Carlon Rectangular Floor Box, Activation Kit, and Covers User Manual

Carlon

®

Rectangular

Floor Box, Activation

Kit and Covers

Installation Instructions

IS125

25701 Science Park Drive, Cleveland,
Ohio 44122 USA

CALL TOLL-FREE OR FAX
Tel: (800) 3-CARLON (1-800-322-7566)

In Ohio: [phone]
FAX: [phone]
TDD/Hearing Impaired Access:

[phone]

www.carlon.com

Single Gang Application

1. Single gang box comes assembled.

Two Gang Application

1. Two single gang boxes are required (2 pieces of E976RFB).

2. Remove the appropriate side of each box to gang them properly. (Fig. 1) Slide
boxes together by aligning the top interlocking tabs on the side of the base
and the bottom tabs and slots. (Fig. 2 and Fig. 3) THESE BOXES DO NOT
SNAP TOGETHER; THEY SLIDE TOGETHER!

Three Gang Application

1. Three single gang boxes are required (3 pieces of E976RFB).

2. Repeat step 2 under Two Gang Application instructions.

NOTE: When ganging 2 or 3 boxes, you must apply a piece of duct tape along

each side and bottom seam. (Fig. 4 and Fig. 5)

1. Set box on level surface with minimum concrete pour of 3

1

/

2".

NOTE: With 3

1

/

2" concrete pour, space for cord plug between electrical device

and closed cover is

7

/8".

2. Set the box so there is a minimum

1

/2" exposure after concrete pour.

IMPORTANT! For above

grade installation, provide adequate concrete thickness
under the floor to preserve the fire rating of the floor in accordance with the
building codes.

3. Secure plastic cap to floor box before pour by cross taping the cap.(Fig.6)

a. For two gang applications, cut the edge of one cap, then overlap the second.

Duct tape the underside seam.

b. For three gang applications, cut both edges of center cap. Overlap both

outer caps onto center cap and duct tape both underside seams.

Conduit Connections

1. Use Carlon PVC cement to adhere Carlon Plus 40 or Carlon Plus 80

nonmetallic conduit or Flex Plus Blue ENT (electrical nonmetallic tubing) to
utilized ports.

2. To feed parallel runs of

3

/

4" conduit use Carlon “Y” adapter E972Y.

3. Use Carlon PVC cement to adhere reducer-plugs (provided with Floor Box) to

seal off unused conduit openings.

4. Floor box sides may be drilled for conduit feeds; to access, stay above

noticeable “scribe lines” on side. (Fig.7)
IMPORTANT! Follow solvent cement manufacturers’ instruction and safety
precautions.

PREPARATION

Before Concrete Pour

Carlon®Rectangular Floor Box E976RFB

Plastic cap

Side

To remove side,
push up on side
from bottom.

Fig. 7

Fig. 6

Cut along both edges (3 gang)

Scribe line

Cut along edge (2 gang)

In Canada, contact:
P.O. Box 60 •35 Killaloe Road
Unit 4 Concord, Ontario
Canada L4K 1A0
[phone]
[phone]
Fax: [phone]
[phone]

1

Top - Fig. 2

Bottom - Fig. 3

2 gang
assembly

3 gang

assembly

Duct
tape

#8 x 3/4

screws

Duct
tape

Divider

Activation

Yokes

#8 x 3/4

screws

Activation

Yoke

Fig. 1

Fig. 4

Fig. 5

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Trim Out After Concrete Pour

Single Gang Yoke Installation

Two and Three Gang Divider and Yoke Installation

1. Remove plastic cap.

2. Determine floor box height and mark cut off line. (Fig. 8)
a. For Carlon Nonmetallic Cover Installation go to page 3., steps 1, 2 and 3.
b. For Carlon Brass Cover Installation go to page 4, steps 1, 2 and 3.

3. Using handsaw, cut off box at marked height. (Fig. 9)

NOTE: Carlon Device Mounting Yoke may be either recessed down in the floor box,
or installed directly to bottom of the Carlon Covers.

Carlon®Activation Kit E976AK2 Installation

Divider

Activation Kit:

• Yoke/Activation ring

• Divider

• Insert plates

• Screws

Yoke

Divider

Fig. 13

Plates

Ground lug
Fig. 11

Low

voltage

plate

Fig. 12

Fig. 10

2

Box cut
off height

Fig. 8

Fig. 9

Yoke Recessed in Floor Box

1. Align Yoke in Floor Box slots (Fig. 7) and move yoke to desired level.

2. Insert #8 x

3

/4" pan head screws provided in Activation Kit into angled holes at

the ends of Yoke and tighten into Floor Box ends.

Yoke Mounted directly to Carlon Nonmetallic Covers

1. Position Yoke on underside of Cover.

2. Fasten Yoke to Cover using four #6 x

1

/2" flat head screws provided in

Activation Kit.

Yoke Mounted directly to Carlon Brass Covers

1. Position Yoke on underside of Cover and retain in place using two #8 x 1

1

/

8"

pan head screws provided with Cover.

2. Insert #8 x 1

1

/

8" pan head screws into angled holes at the ends of cover and

tighten into Floor Box ends.

IMPORTANT! It is necessary in accordance with NEC regulations to keep low
voltage (voice, data or video) separate from power requirements. To comply,
Divider provided in Activation Kit must be used.

Divider

1. If using two or three gang box for either all power or all communication, Divider

(Fig.13) is not required. Go to Step 5 per your application.

2. Break off the edge of the Yoke (score line) on the side that the Divider is to be

located. (Fig.10)

3. Cut Divider to length.

a. For Carlon Nonmetallic Cover, cut Divider

3

/4" below carpet flange underside at

installed position.

b. For Carlon Brass Cover, cut Divider

1

/4" below carpet flange underside at

installed position.

4. Slide divider down into slots created when 2 or 3 Carlon E976RFB Floor Boxes

are ganged together. (Fig. 10)

Yoke Recessed in Floor Box

5. Align Yoke in Floor Box slots (Fig. 5) and move yoke to desired level.

6. Insert #8 x

3

/

4" pan head screws provided in Activation Kit into angled holes at

the ends of Yoke and tighten into Floor Box ends.

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Yoke Mounted to Carlon Nonmetallic Covers

5. Position Yoke on underside of Cover.

6. Fasten Yoke to Cover using four #6 x

1

/2" flat head screws provided in Activation Kit.

Yoke Mounted to Carlon Brass Covers

5. Position Yoke on underside of Cover and retain in place using two #8x1-1/ 8" pan head screws provided with Cover.

6. Insert #8 x 11/8" pan head screws into angled holes at the ends of cover and tighten into Floor Box ends.

1. Attach conductors to a standard electrical device (Duplex, GFCI or Single Round receptacle).

Canadian Applications: Per Canadian electric code, a separate bonding connection is required in nonmetallic
electrical boxes. Utilize Grounding Lug (Fig. 11) and green Ground Screw provided with Yoke.

2. Install electrical device in Yoke with device furnished 6-32 screws.

3. Attach the appropriate device plate using #6-32 x

5

/8" oval head screw(s) provided in Activation Kit.

Carlon®Nonmetallic Covers Installation
E9761__*, E9762__* & E9763__*

*B=Brown; C=Caramel; S=Slate

Plate Installation Power Applications

Plate Installation Low Voltage (Voice, Data & Video) Applications

3

1. A 6 port Low Voltage Plate (Fig. 12) is included in Activation Kit E976AK2. The Low Voltage Plate will accept
the following Manufacturer’s “Keystone” style jacks:

- Allen Tel - Amp - Dynacom - Homaco - Hubbell - Krone - Leviton - 3M - Ortronics - Wiremold ­Hellermann Tyton

2. Following Manufacturer’s instructions connect wire or cable to the jack(s). Snap wired jack(s) into Low Voltage
Plate with jack(s) aligned in the “UP” position. Snap blank modules into unused ports.

3. Attach the Low Voltage Plate to the yoke using #6-32 x

3

/

4" oval head screws provided with Low Voltage Plate.

Fig. 14

Floor
Covering

#8 X 11/

8''

Cover mtg. screws

Cord door

Cord door

Fig. 15

Carpet
Flange

Cover

Score line

NOTE: Carlon Activation Kit E976AK2 is required for installation.

