© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 1 PLC MODULE INSTALLATION INSTRUCTIONS IN CGR1240.

© 2006 Cisco Systems, Inc. All rights reserved. Cisco ConfidentialSteelers Mechanical Design Review 1

PLC MODULEINSTALLATION INSTRUCTIONS

IN CGR1240

© 2006 Cisco Systems, Inc. All rights reserved. Cisco ConfidentialSteelers Mechanical Design Review 2

PLC MODULE INSTALLATION KIT Included

1. PLC Internal Wiring Harness PN: FIJI-MN-04PMMS-SF8(03)

2. PLC Module PID: CGM-PLC-1901.2-A

3. Tie wrap

Not Included

1. External PLC Signal Cord PN: FIJI-MN-04AFFM-L30FT(02)

Tools needed

1. Ratchet wrench2. Socket size ½”3. Flat head screwdriver (0.1” flat head tip)4. Regular #2 Phillip screwdriver5. Torque wrench (10-100 in/lbf)6. Open End Wrench, or deep socket size 1”

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Step 1Remove the nut from PLC Internal Wiring Harness

Step 2Remove the PG-13 plug from CGR1240. NOTE: Remove plug location as shown.

PLC MODULE INSTALLATION INSTRUCTIONS

NOTE: To open the front door of the CGR1250, please refer to CGR1240 Hardware Installation Guide for internal compartment access

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PLC MODULE INSTALLATION INSTRUCTIONS

Step 3Fish the PLC Internal Wiring Harness through the cable port hole from outside.

Next, hand tighten the PLC Wiring Harness to the cable port hole first before tightening it down to with a wrench.

Tighten it down to 72-84inlbf

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Step 4Install the PLC Module into the CGR1240 bottom right slot. Tighten both of the thumbscrews to 15-20inlbs

PLC MODULE INSTALLATION INSTRUCTIONS

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Step 5Install each of the cable into the PLC module. Carefully match the color of the cables to the callouts (NEU, P1, P2, P3) on the faceplate of the PLC module. Slightly pull the cables to ensure secure connection to the PLC module

Wiring Color PLC Faceplate Callouts

BLUE NEU

BLACK P1

BROWN P2

GRAY P3

PLC MODULE INSTALLATION INSTRUCTIONS

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Step 6Using your index and middle fingers, tuck and push all the wires underneath the CGR1240 card cage. Ensure all the excess wires bundled together and are all pushed underneath the card cage. This is to ensure the wires doesn’t rub against the door of the CGR1240.

NOTE: The wire bundle is nicely tucked to the right side of the PLC module handle

PLC MODULE INSTALLATION INSTRUCTIONS

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Step 7Secure the location of the wire bundle to the PLC module handle using a tie wrap by looping it around through the module handle hole

Next, trim the tie wrap excess.

PLC MODULE INSTALLATION INSTRUCTIONS

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Step 8Take the PLC External Power Cord and locate the notch on the mating connector and match it to key feature on the PLC Internal Wiring panel mounted connector. Next, secure the mating connector to the panel mounted connector.

PLC MODULE INSTALLATION INSTRUCTIONS

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Your PLC Module installation is now complete.

NOTE: Please refer to CGR1240 Hardware Installation Guide to complete the installation of the CGR1240.

Please refer to next section for typical power mains connection instructions to External PLC Signal Cord

PLC MODULE INSTALLATION INSTRUCTIONS

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WIRING INSTRUCTIONS FOR CONNECTING

EXTERNAL PLC SIGNAL CORD TO THE

CUSTOMER’S AC POWER DISTRIBUTION

LINES

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EXTERNAL PLC SIGNAL CORD WIRING INSTRUCTIONS

NOTE: Wire colors are the same between the External PLC Signal Cord and the PLC Internal Wiring Harness.

PLC Internal Wiring

Harness Color Code

PLC Faceplate Callouts

External PLC Signal Cord Color Code

BLUE NEU BLUE

BLACK P1 BLACK

BROWN P2 BROWN

GRAY P3 GRAY

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PLC WIRING CONNECTORS PINOUTS

EXTERNAL PLC SIGNAL CORDFIJI-MN-04AFFM-L30FT(02)

FRONT VIEW

PLC INTERNAL WIRING HARNESSFIJI-MN-04PMMS-SF8(03)

FRONT VIEW

PINOUT # COLOR FUNCTION4 WHITE PHASE 33 BROWN PHASE 22 BLACK PHASE 11 BLUE NEUTRAL

Longer Pin

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EXTERNAL PLC SIGNAL CORD TYPICAL CONNECTION INSTALLATION INSTRUCTIONS

PLC External Power Cord Wiring Color

Power Input Polarity

BLUE NEUTRAL

BLACK Phase 1

BROWN Phase 2

GRAY Phase 3

Typical connection diagram for 3-phase Wye AC power distribution shown below:

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PLC External Power Cord Wiring Color

Power Input Polarity

BLUE Phase 1

BLACK Phase 2

BROWN NO CONNECTION

GRAY NO CONNECTION

EXTERNAL PLC SIGNAL CORD TYPICAL CONNECTION INSTALLATION INSTRUCTIONS

Typical connection diagram for 2-phase differential AC power distribution shown below: