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
Your Powerbox is designed to plug directly into a 240-volt, 4-prong range-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 range-type outlets
have a 50 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 50 Amp breaker is only 40 Amps continuous. To take full
advantage of the 50 Amp continuous capacity of the Powerbox, it is recommended to install a 60 Amp circuit breaker at your panel and the appropriate gauge
wiring (either 6 or 4-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.
With a simple electrical tester, use the two probes to perform the following tests on the circuit to determine if it is wired properly:
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
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. Next, switch the Powerbox Main power on by switching the circuit breaker to the uppermost position.
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 14-50R 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
.) 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-12000 and 15000 series can be wired directly to a live bus bar, or can be installed with an additional 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. The Powerbox circuit breaker is designed to run at a 100% load. Therefore, if installing a 50 amp Powerbox, it is recommended that you install
a 60 Amp, double-pole circuit breaker. If installing a 60 amp Powerbox, it is recommended that you install an 80 amp breaker at the panel. 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. If you are installing a 60 amp circuit breaker at the panel, and the
distance of your wire run is under 75 feet, you will use 6-gauge wire for all connections. If you are installing an 80 amp circuit breaker and your distance is under
75 feet, you will use 4-guage wire. If you are installing an 80 amp breaker and the distance is over 75 feet, you would use 2-gauge wire. 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.
2.3A INSTALL OUTLET RECEPTACLE
Install a NEMA 14-50R 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 per the instructions that come with the outlet. Be sure to tightly connect the wires to the appropriate locations on the 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.
!
!
4-Wire Connection:
TEST
PROPER RESULT
1+3
120 Volts AC
2+3
120 Volts AC
1+2
240 Volts AC
1+4
120 Volts AC
2+4
120 Volts AC
4-Wire Connection:
1
st
Wire: 120-Volt Phase 1
2
nd
Wire: 120-Volt Phase 2
3
rd
Wire: Neutral
4
th
Wire: Ground
!
