark Ofce. All other product or service names are the property of their registered owners.
©2019 Appleton Grp, LLC. All rights reserved.
504543-000 Rev. C 1/3/2020 • Page 19 of 19
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