INSTALLATION AND SERVICE INSTRUCTION

SD39PDA-1
Issue: 2*
February 1994

ADVANCED PROCESS AUTOMATION AND CONTROL SYSTEM (APACS)

POWER DISTRIBUTION ASSEMBLY (PDA)

1.0 INTRODUCTION

This Instruction provides installation and maintenance information for the following APACS
hardware:

PN 16114-65 Power Distribution Assembly (PDA) for 115 Vac Service

PN 16114-131 Power Distribution Assembly (PDA) for 230 Vac Service

PN 16114-94 Power Distribution Assembly Expansion Kit (this accessory supported by an

Instruction supplied in the kit)

This Instruction is divided into three major sections.

Section 1, Introduction, contains product description and specification information.

Section 2, Installation, describes installation preparation and mechanical and electrical

installation.

Section 3, Maintenance, has fuse and assembly replacement procedures, and spare and
replacement parts suggestions.

IMPORTANT

Save this Instruction and make it available for

installing and servicing the above hardware.

1.1 RELATED LITERATURE

The following Instructions may be needed during PDA installation.

! SD39MODULPAC-1, APACS MODULPAC 1000 Installation And Service Instruction

! SD39MODULPAC-2, APACS MODULPAC 2000 Installation And Service Instruction
! SD39MODULRAC-1, APACS MODULRAC Installation And Service Instruction

S)))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))Q
* For Issue 2, information about a PDA for 230V service has been added to that for the PDA
for 115V service.
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1.2 PRODUCT DESCRIPTION

The Power Distribution Assembly (PDA) is a cabinet input power distribution element of the
Advanced Process Automation and Control System. It can be mounted in a MODULPAC 1000
or 2000 cabinet or in a user supplied cabinet.

There are two PDA models: one for 115 Vac service and one for 230 Vac service. Each is used
to terminate the AC input power cable and to distribute AC operating power to assemblies
installed in the cabinet, such as:

! MODULRAC Recirculation Fan

! POWERAC Power Supply Rack
! Power Supply Module (PSM)
! MODULPAC Roof Fan
! User-supplied devices

A PDA's modular components are assembled to a 35 mm x 7.5 mm DIN Rail for mounting in an
APACS MODULPAC or user supplied cabinet. The following defines the modular components
illustrated in Figures 1-1, 1-2, 1-3, and 1-4.

END CLAMP: Provides end support for terminal block groupings on the DIN rail.

SAFETY GROUND TERMINAL BLOCK: Provides for connection of the AC power input
cable Ground lead (green or uninsulated). The captive center screw is tightened to ensure
positive clamping and a good electrical connection to the DIN mounting rail. The remaining two
screw terminals are internally connected to the center screw and, therefore, connected to the DIN
rail.

LEVER FUSE HOLDER TERMINAL BLOCK, 115 Vac SERVICE: Provides for connection of
the AC power input cable L1 or Hot lead (black). A fuse is provided to protect the power source.
When the lever is moved, the cartridge fuse holder (and fuse) is rotated, disconnecting the fuse
from both L1 contacts of the terminal block. This permits shock-proof replacement of the fuse.
A #10 jumper wire connects AC power to the Varistor Terminal Block's L1 terminals.

2-POLE LEVER FUSE HOLDER TERMINAL BLOCK, 230 Vac SERVICE: Provides for
connection of the AC power input cable L1 (brown) and Neutral (blue) leads. Two fuses, for the
L1 and Neutral lines, are provided to protect the power source. When either ganged lever is
moved, the cartridge fuse holders (and fuses) are rotated, disconnecting the fuses from both L1
and Neutral contacts of the terminal blocks. This permits shock-proof replacement of the fuse.
#14 jumper wires connect AC power to the Surge Arrest's L1 and Neutral terminals.

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VARISTOR TERMINAL BLOCK, 115 Vac SERVICE: Provides surge voltage protection to
devices connected to the PDA. The varistor is internally connected between the terminal blocks's
L1 terminals and the DIN rail. As mentioned above, the DIN rail must be connected to building
safety ground through the Safety Ground Terminal Block and the ground wire of the three-wire
power cable.

