240-VOLT AC POWER IS EXTREMELY DANGEROUS. OBSERVE ALL CAUTIONS. MISUSE OF THIS DEVICE MAY SUBJECT
YOU TO POTENTIALLY FATAL ELECTRIC SHOCK. CONSULT A PROFESSIONAL ELECTRICIAN FOR INSTALLATION. DO NOT
PLUG INTO ANY POWER OUTLET OTHER THAN THE INTENDED TYPE. THIS POWERBOX REQUIRES A MAIN CIRCUIT
BREAKER UPSTREAM FROM THE DEVICE. PLUG ONLY INTO A PROPERLY GROUNDED AND EARTHED OUTLET.
SECTION 1. MAIN CONNECTION
Depending on which model you have, your Powerbox is designed to plug directly into a 3 or 4-prong dryer-type outlet for its main power connection (or alternatively to be hard-wired directly to a circuit at the panel.) Before plugging your Powerbox into an existing main power outlet, make sure that the circuit breaker for
the circuit in question is switched to the OFF position and that no power is flowing to the outlet. Make sure the plug on your Powerbox matches the outlet receptacle you have.
1.1 CONNECTING TO AN EXISTING CIRCUIT
If you already have an existing 240-volt outlet to plug your Powerbox into, it is important to understand the true capacity of that circuit. Most dryer-type outlets have a 30 Amp, double-pole circuit breaker at the main panel to prevent overloads. Since residential circuit breakers are designed to handle only 80% of their rated capacity when running on a continuous basis, the true amount of current you can receive from a 30 Amp breaker is only 24 Amps continuous. To take full advantage of the 30 Amp continuous capacity of the Powerbox, it is recommended to install a 40 Amp circuit breaker at your panel and the appropriate gauge wiring (either 6 or 8-gauge) to the Powerbox. For more information, see SECTION 2, INSTALLING A NEW CIRCUIT.
1.2 TEST CIRCUIT BEFORE CONNECTING POWERBOX
In our experience, we have found that very often, 240-volt outlets are not wired correctly in residential and commercial structures. For this reason, it is highly recommended that you test the voltage at the outlet with an electrical tester before plugging in your Powerbox. Plugging the Powerbox into an outlet that is improperly wired will cause the unit to not function properly and may cause damage to the unit and/or could subject you to dangerous voltages.
3-Wire Connection:
1 st Wire: 120-Volt Phase 1
2 nd
3 rd
Wire: 120-Volt Phase 2
Wire: Neutral
4-Wire Connection:
1 st Wire: 120-Volt Phase 1
2 nd
3 rd
4 th
Wire: 120-Volt Phase 2
Wire: Neutral
Wire: Ground
FIGURE 2
FIGURE
3
With a simple electrical tester, use the two probes to perform the following tests on the circuit to determine if it is wired properly:
3-Wire Connection:
TEST
1+3
PROPER RESULT
120 Volts AC
4-Wire Connection:
TEST
1+3
PROPER RESULT
120 Volts AC
2+3
1+2
120 Volts AC
240 Volts AC
2+3
1+2
120 Volts AC
240 Volts AC
1+4
2+4
120 Volts AC
120 Volts AC combinations do not produce the expected result, the circuit is wired incorrectly. Do not plug in the Powerbox. Have the circuit checked by an electrician.
1.3 CONNECTING THE POWERBOX
Before plugging your Powerbox into the main outlet, make sure the circuit breaker feeding the circuit is switched to OFF and that no live power is flowing to the outlet. Align the prongs of the Powerbox plug with the openings of the receptacle and press firmly until the prongs seat themselves all the way into the outlet.
Mount the Powerbox to the wall or set on a flat surface out of the way of potential hazards such as water. Do not plug any appliances into the Powerbox yet.
Switch the circuit breaker feeding the circuit to ON. The green LED should light up to indicate the unit is receiving power. Proceed to SECTION 3, TIMER
PROGRAMMING.
SECTION 2. INSTALLING A NEW CIRCUIT
If you are installing a new dedicated circuit for your Powerbox, you should be installing a 4-wire 240-volt circuit, which consists of two hot wires, a neutral and a ground wire. You have the choice of 1.) Installing a NEMA 14-30R outlet receptacle for your main Powerbox cord to plug directly into (See SECTION 2.3A), or 2.)
Installing a junction box that will be used to join the wires from the Powerbox to the incoming wires from the breaker panel (hardwire installation – See SECTION
2.3B.) Due to the portable nature of a plug & play installation, it is highly recommended to chose a plug & play Powerbox and install the NEMA 14-30R outlet.
Either way, the materials needed will be the same, up to the point where the circuit terminates to either an outlet or a junction box.
2.1 INSTALL CIRCUIT PROTECTION DEVICE
The DPC-7500 requires the installation of a main circuit interruption device (circuit breaker) upstream from the unit, at your main electrical panel, or sub-panel. It is important to know that most circuit breakers are designated to function at 80% of their rated capacity when running continuous loads. Therefore, it is recommended that you install a 40 Amp, double-pole circuit breaker, if you intend to run the Powerbox at or near its full rated capacity. A 40 Amp breaker will provide 32 Amps of continuously available power. Determine the brand or type of circuit breaker you will need by inspecting your electrical panel. Take a picture of the panel, or remove an old breaker, to have with you when shopping for the circuit breaker. For added safety and enhanced protection, a GFCI circuit breaker is recommended.
2.2 INSTALL PROPERLY GAUGED WIRE
Selecting the appropriate wire gauge is critical for maintaining a safe and reliable installation. Use 8-gauge stranded copper wire if your wire run distance is less than 50 feet. Use 6-gauge stranded copper wire if your wire run is from 50 feet to 100 feet. Do not use aluminum wire. Use the same gauge wire for each of the four conductors. Plan a safe and efficient route from your breaker panel to your Powerbox installation that is as short as practically possible and install the appropriate conduit to house and protect the wire.
If ALL of the tests on your circuit produce the proper result, turn the breaker off and it is safe to plug your Powerbox into the outlet. If ANY of the test
2.3A INSTALL OUTLET RECEPTACLE
Install a NEMA 14-30R outlet receptacle by mounting the receptacle in the desired location and terminating conduit from the main panel to the outlet. Connect wires to outlet terminals as pictured in FIGURE 3, and as per the instructions that come with the outlet. Be sure to tightly connect the wires to the appropriate locations on the rear terminals of the outlet, as specified. Once complete, refer back to SECTION 1.2, TEST THE CIRCUIT BEFORE CONNECTING POWERBOX.
2.3B INSTALL JUNCTION BOX
If installing a Powerbox hardwire model, select a standard metal junction box of sufficient size (roughly 5”x5”) where the incoming conduit will terminate and the panel wires will join with the wires from the Powerbox. Mount the junction box securely to the wall. Use Split-Bolt Connectors to join wires together, and once joined, wrap each connection with four turns of self-fusing amalgamating tape, followed by four turns of black electrical tape. When connections are complete, secure the junction box with a cover plate.
BASIC CONNECTION FROM PANEL
SOME OF THE ITEMS YOU MAY NEED:
40 Amp double pole
GFCI circuit breaker.
NEMA
14-‐30R
wall-‐mount
receptacle
for
plug
&
play
installation.
Standard
metal
junction
box
for
hardwire
installation.
Split-‐bolt
connector
used
for
joining
wires
in
hardwire
installation.
SECTION 2.4 TURN ON THE POWERRBOX
1. Once you have completed making the Main Connection, with the circuit breaker at the panel still in the OFF position, flip open the lid to the timer and make sure the recessed switch at the bottom is switched to the “OFF” position.
2. Set the switch on the right side of the Powerbox (FIGURE 1, #6) to the desired position, “Timed” or “Constant.”
3. Turn the circuit breaker at the panel to the ON position.
4. Turn the recessed switch at the bottom of the timer to the “ON” position.
5. Proceed to SECTION 3, TIMER PROGRAMMING.
Self-‐Amalgamating
Tape
used
to
wrap
and
insulate
connections
made
with
Split-‐bolts.
SECTION 3. TIMER PROGRAMMING INSTRUCTIONS
The built-in programmable digital timer is flexible and easy to setup. You can program up to 7 ON/OFF cycles for any individual day, or for every day of the week.
For instance, it would take one program to set the Powerbox to go on and off once per day, every day of the week.
1. Pop open the door of the Digital Timer with a small screw driver.
2. Ensure the ON/OFF switch at the bottom of the Digital Timer is set to the ON position.
3. Reset the Digital Timer by using a small paperclip to depress the recessed RESET button (small round hole).
SETTING THE CLOCK
4. The Digital Timer displays the time in 24-hour format by default following a reset. To change to 12-hour format, press the MIN and HOUR buttons simultaneously and briefly (0:00 display = 24-hour format,12:00 display = 12-hour format).
5. Set the time using the HOUR and MIN buttons. If you have selected the 12-hour format, ensure that PM appears on the screen when an afternoon time is displayed.
6. Set the day by using the DAY button.
7. Press one of the control buttons or close the Digital Timer door to return to normal operation.
PROGRAMMING THE DIGITAL TIMER
8. You can set up to 7 different programs with the digital timer. However, for a standard routine where the unit comes on and off at the same time every day, you only need to set one program, and select all days of the week. To set a program, you need to enter its start time (ON) and its end time (OFF). a. Pry the Digital Timer door open using a small screwdriver. b. Press the PGM button once, and program number 1 (P1) and its On time (ON) will appear. -:-- will appear instead of the time if the program is not set (inactive). c. Press the DAY button to select the day to which you want to apply the program. If you want to apply the program to every day of the week, press DAY until all the days are displayed. This will count as only 1 program. d. Press the HOUR and MIN buttons to set the ON time (time when you want devices to turn ON). If you have selected the 12-hour format, ensure that PM appears on the screen when an afternoon time is displayed. e. After you have programmed the ON time, press the PGM button briefly to display the OFF time (time when you want the devices to turn OFF). f. By default, the same DAY(s) you selected for the ON time will be displayed for the OFF time. g. Press the HOUR and MIN buttons to set the OFF time (time when you want devices to turn OFF). If you have selected the 12-hour format, ensure that PM appears on the screen when an afternoon time is displayed. h. To set another program, repeat steps (b) through (f). Programs that are not set will remain inactive. i. Press one of the control buttons or close the switch door to return to normal operation.
SELECTING THE OPERATING MODE
9. The Digital Timer has 2 operating modes: manual (MAN) and automatic (AUTO). To switch modes, press and hold the switch door in for 3 seconds. a. Manual Mode. The Digital Timer operates as a regular switch. Briefly press the switch door in to turn devices On of Off. The mode (MAN) and state (ON or OFF) are displayed. b. Automatic Mode. The Digital Timer follows the programmed schedule. The mode (AUTO), state (ON or OFF) and current program number are displayed. To temporarily override the programmed schedule, briefly press the switch door. The new state (ON or OFF) will flash to show that this state is temporary. The override remains in effect until you press the switch door again or until the beginning of the next program.
PROGRAMMING FOR USE IN CONJUNCTION WITH FLIPBOXES
10. When using a Flipbox in conjunction with your Powerbox lighting controller, it is recommended to power the ballasts off for 10 minutes during each flip cycle during the time the flip is set to occur. For instance, if your light flip times are 12:00 AM and 12:00 PM, you would program your Powerbox lighting controller’s timer as follows:
Program Powerbox Lighting Controller as follows:
P1 ON Time: 12:05 PM, P1 OFF Time: 11:55 PM
P2 ON Time: 12:05 AM P2 OFF Time: 11:55 AM
Be sure to set both P1 and P2 for ALL days of the week.
Program the Flipbox timer as follows:
P1 ON Time at 12:00 AM and P1 OFF Time and 12:00 PM.
Be sure to set P1 for ALL days of the week.
TROUBLE SHOOTING GUIDE
BLANK TIMER DISPLAY: Verify there is power to the unit. Ensure the ON/OFF selector switch on the Digital Timer is set to ON. Reset the Digital Timer using a small paperclip.
TIMER DISPLAY HARD TO READ OR APPEARS FADED OUT: Verify that the neutral wire is properly connected at the main panel and at the point where it connects to the Powerbox. If timer display still appears faint, the internal backup battery may need recharging. Leave the unit connected to the main power and make sure the recessed switch at the bottom of the timer is set to the ON position. Leave the unit on for 90 minutes to give the battery time to fully charge. Check the display again and it should appear normal.
PROGRAMS DO NOT RUN AS EXPECTED: Make sure the Digital Timer is properly programmed. Note that -:-- indicates an inactive program, 00:00 indicates midnight. If the Timer has been configured for 12-hour format, check that PM appears on the left side of the screen when as afternoon time is displayed. Make sure the timer is in AUTO mode.
CANNOT SWITCH BETWEEN 24-HOUR and 12-HOUR FORMAT: First, press one of the control buttons so that MAN or AUTO appears on the display.
TIMED OUTLETS DON’T WORK / WON’T TURN ON: Check that the main circuit breaker is turned on. Check that the recessed switch under the timer front panel is switched ON. Check that the timer display reads ON. Check the main connection and ensure that all wires are connected properly.
TIMED OUTLETS DON’T WORK / ONE CONSTANT OUTLET WORKS: One of the 120V hot legs is missing or improperly connected. Turn off the power at the main breaker and check all connections.