Nonmetallic carpet flanges will conceal opening sizes as follows: Single Gang
73/8" x 51/8", Two Gang 73/8" x 81/2" and Three Gang 73/8" x 113/4".

1. Determine type and thickness of floor covering to be used. Covers may be
installed in carpet, tile or other floor covering.

NOTE: Remember to check height of finished floor covering.

2. Mark a line a

1

/8" below desired final installed height of nonmetallic Cover’s
top surface. Using a saw, cut off box at marked height. (Refer to page 2,
Trim Out After Concrete Pour)

3. Methods of Installation

a. Tile or Carpet: The cover may either be installed as is with carpet flange or,
b.

Tile: Carpet flange may be removed using a sawsall, jig saw or saber saw to cut along
the score lines. Avoid using pliers or similar tools to break away the flange. (Fig. 14)
If option of removing carpet flange is selected, set Cover so top surface of flange
is at finished tile height. Work tile to Cover flange.

c. Carpet: Install carpet up to Floor Box outside edge.
d. Tile or Carpet: Cover may be inverted and a section of carpet or tile installed in

the Cover to make the Cover less noticeable. Use template on page 4, Fig. 17, to
size section of floor covering to be installed in inverted cover. If inverted cover
option is chosen, small Cord Door must be removed and re-installed on the
opposite side of the cover. (Fig. 14)

4.

Yoke provided in Activation Kit may be either mounted directly to bottom of the
Nonmetallic Cover or recessed down in the box. See Activation Kit Installation page 2.

5.

To attach Cover to Floor Box, insert #8 x 11/8"

pan head screws (provided with Cover)

into angled holes at the ends of Cover and tighten into Floor Box ends. (Fig. 15

)

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IS125 Rev. 2/00

© Lamson & Sessions 1999

25701 Science Park Drive,
Cleveland, Ohio 44122 USA

Call toll-free or fax
Tel: (800) 3-CARLON (1-800-322-7566)
In Ohio, [phone]
FAX: [phone]
TDD/

Hearing Impaired Access

:

[phone]
In Canada, contact:

P.O. Box 60
35 Killaloe Road, Unit 4
Concord, Ontario
Canada L4K 1A0
[phone] • [phone]
Fax: [phone] • [phone]

www.carlon.com

Carlon®Brass Covers
E9761BR, E9762BR &
E9763BR

NOTE: Carlon Activation Kit E976AK2 is required for installation.
Brass flanges will conceal opening sizes as follows: Single Gang

6

3

/4" x 41/2", Two Gang 63/4" x 73/4" and Three Gang 63/4" x 11".

1. Determine type and thickness of floor covering to be used.
Covers may be installed in carpet, tile or other floor covering.

NOTE: Remember check height of finished floor covering.

2. Mark a line a

3

/16" below desired final installed height of Brass
Cover’s top surface. Using a saw, cut off box at marked height.
(Refer to page 2, Trim Out After Concrete Pour)

Caution: If 1

1

/2" or more is removed from top of box, larger

section of support ribs on the ends of the box may be above
concrete. If needed, remove top of end support ribs to allow

finished floor covering to be installed within

5

/8" of box inside.

3. Methods of Installation

a. Tile: Set Cover so top surface of flange is at finished tile

height. Work tile to Cover flange.

b. Carpet: Install carpet up to Floor Box outside edge.

4. Yoke provided in Activation Kit may be either mounted directly to
bottom of the brass cover or recessed down in the box. See
Activation Kit Installation page 2.

5. To attach Cover to Floor Box: Insert #8 x 1

1

/8" pan head screws
(provided with Cover) into angled holes at the ends of Cover and
tighten into Floor Box ends. (Fig. 16)

4

Fig. 17

1

1

/8''

1

1

/8''

1

5

/

16''

4

15

/16''

2

5

/8''

2

5

/8''

1

5

/16''

US Patent 5,866,845
Patent Pending

#8 X 11/

8''

Cover mtg. screws

Fig. 16

Nonmetallic Cover

Template

Carpet or Tile Insert

Gross Automation [phone] · www.carlonsales.com · [e-mail]