SURGE ARREST TERMINAL BLOCK, 230 Vac SERVICE: Provides surge voltage protection to
devices connected to the PDA. Featured are an L1-to-Neutral thermally monitored MOV (Metal
Oxide Varistor) and a Neutral-to-PE (Ground) Gas Discharge Arrestor (Gas Tube).

As the Varistor ages, excessive leakage current can be caused by high and/or frequent voltage
transients. Leakage current will cause the Varistor to overheat, therefore, the Varistor is monitored
by a thermal disconnect device which disconnects the Varistor before serious overheating occurs.

A disconnection is annunciated by a red control lamp. Also, a second thermal disconnect device
provides remote alarm contacts to warn of the disconnect. When a thermal disconnect occurs, the
normally closed contacts of both thermal devices remain permanently open leaving the distibuted
230 Vac circuits unprotected. Replace the Surge Arrestor after a disconnect to restore circuit
protection.

A green control lamp (normally on) monitors the mains voltage. A thermal disconnect of the
Varistor does not disconnect the mains voltage. A blown fuse or manual "fuse disconnect" will
extinguish the green lamp.

L1/N/G TERMINAL BLOCK: There are five separate terminal blocks, each of which provides for
the connection of the L1 (Hot), Neutral, and Ground cable leads from fans, power supplies, and
user-supplied AC-powered devices. Each terminal block has:

! Two internally connected L1 (H) terminals

! Two internally connected Neutral (N) terminals
! One Ground terminal

The five terminal blocks are interconnected to form three buses, as shown in Figures 1-2 and 1-4.

! Neutral Bus - One row of Neutral terminals is interconnected by a 5-Prong Insertion Bridge to
create two rows of a common Neutral Bus.

! L1 or Hot Bus - L1 terminals are connected by a central Cross Connect Shorting Bridge to create
two rows of a common L1 Bus.

! Ground Bus - Ground terminals are mechanically connected to the DIN rail to create a
ground bus, which is connected to safety ground through the ground wire of
the three-wire power cord.

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FIGURE 1-1 Power Distribution Assembly (PDA), 115V Service

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FIGURE 1-2 PDA Internal Electrical Connections, 115V Service

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FIGURE 1-3 Power Distribution Assembly (PDA), 230V Service

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FIGURE 1-4 PDA Internal Electrical Connections, 230V Service

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1.3 SPECIFICATIONS

PDA PN 16114-65, 115V Service

Voltage and Current,

PDA Applied Input Voltage ..................................................... 115 Vac Nominal; 100 to 132 Vac
PDA Current-Carrying Capacity .............................................. 30A Maximum; 27A Steady State

Lever Fuse Holder Terminal Block, 115 Vac Service

Number of L1 Terminals ...................................................... 2
Maximum Wire Size ............................................................ #8 AWG
Fuse Physical Size ................................................................ 10.3 X 38 mm cartridge
Fuse Electrical Rating .......................................................... 30A, 250V, Slow-Blow

Varistor Terminal Block

Number of L1 Terminals ...................................................... 2
Maximum Wire Size ............................................................ #10 AWG
Metal Oxide Varistor Rating
Continuous RMS Voltage .................................................. 115 Vac
Transient Peak Current (8/20 us) ....................................... 6500A, 1 Operation
950A, 100 Operations

PDA PN 16114-131, 230V Service

Voltage and Current,

PDA Applied Input Voltage ..................................................... 230 Vac Nominal; 207 to 250 Vac
PDA Current-Carrying Capacity .............................................. 16A Maximum; 14.5A Steady State

2-Pole Lever Fuse Holder Terminal Block, 230 Vac Service

Number of L1 Terminals ...................................................... 2
Number of N Terminals ....................................................... 2
Maximum Wire Size ............................................................ #8 AWG
Fuse Physical Size ................................................................ 10.3 X 38 mm cartridge
Fuse Electrical Rating .......................................................... 15A, 250V, Slow-Blow

Surge Arrest Block

Number of L1, N, PE Terminals .......................................... 2
Remote Alarm Contacts, Failure Mode ............................... 2 Normally Closed, Max. 250 Vac
@1A continuous
Response Time ..................................................................... Line-Line #25ns, Line-Gnd #100ns
Nominal Surge Current ........................................................ Line-Line 2.5kA, Line-Gnd 2.5kA
Maximum Surge Current ..................................................... Line-Line 6.5kA, Line-Gnd 6.5kA
Maximum Voltage/Current .................................................. 250 Vac/16A
Maximum Wire Size ........................................................... #14 AWG stranded, #12 AWG solid

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Individual Component Specifications, 115 and 230V Service

DIN Rail .................................................................................... EN 50 022 - 35 mm X 7.5 mm

Safety Ground Terminal Block

Number of Terminals .......................................................... 2
Maximum Wire Size ........................................................... #4 AWG

L1/N/G Terminal Block

Number of Neutral Terminals ............................................. 2
Number of L1 Terminals ..................................................... 2
Number of Ground Terminals ............................................. 1
Maximum Wire Size ........................................................... #10 AWG

2.0 INSTALLATION

This section describes general APACS power requirements and the mechanical and electrical
installation of a Power Distribution Assembly (PDA). The PDA procedures provided are for
installation in an APACS MODULPAC, however, they can be adapted for user supplied cabinets.

NOTE

The installation must be in accordance with the National Electrical Code

and all other applicable construction and electrical codes.

2.1 INSTALLATION CONSIDERATIONS

Review the following installation considerations before beginning a PDA installation.

1. Power Requirements:

Determine the power requirements for each APACS Local Area System and for each
MODULPAC in each System. Refer to the Installation And Service Instruction for each
involved APACS assembly and to the instruction accompanying each user-supplied assembly
for voltage and current requirements.

Note and record the following.

! Equipment to be powered and the voltage/current needs of each assembly
! Number of AC power input lines needed and the cable lengths needed for routing from the
site's power source (circuit breaker box) to MODULPACs; redundant MODULRACs need
separate, dedicated power input lines
! Current to be carried by each power input line and needed wire gage

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 SD39PDA-1

! Total system power requirement

! Need for an uninterruptible power source for increased reliability and power quality

IMPORTANT

The sum of the steady state currents drawn by the assemblies connected to
a Power Distribution Assembly should not exceed that specified in section
1.3. Install additional PDAs and divide the current load if necessary.

2. Power Source:

A reliable, electrically clean, power source must be provided by the user to power APACS
Power Supply Modules, POWERAC power supplies, and additional AC powered equipment
mounted in MODULPACS.

The power source must be dedicated solely to powering the equipment mounted MODULPACs.
High-power EMI-producing equipment should not be connected to any power lines dedicated to
APACS equipment.

3. Power Wiring:

! The AC power input cable must have three conductors color-coded according to the service
voltage rating (i.e., 115V or 230V).
! Install the cable in conduit between the power source (circuit breaker box) and the
MODULPAC.
! At the breaker box, connect the ground wire of the 3-wire power line to factory safety
ground.
! Within a MODULPAC, connect each AC input line to a PDA.

4. Install the following equipment.

! MODULPACs that contain or will contain equipment to be powered from PDAs

! Power input cable conduit from the power source (breaker box) to the MODULPAC;
conduit connectors and seals as needed
! MODULRACs, card cage fans, and roof fans (optional)
! APACS POWERACs and power supplies
! User-supplied AC equipment

5. Remote Alarm, 230V Service:

When using a 230 Vac PN 16114-131 PDA, consider connecting a remote alarm to the PDA as a
warning to replace the Surge Arrestor after a thermal disconnect.

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2.2 MECHANICAL INSTALLATION

This section provides installation information for mounting a PDA in a MODULPAC.

A PDA is shipped individually packaged. On factory assembled APACS systems, a PDA is

installed and wired to installed fans, power supplies, etc., excluding the AC power input cable.

1. The PDA mounts to the front and rear vertical frame struts on either the right or left side of the
MODULPAC 1000 frame, as shown in Figure 2-1, or on the system chassis of a MODULPAC
2000 frame, Figure 2-2.

Spacing between the two 0.25" (6.35 mm) mounting holes on the PDA's DIN rail is 12.8 inches
(325 mm).

