Eaton Cuttler-Hammer Pow-R-Command 100 Handbuch

April2003

Pow-R-CommandTM (PRCTM) 100

Instruction Leaflet

IL01412003 For More Information visit www.cutler-hammer.com

Installation Leaflet

Page 2 Effective: April 2003 Pow-R-Command 100

IL01412003 For More Information visit www.cutler-hammer.com

Pow-R-Command System

Installation Leaflet

Notes and Warnings

-Read this guide completely and carefully prior to any installation. Failure to follow the instructions or the

prescribed procedures may cause severe injury or death and/or damage to the equipment.

-All installation and service must be performed by qualified personnel or service technicians. Keep this guide

available to those responsible for installation, programming, operation, and maintenance of the system.

-All installation and wiring information contained herein is based on industry-accepted standards and practices.

This information is not meant to conflict with or overrule any applicable codes or ordinances. If any conflicts

exist, please contact your Cutler-Hammer Representative before proceeding with the installation.

-USE EXTREME CAUTION WHEN OPERATING THE SYSTEM. DANGEROUS VOLTAGES MAY EXIST

INSIDE THE UNITS. Failure to follow any or all warnings and instructions contained herein may cause severe

injury or death and/or damage to the equipment.

-Panels are shipped from the factory with the electronic boards installed and tested. Many of the electronic

components may be sensitive to static electricity. Do not handle electronic parts without proper electrostatic

protection.

-Document all wiring, device termination and locations. This information will be required for system start up and

programming.

-Under no circumstances switch on the power to the electronics during or after installation. Power up,

programming and system configuration should be performed by qualified personnel during the system start up.

-The instructions and prescribed procedures in this Installation Guide do not purport to cover all possible

contingencies, which may arise during installation, and all details and variations of the system. If further

information is desired by regarding the particular installation of the system, please contact your

Cutler-Hammer Representative.

Installation Leaflet

Page 3 Effective: April 2003 Pow-R-Command 100

IL01412003 For More Information visit www.cutler-hammer.com

Table Of Contents

SECTION 1: MOST COMMON CONFIGURATIONS AND DESCRIPTIONS 4

1-1POW-R-COMMANDPANELBOARDS 4

1-2EXPANSION/CONTROLCABINET 5

1-3 RELAY PANEL 5

SECTION 2: POWER SUPPLY TERMINATION 6

2-1PANELBOARD 6

2-2RELAYPANEL,EXPANSION/CONTROLCABINET 6

SECTION 3: LOW-VOLTAGE TERMINATION 7

3-1PANELBOARD 7

3-2RELAYPANEL,EXPANSION/CONTROLCABINET 8

3-3CONTROLLABLEBREAKERREMOTETERMINATION 9

SECTION 4: APPLICATION SPECIFIC CARD TERMINATION 10

4-1UNIVERSALSYSTEMCONTROLLER 10

4-2SWITCHOVERRIDECONTROLLER 10

4-3UNIVERSALI/OMODULE 11

4-4LOW-VOLTAGE INPUTS & OUTPUTS 11

4-5LOW-VOLTAGEWIRINGAPPLICATION 13

SECTION 5: NETWORK TERMINATION 21

5-1NETWORKTERMINATION 22

5-1.1PANELBOARD 22

5-1.2RELAYPANEL, EXPANSION/CONTROL CABINET 23

5-27X EXPANSIONCHASSISNETWORKTERMINATION 24

5-3NETWORKREPEATER 25

SECTION 6: PERSONAL COMPUTER TERMINATION 26

6-1NIB TOPCCONNECTION 26

6-2ETHERNETSERVERTOPCCONNECTION 26

6-3NIB TOMODEMCONNECTION 27

6-4ETHERNETSERVERTOETHERNETWITHBACKUPCONNECTION 27

SECTION 7: CONTROLLER ADDRESSING 28

7-1ADDRESSINGUSINGAPC 28

7-2ADDRESSINGUSINGAPOCKETPCTESTTOOL 30

Installation Leaflet

Page 4 Effective: April 2003 Pow-R-Command 100

IL01412003 For More Information visit www.cutler-hammer.com

SECTION 1: MOST COMMON

CONFIGURATIONSAND

DESCRIPTIONS

Cutler-Hammer offers a full line of different

types of chassis and configurations for

Pow-R-Command 100 applications. Most

common configurations are described

below.

