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. 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.
Also, it is very important to keep in mind that a proper 3-wire outlet connection consists of two hot wires, and a NEUTRAL wire – NOT A GROUND. If your 3-
wire outlet or connection contains a ground instead of a neutral, it must be re-wired so that the 3
rd
wire is a true neutral, otherwise the Powerbox will not
function properly.
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. 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 (for a 30A capacity box), or a NEMA 14-50R outlet (for a 50A capacity box) for your main
Powerbox cord to plug directly into (See
SECTION 2.3A
), or 2.) For a hardwire version, 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 or 14-50R 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. Do not use aluminum wire. The gauge of wire selected will depend
on the capacity of your Powerbox, and the distance the wire must travel. Consult a qualified electrician for help in selecting the appropriate gauge of wire required
for your installation. Failure to select the proper wire gauge can result in dangerous conditions and may cause malfunction of equipment. 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.
3-Wire Connection:
1
st
Wire: 120-Volt Phase 1
2
nd
Wire: 120-Volt Phase 2
3
rd
Wire: Neutral
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
3-Wire Connection:
TEST
PROPER RESULT
1+3
120 Volts AC
2+3
120 Volts AC
1+2
240 Volts AC
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
FIGURE 2
FIGURE 3