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SD39PDA-1

FIGURE 2-1 PDA Mounting, MODULPAC 1000 Cabinet

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 SD39PDA-1

FIGURE 2-2 PDA Mounting, MODULPAC 2000 Cabinet

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 SD39PDA-1

2. Move the PDA vertically to select a location which will minimize cable runs and permit access
for wiring and servicing the PDA. Move the system chassis in a MODULPAC 2000 cabinet for
best PDA location.

3. Secure the PDA with the supplied mounting screws.

This completes the mechanical installation.

2.3 ELECTRICAL INSTALLATION

This section describes installing the AC power input cable and connecting it to a PDA. Also,
generally described are connections for fans, power supplies and other devices to be powered from a
PDA.

2.3.1 POWER INPUT CABLE INSTALLATION AND CONNECTION

WARNING

Electrical shock hazard - remove AC power from all involved wires and terminals.

1. Pull power cable through conduit and into the cabinet.

2. Route power cable to a PDA. Leave enough slack in the cable to permit connection to the
terminal blocks. Clamp the cable as needed.

3. Remove a length of the cable jacket sufficient to permit easy wire connection to the terminal
blocks and good cable dress.

4. Refer to Table 2.1 and strip the end of each conductor.

5. Refer to Figure 1-1 or 1-3 and identify the following terminal blocks:

! Lever Fuse Holder Terminal Block

! L1/N/G Terminal Blocks
! Safety Ground Terminal Block (color coded Green/Yellow)

6. Connect the power cable to the PDA.

115V Service: Refer to Figures 1-1 and 2-3
230V Service: Refer to Figures 1-3 and 2-4

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FIGURE 2-3 Typical APACS Hardware Wiring to PDA, 115V Service

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SD39PDA-1

FIGURE 2-4 Typical APCAS Hardware Wiring to PDA, 230V Service

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 SD39PDA-1

TABLE 2.1 115/230 Vac Power Input Cable Connection Data

CONDUCTOR CONDUCTOR CONDUCTOR END PDA TERMINAL BLOCK

COLOR STRIP DIMENSION CONNECTION
L1 (Hot) Black 0.43" "L1" on Lever Fuse Holder Terminal
115 Vac (11mm) Block
Neutral White 0.31" "N" on L1/N/G Terminal Block
115 Vac (8mm)
Ground Green 0.43" Either Terminal of Safety Ground
115 Vac (11mm) Terminal Block
L1 Brown 0.43" "L1" on Lever Fuse Holder Terminal
230 Vac (11mm) Block
L1/Neutral Blue 0.31" "N" on Lever Fuse Holder Terminal
230 Vac (8mm) Block
Ground Green/ 0.43" Terminal of Safety Ground Terminal
230 Vac Yellow (11mm) Block

2.3.2 L1/N/G TERMINAL BLOCK CONNECTIONS

The PDA's L1/N/G Terminal Blocks are the AC power distribution points for APACS assemblies
(e.g., fans, PSMs, POWERAC power supplies) and for user-supplied assemblies.
WARNING

Electrical shock hazard - remove AC power

from all involved wires and terminals.

GUIDELINES

A. The sum of the steady state currents drawn by the assemblies connected to the L1/N/G Terminal
Blocks must not exceed that specified in section 1.3. Refer to the Installation And Service
Instruction for each APACS assembly and the instruction accompanying a user-supplied
assembly for current requirements.

B. One "N" terminal on a PN 16114-65 PDA (115 Vac service) must be reserved solely for the
power input cable's Neutral lead.

C. Two wires from separate assemblies can be connected to a single L1, N, or G terminal provided
the wire sizes are #16 AWG or smaller.

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D. If additional terminals are needed, a PDA Expansion Kit provides four terminal blocks. Refer to
section 1 for Kit part number. Maximum PDA current remains as specified.

E. It is not recommended that a wire connection be made to the ground terminal of the 115 Vac
Varistor Terminal Block of a PN 16114-65 PDA. A loosely clamped wire can result in a poorly
grounded Varistor which can reduce its effectiveness.

PROCEDURE

APACS and user-supplied assemblies to be connected to a PDA may have an unterminated power
cord attached or may require that a power cord be fabricated. Refer to the following typical steps
when wiring a fan, power supply or other device to a PDA.

1. Isolate the L1/N/G Terminal Blocks by removing the fuse(s) from the Lever Fuse Holder(s).

2. Refer to each APACS assembly's Installation And Service Instruction and to the instruction for
each user-supplied assembly for power connections.

3. Determine the length of three-conductor power cord needed to interconnect the PDA and the
assembly to be powered. Allow sufficient length for:

! Dressing and clamping the cable

! Conductor end preparation

4. Prepare cable ends by striping jacket as needed and individual conductors as indicated in Table
2.2.

TABLE 2.2 L1/N/G Terminal Block Connection Data

TERMINAL FUNCTION \ WIRE SIZE, MAXIMUM STRIP WIRE END

TERMINALS AVAILABLE

L1 (Hot)\10 #10 AWG 0.31" (8 mm)

N (Neutral)\10 #10 AWG* 0.31" (8 mm)
Ground (Green/Yellow)\5 #10 AWG 0.31" (8 mm)

* The five terminals to which the Insertion Bridge is connected are limited to #12 AWG max.

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4. Make needed connections.

115V Service: Refer to Figures 1-1, 1-2, and 2-3
230V Service: Refer to Figures 1-3, 1-4, and 2-4

Repeat steps until all assemblies are connected to the PDA.

5. Install the cartridge fuse(s) in the Lever Fuse Holder(s). Do not close at this time. Go to section
2.3.3.

2.3.3 PDA POST INSTALLATION CHECKOUT

Do not apply power to the PDA until all wiring is completed and checked.

1. PN 16114-65 PDA Only: Ensure that the Green\Yellow ground terminal of the Varistor
Terminal Block is screwed firmly to the lip of the DIN rail to provide a good ground for the
Varistor.

2. Ensure that all input and output cable wires are firmly clamped to their respective terminal.

3. Ensure that each prong of the Insertion Bridge is firmly clamped in its respective "N" terminal.

4. Ensure that a fuse of the correct capacity is installed in the Lever Fuse Holder.

5. Ensure that each device to be powered from the PDA is correctly wired.

6. Rotate the Lever Fuse Holder's lever to engage the fuse(s).

3.0 MAINTENANCE

The Power Distribution Assembly requires minimal maintenance. Some routine maintenance is
recommended in the form of a visual inspection and cleaning.

WARNING

Electrical shock hazard - remove AC power before inspecting or servicing

a PDA. Use a digital multimeter or similar tester to confirm that power
has been removed before proceeding.

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3.1 TOOL AND EQUIPMENT REQUIREMENTS

The following tools are necessary for servicing:

A. Set of common (flat blade) screwdrivers

B. Digital Multimeter (DMM)

Voltmeter section ................. Accuracy +/-0.1% of reading
Input impedance 10 Megohms

3.2 VISUAL INSPECTION

A PDA should be subjected to a periodic visual inspection for cleanliness. The frequency of
inspection will depend on the severity of the operating environment.

1. Remove AC power to PDA terminals.

WARNING

Electrical shock hazard - remove AC power from

all involved wires and terminals.

2. Inspect for excessive accumulation of dust, dirt, chemical particulate, or other foreign material
adhering to the surfaces of the terminal blocks and terminal screws that may accelerate terminal
corrosion. Accumulation of an electrically conductive foreign material may lead to high voltage
arcing, cross circuit shorts, or a short to ground. This can cause an APACS electrical system
failure or equipment breakdown.

A PDA installed in a cabinet complying with the NEMA 12/IP65 specification need not be
inspected for cleanliness.

PN 16114-131 PDA Only: A daily inspection of the status of the Surge Arrest's red lamp is
recommended if a remote alarm does not provide automatic annunciation of a thermal disconnect of
the MOV surge protector. If the red lamp is lit, replace the Surge Arrest to restore surge protection.

3.3 CLEANING AND CONNECTION SECURITY

1. Remove AC power to PDA terminals.

WARNING

Electrical shock hazard - remove AC power

from all involved wires and terminals.