1-1 POW-R-COMMAND PANELBOARD

Pow-R-Command 100 Panelboard can come

in two main configurations:

1) Panelboard with 5X-Controller

Chassis (see Fig. 1-1). The 5X-Controller

Chassis contains the Universal Systems

Controller (USC) allowing the user to

control the GHBS or BABR breakers

using the time schedules or the console.

Panelboard with 5X-Controller Chassis

and 7X-Expansion Chassis

(see Fig. 1-2).

2) Combining the 5X Controller Chassis, the

7X Expansion Chassis accommodates

one of the Application Specific Control-

lers which expand the panels capabili-

ties.

For low-voltage device termination, please

refer to SECTION 3 Subsection 3-1.

Panelboards can operate as stand-alone or

be a part of network system. For network

termination, please refer to SECTION 5.

RemotelyControlled

Branch Circuit Breakers

5X-Controller Chassis With

USCControllerCardInstalled

P/SCable

7x-Expansion Chassis

Figure 1-1 (Left): Pow-R-Command 100 Panelboard With 5X-Controller Chassis &

Figure 1-2 (Right): Pow-R-Command 100 Panelboard With 5X-Controller Chassis and 7X-Expansion Chassis

Installation Leaflet

Page 5 Effective: April 2003 Pow-R-Command 100

IL01412003 For More Information visit www.cutler-hammer.com

1-2 EXPANSION / CONTROL CABINET

An Expansion Cabinet is mounted exter-

nally, and in close proximity to a panelboard

containing GHBS or BABR breakers. The

expansion cabinet is used in conjunction

with a smart panelboard. In these condi-

tions, the Expansion Cabinet is linked to the

panelboard using the network. For the

termination of the Network, please refer to

SECTION5.

A Control Cabinet provides control

capabilities to a standard panelboard

equipped with remote controlled breakers

(Panelboard without the 5X-Controller

Chassis). This configuration, includes the

USC (control board) mounted in an

Expansion Cabinet. The remote controlled

breakers are then controlled remotely, using

pigtails between the Expansion / Control

Cabinet and remote controlled breakers

mounted in the panel. For low-voltage

device termination, please refer to SECTION

3 Subsection 3-2. For remote controlled

breaker termination, please refer to

SECTION 3 Subsection 3-3.

1-3 RELAYPANEL

A Relay Panel is an another option for

controlling circuits with noncontrollable

breakers. The USC Control Card, as well as

Application Specific Controller cards, can

be installed in the Relay panel. The Relay

Panel can operate as stand-alone or be a

part of the network system. For Network

termination, please refer to SECTION 5. For

low-voltage device termination, please

refer to SECTION 3 Subsection 3-2.

Power Supply Terminals Cover

Power Supply Section

Relay Termination Adaptor Board

Network Terminals

Low-Voltage Device Terminals

Relay/Breaker Connectors

Figure 1-3: Expansion/Control Cabinet

Line Power Terminals

Transformer Tap Terminal

Relay Panel Control Card (USC)

Relay Termination Adaptor Board

RelayTermination Board

Network Terminal

Switch Override Controller

Low-Voltage Device Terminals

Lighting Relays

Figure 1-4: Pow-R-Command 100 Relay Panel

RelayTermination Board

Installation Leaflet

Page 6 Effective: April 2003 Pow-R-Command 100

IL01412003 For More Information visit www.cutler-hammer.com

SECTION2: POWER SUPPLY

TERMINATION

2-1 PANELBOARD

Panelboards are shipped with the

Controller’s Chassis power supply for the

electronics terminated to the correct

voltage. There is no need for the personnel

installing the panel to supply connections to

the power supply of the 5X-Controller

Chassis or 7X-Expansion Chassis. Please

verify that the panels supply voltage

matches the voltages specified on the label

of the panel. On the left side of the 5X-

Controller Chassis find the wires feeding

primary side of the power supply. If wire is

not used for the application, it should

contain isolating cap. Wires are color coded

as follows:

-RED 120VAC

- YELLOW 277VAC

-BROWN NEUTRAL

-GREEN GROUND

2-2 RELAYPANEL, EXPANSION / CONTROL

CABINET

The personnel installing the Relay Panel or the

Expansion/Control Cabinet are responsible for

providing and terminating the power wires to

these panels.

If the trim is installed, remove the trim (for the

Expansion/Control Cabinet, remove the door

and the power supply cover). There are two

terminal sets on the power supply. The right

side of the power supply is marked “Trans-

former Tap 120/277VAC” and the left side is

marked “Line Power 120/277VAC”.