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2. Brushing the terminal blocks with an insulated handle brush to remove the accumulated
material.

3. Check each connection for tightness and conductor or insulation damage.

3.4 FUSE REPLACEMENT

A fuse can be safely replaced without turning off the AC input power to the PDA. After
determining and correcting the cause of the fuse failure, replace a fuse as follows:
1. Refer to Figure 1-1 or Figure 1-3 and identify the Lever Fuse Holder Terminal Block.

2. Rotate the lever of the fuse holder to expose and disconnect the fuse(s) from the terminal block's
power input/output terminals.

3. Remove and replace the fuse. Refer to section 1 for part number and description.

4. Counter-rotate the lever of the fuse holder to engage the fuse(s) to the terminal block.

5. Operate the equipment off-line for several minutes to be sure that a condition does not exist
which will cause the replacement fuse to fail.

3.5 PDA MODULAR ASSEMBLY REPLACEMENT

A defective or damaged modular terminal block assembly within the PDA group can be removed
and replaced by a new assembly.

1. Take appropriate steps to shutdown the process. Connected equipment will be removed from
service if the PDA is the sole source of operating power. Determine the effect shutdown will
have on the process.

2. Turn off input power to the PDA.

WARNING

Electrical shock hazard - remove AC power from all involved

wires and terminals. Isolate the L1/N/G Terminal Blocks by
removing the fuse from the Lever Fuse Holder.

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3.5.1 SAFETY GROUND TERMINAL BLOCK REMOVAL/REPLACEMENT

REMOVAL PROCEDURE

1. Refer to Figure 1-1 and identify the rail clamping screw on the Safety Ground Terminal Block
and on the adjacent End Clamp.

2. Remove all ground wires connected to the Safety Ground Terminal Block.

3. Loosen the rail clamping screw (center screw) on the Safety Ground Terminal Block until the
mounting fingers move apart and the Block can be lifted from the DIN rail.

REPLACEMENT PROCEDURE

1. Loosen the rail clamping screw on the replacement Safety Ground Terminal Block until the
mounting fingers move apart and the Block can be placed on the DIN rail.

Place the Block on the rail next to the Lever Fuse Holder Terminal Block.

2. Tighten rail clamping screw to secure the Safety Ground Terminal Block to the rail.

FIGURE 3-1 Typical Component Installation

3. Reconnect removed ground wires to the Safety Ground Terminal Block.

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3.5.2 LEVER FUSE HOLDER TERMINAL BLOCK REMOVAL/REPLACEMENT

REMOVAL PROCEDURE

1. Refer to Figure 1-1 or Figure 1-3 and identify the Lever Fuse Holder Terminal Block.

2. Remove the jumper wire(s) and AC input power cable wire(s) from the terminal block.

3. Refer to section 3.5.1 and remove the Safety Ground Terminal Block.

4. Refer to Figure 2-1 and remove and set aside the DIN rail mounting screws.

5. Slide the Lever Fuse Holder Terminal Block from the rail. Do not attempt to pry it from the rail.

6. Remount the DIN rail to the cabinet frame.

REPLACEMENT PROCEDURE

1. Ensure the replacement Lever Fuse Holder Terminal Block is properly fused (section 3.4).

2. Refer to Figure 3-1 and snap the replacement Lever Fuse Holder Terminal Block to the DIN rail
and position it against the Varistor or Surge Arrest Terminal Block, whichever is present.

3. Refer to section 3.5.1 and remount and secure the Safety Ground Terminal Block to the rail.

4. Reconnect the jumper wire(s) and AC input power cable wire(s) to the Lever Fuse Holder
Terminal Block.

3.5.3 VARISTOR TERMINAL BLOCK REMOVAL/REPLACEMENT

REMOVAL PROCEDURE
1. Refer to Figure 1-1 and identify the Varistor Terminal Block and the Cross Connect Shorting
Bridge.

2. Remove the #10 AWG jumper wire from the Varistor Terminal Block.

3. Loosen the rail clamping screws on the Safety Ground Terminal Block.

Slide, as a group, the Lever Fuse Holder Terminal Block, and Ground Terminal Block slightly
away from the Varistor Terminal Block.

4. Remove the Cross Connect Bridge's five securing screws and remove the Cross Connect Bridge.
Retain all hardware.

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5. Loosen the ground terminal (green/yellow) rail clamping screw of the Varistor Terminal Block.

6. Use a screw driver with a thin blade to carefully separate (pry) the Varistor Terminal Block from
the adjacent L1/N/G Terminal Block.

7. Refer to Figure 3-1 and unsnap the Varistor Terminal Block (the end opposite the rail clamping
screw) from the rail and remove the assembly.

8. Carefully pry the spacer plate (see Figure 1-1) loose from the Varistor Terminal Block with a
thin-blade screwdriver. Retain the spacer plate.

REPLACEMENT PROCEDURE

1. Loosen the ground terminal (green/yellow) rail clamping screw of the replacement Varistor
Terminal Block.

2. Retrieve the spacer plate removed in the above step 8 and install it on the replacement terminal
block.

3. Note that the side of the Varistor Terminal Block that butts against the adjacent L1/N/G
Terminal Block has four protrusions which snap into holes in the side of the L1/N/G Terminal
Block.

4. Place the replacement terminal block at the proper location and mount it to the rail. See Figure
3-1.

5. Snap the Varistor Terminal Block into the adjacent L1/N/G Terminal Block and firmly tighten
its rail clamping screw.

6. Slide, as a group, the Lever Fuse Holder Terminal Block, and Ground Terminal Block against
the Varistor Terminal Block and tighten the rail clamping screws on the Safety Ground Terminal
Block.

7. Reconnect the #10 AWG jumper wire to the Varistor Terminal Block.

8. Retrieve and install the Cross Connect Bridge.

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3.5.4 L1/N/G TERMINAL BLOCK REMOVAL/REPLACEMENT

As shown in Figure 1-1, there are five L1/N/G Terminal Blocks in the PDA with an end cover plate
installed between the last Block and the End Clamp.

REMOVAL PROCEDURE

1. Refer to Figure 1-1 for component location and remove and retain the Insertion Bridge and
Cross Connect Bridge. Tag any wires removed for later reconnection.

2. Loosen the rail clamping screw of the End Clamp adjacent to the last L1/N/G Terminal Block in
the group and slide the End Clamp away from the terminal block.

3. Remove and tag all wires connected to the L1/N/G Terminal Block to be replaced.

4. Loosen the ground terminal rail clamping screw in each Block from the End Clamp up to, and
including, the Block to be removed. Remove and tag ground wires as necessary.

5. Use a thin-blade screwdriver to carefully pry loose the terminal block to be removed from the
adjacent terminal blocks. Slide terminal blocks as necessary to create room for removal.

6. Refer to Figure 3-1 and unsnap the L1/N/G Terminal Block (the end opposite the ground
terminal rail clamping screw) from the rail and remove the assembly. If this Terminal Block
was next to the End Clamp, carefully pry loose and retain the cover plate.

REPLACEMENT PROCEDURE

1. Place the replacement L1/N/G Terminal Block at the proper location and mount it to the rail;
See Figure 3-1. If applicable, install the cover plate.

2. Snap the replacement terminal block to each adjacent terminal block.

3. Reconnect the removed tagged wires to the replacement terminal block.

4. Reconnect any ground wires removed from other terminal blocks.

5. Install the Insertion Bridge and Cross Connect Bridge.

6. Position the End Clamp against the last terminal block and secure it to the rail.

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3.5.5 SURGE ARREST REMOVAL/REPLACEMENT

REMOVAL PROCEDURE

1. Refer to Figure 1-3 and identify the Surge Arrest Terminal Block and its dismount tab projecting
from the foot of the device.

2. Remove all #14 AWG jumper wires from the Surge Arrest Terminal Block.

3. Place the flat blade of a screwdriver in the groove of the dismount tab. Using the body of the
terminal block as a fulcrum for the shaft of the screwdriver, rotate (up) the screwdriver and
disengage the Surge Arrest from the DIN rail.

REPLACEMENT PROCEDURE

1. Engage the top of the replacement Surge Arrest with the top of the DIN rail, then push down on
the device until it snaps onto the DIN rail.

2. Reconnect all #14 AWG jumper wires to the Surge Arrest Terminal Block.

3.6 SPARE AND REPLACEMENT PARTS

Spare cartridge fuses and Surge Arrests should be available to support the quantity of PDAs
installed. Refer to the following list for part number and description. Spare fuses and replacement
parts can be ordered from one the addresses in the Warranty statement or through a local Moore
Products Co. representative.

PDA Components
PN 16114-63 DIN Rail, 35 mm X 7.5 mm
PN 7418-516 DIN Rail End Clamp
PN 7418-522 Insertion Bridge
PN 7418-527 Cross Connect Bridge
PN 7418-542 Ground Terminal Block
PN 7418-541 Lever Fuse Holder Terminal Block (used on PN 16114-65)
PN 7418-540 Varistor Terminal Block, 115 Vac Service (used on PN 16114-65)
PN 7418-518 Spacer Plate (used with P/N 7418-540)
PN 7418-543 L1/Neutral/Ground Terminal Block
PN 7418-517 End Cover (used with P/N 7418-543)
PN 7447-205 Cartridge Fuse, 30A, 250V, Slow-Blow (used on PN 16114-65)
PN 7448-46 2-Pole Lever Fuse Holder Terminal Block (used on PN 16114-131)
PN 7418-548 Surge Arrest Block, 230 Vac Service (used on PN 16114-131)
PN 7447-212 Cartridge Fuse, 15A, 250V, Slow-Blow (used on PN 16114-131)

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3.7 RETURN FOR REPAIR

TO RETURN EQUIPMENT

! Call the Service Department at (215) 646-7400, ext 4RMA (4762) weekdays between 8:00 a.m.
and 4:45 p.m. Eastern Time to obtain an RMA number. Mark the RMA number prominently on
the outside of the shipment.

! When calling for an RMA number, provide the reason for the return. If returning equipment for
repair, failure information (e.g., error code, failure symptom, installation environment) will be
requested. Supply a purchase order number for nonwarranty repairs.

MATERIAL SAFETY DATA SHEET

! A Material Safety Data Sheet (MSDS) must be included with each item being returned that was
stored or used anywhere hazardous materials were present.

PACKAGING

! Package assembly in original shipping materials. Otherwise, package it for safe shipment or
contact the factory for shipping recommendations.

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WARRANTY

The Company warrants all equipment manufactured by it and bearing its nameplate, and all repairs
made by it, to be free from defects in material and workmanship under normal use and service. If
any part of the equipment herein described, and sold by the Company, proves to be defective in
material or workmanship and if such part is within twelve months from date of shipment from the
Company's factory, returned to such factory, transportation charges prepaid, and if the same is found
by the Company to be defective in material or workmanship, it will be replaced or repaired, free of
charge, f.o.b. Company's factory. The Company assumes no liability for the consequence of its use
or misuse by Purchaser, his employees or others. A defect in the meaning of this warranty in any
part of said equipment shall not, when such part is capable of being renewed, repaired or replaced,
operate to condemn such equipment. This warranty is expressly in lieu of all other warranties,
guaranties, obligations, or liabilities, expressed or implied by the Company or its representatives.
All statutory or implied warranties other than title are hereby expressly negated and excluded.

Warranty repair or replacement requires the equipment to be returned to one of the following
addresses.

Equipment manufactured or sold by MOORE PRODUCTS CO.:

MOORE PRODUCTS CO.

Sumneytown Pike
Spring House, PA 19477

Equipment manufactured or sold by MOORE PRODUCTS CO. (CANADA) INC:

MOORE PRODUCTS CO. (CANADA) INC.

2KM West of Mississauga Rd. Hwy. 7
Brampton, Ontario, Canada

Equipment manufactured or sold by MOORE PRODUCTS CO. (UK) LTD.:

MOORE PRODUCTS CO. (UK) LTD

Copse Road,
Lufton, Yeovil,
Somerset, BA22 8RN, ENGLAND

The warranty will be null and void if repair is attempted without authorization by a member of the
MOORE PRODUCTS CO. Service Department.

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