On the Transformer Tap terminal, verify the

correct jumper position for the voltage that

you will be connecting to the panel. Move the

jumper if necessary. The correct jumper

positions are:

- 277 to COM for 277VAC

- 120 to COM for 120VAC.

Note: All units are generally shipped with the

jumper strapped for 277VAC. However, be

sure to verify this setting. Applying 277VAC to

the unit set for 120VAC may damage the unit.

On the Line Power terminal, connect

ground wire to the terminal marked:

“GND”. Connect neutral wire to the

terminal marked: “LO”. Connect hot

wire to the terminal marked: “HI”. For

power connections use a minimum #12

AWG copper wire.

Power Terminal Cover

Line Power Terminals

Transformer Tap Terminal

Figure 2-1: Power Supply Terminations In Pow-R-Command 100 Relay Cabinet & Control Cabinet

Installation Leaflet

Page 7 Effective: April 2003 Pow-R-Command 100

IL01412003 For More Information visit www.cutler-hammer.com

SECTION3:LOW-VOLTAGE DEVICE

TERMINATION

All open areas in the panels are considered

as low-voltage/class-2 termination areas.

No voltages above 28VAC are permitted in

this area. Inputs are designed so that only

dry contact devices are accepted.

NO EXTERNAL VOLTAGES SHOULD BE

APPLIED TO THE LOW-VOLTAGE

TERMINAL BLOCKS. ALL NECESSARY

POWER IS PROVIDED BY THE PANEL.

Low-voltage devices should be terminated

using a minimum #22AWG twisted pair

wire. Shielding is generally not required.

Low-voltage device cables should not be

located in the same conduit with the high-

voltage load wires. Be sure the wire type

you use is rated properly, especially for

plenum or hazardous applications.

3-1 PANELBOARD

In most cases, Application Specific Cards

will be located in the 7X Expansion Chassis

installed in the panel. Power supply and

Network connections will be provided in the

factory.

In rare case of the 7X-Expansion Chassis

located externally to the panel, the network

cable and the power supply cable should

be installed between the panel and the 7X-

Expansion Chassis. For Network termina-

tion, please refer to SECTION 5.

The personnel installing the panel are

responsible for providing and termination

wiring of all external low-voltage devices.

Use knockouts provided on the bottom and

sides of the chassis to enter the low-

voltage termination area.

All low-voltage (dry closure) devices

should be terminated on the 7X board

terminal blocks TB1, TB2, and TB3. Terminal

blocks TB1 and TB3 are designated

locations for inputs from low-voltage

devices—numbered respectively 1-24 and

25-48. Terminal block TB2 is a COMMON

(ground) terminal for all low-voltage

devices terminated in the panel.

Network “Out”

Connector

Power Supply

Connector

Network “In”

Connector

Low-Voltage Device

TerminalsCOMMON

Application Specific

Controller Connectors

Low-Voltage Device

Terminals 1-24

Low-Voltage Device

Terminals 25-48

Figure 3-1: 7X-Expansion Chassis Back-Plane Board

Installation Leaflet

Page 8 Effective: April 2003 Pow-R-Command 100

IL01412003 For More Information visit www.cutler-hammer.com

3-2 RELAY PANEL, EXPANSION/CONTROL

CABINET

The Relay Panel and Expansion / Control

Cabinet use the same Relay Termination

Board for low-voltage (dry-contact) device

termination.

A Relay Panel is used to control loads

down-line from a breaker panel not

equipped with controllable breakers. A

Relay Panel is shipped from the factory

with the low-voltage side of the relays

terminated to the Relay Termination Board.

Personnel installing the Relay Panel are

responsible for providing and terminating

wires to load side of the relays. Maximum

wire size accepted by the relay terminals is

#10AWG.

An Expansion / Control Cabinet is installed

externally to a breaker panel. The person-

nel installing the above mentioned devices

are responsible for providing termination of

the power supply, network, and all external

low-voltage devices. For power supply

termination, please refer to SECTION 2

Subsection 2-2. For network termination,

please refer to SECTION 5.

Use bottom of the previously described

enclosure types to attach conduit and

provide access to the low-voltage

termination area.

Panels using Expansion Cabinet might or

might not contain 5X-Controller Chassis. For

panels with a 5X-Controller Chassis, the

Expansion Cabinet is used for Application

Specific Controllers only. Only low-voltage

devices and network are terminated in the

Expansion Cabinet. For panels not

containing the 5X-Controller Chassis the

additional step of terminating the remote

controlled breakers to the Control Cabinet

Relay Termination Board is required. For

remote controlled breaker termination,

please refer to SECTION 3 Subsection 3-3.

All low-voltage devices should be termi-

nated on the Relay Panel, Expansion /

Control Cabinet board terminal blocks TB3,

TB4, and TB5. Terminal blocks TB3 and TB5

are designated locations for inputs from

low-voltage devices—numbered respec-

tively 1-24 and 25-48. Terminal block TB4 is

a COMMON (ground) terminal for all low-

voltage devices terminated in the panel.

Power Supply Connector

Relay/Breaker

Connectors

Controller Ports

RelayTermination

Adaptor Board

Network Terminal

RelayTermination

Board

Low-Voltage Device

Terminals 1-24

Low-Voltage Device

Terminals 25-48

Low-Voltage Device

TerminalsCOMMON

Figure 3-2: Relay Panel, Expansion/Control Cabinet Interior

Installation Leaflet

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3-3 CONTROLLABLE BREAKER REMOTE

TERMINATION

For panels without a 5X-Controller Chassis,

a Control Cabinet must be used. In addition

to low-voltage device termination, connec-

tions to the GHBS, BABR, BABRS, or

GHQRS breakers in the panel should be

made using pigtails.

Figure 3-3: GHBS Pigtail Termination In Expansion/

Control Cabinet

Figure 3-5 BABR, BABRS, or GHQRS Pigtail

Termination In Expansion/Control Cabinet

On the Control Cabinet side, pigtails are

connected to the Relay Termination Board

using four pin AMP type connectors. The

connectors are numbered 1-24 on the left

side of the board, and 25-48 on the right

side of the board (see Fig. 3-3).

On the Panel side, the pigtails are connected

to the low-voltage connectors on the back

of the GHBS breakers using a three pin AMP

type connector (see Fig. 3-4) or the pigtail

four pin connector on the BABR, BABRS,

and GHQRS breakers.

The length of the pigtail should not exceed

50’ for #22 AWG stranded wire for single

pole breaker. For double pole remote

controlled breakers and longer distances,

higher gauge wire is recommended. Please

verify that the wire type used for pigtails is

rated properly.

TOENSURESIMPLEOPERATIONAND

MAINTENANCEBE CAREFULTOMATCHTHE

EXPANSIONCONTROLLERCIRCUITNUMBER

TOTHEAPPROPRIATEPANELBOARD

CIRCUITBREAKERPOSITION.

Figure 3-6: BABR, BABRS, or GHQRS Pigtail

Termination/Breaker

Figure 3-4: GHBS Pigtail

Termination/Breaker

Installation Leaflet

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IL01412003 For More Information visit www.cutler-hammer.com

SECTION 4:APPLICATIONSPECIFIC

CARDSTERMINATION

4-1 UNIVERSAL SYSTEM CONTROLLER

The Universal Systems Controller (USC)

handles direct breaker control and status.

In addition to controlling breakers, the USC

has low voltage inputs and outputs which

can be used for switches, pilot lights,

photocells, dimmer ballasts, or other

external devices. The GHBS / BABRS

jumper is used to identify if the USC is

controlling GHBS/ BABR type breakers or

BABRS/GHQRS type breakers.

4-2 Switch Override Controller

The Switch Override Controller (SOC) is an

Application Specific Controller accepting

dry-contact closures as input. The SOC

can be installed in the 7X-Expansion

Chassis or in the bottom position of an

Expansion/Control Cabinet. The SOC will

accept only dry-contact closure devices

(i.e. switches, occupancy sensors,

Building Management System relay, etc.).

Contact closure is processed by the SOC

card, resulting in state control of the load

Relays / Breakers. Action of the devices

terminated for SOC card will not have any

effect on the system operation until the

system is correctly programmed. Program-

ming of the system must be performed by

qualified start-up personnel.

The personnel installing the panel with the

SOC card are responsible for providing and

terminating wires for low-voltage devices.

For low-voltage device termination for the

SOC card, please refer to SECTION 3.

GHBS/BABRS

SelectionJumper

Network/RS-485

Test Port

Reset Button

Low-Voltage

Inputs/Outputs

Figure 4-1: Universal System Controller (USC)

StandardPilot

Lamp Outputs

AdditionalPilot

Lamp Outputs/Card

Reset Button

Low-Voltage

Inputs/Outputs

Network/RS-485

Test Port

Figure 4-2 Switch Override Card (SOC) and Optional Pilot Lamp Output Card

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