user manual - PRG

USER MANUAL
PRG Series 400
400 Amp Disconnect
02.9680.0200 A -1
02.9680.0200 A

AutoPar , PRG Series 400 , Mbox Extreme , Virtuoso®, Virtuoso® DX, Virtuoso® DX2, and Visionary 3D
are trademarks of Production Resource Group, LLC, registered in the U.S. and other countries.
Neutrik® and PowerCon® are registered trademarks of Neutrik AG.
All other brand or product names which may be mentioned in this manual are trademarks or registered trademarks of their respective companies.
This manual is for informational use only and is subject to change without notice. Please check www.prg.com for latest version.
PRG assumes no responsibility or liability for any claims resulting from errors or inaccuracies that may appear in this manual.
PRG Series 400 400 Amp Disconnect User Manual
Version as of: December 7, 2006 | PRG part number: 02.9680.0200 A
Production Resource Group
Dallas Office
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
www.prg.com
PRG Series 400 400 Amp Disconnect User Manual
©2006 Production Resource Group, LLC. All Rights Reserved.

Introduction
About This Guide
INTRODUCTION : ABOUT THIS GUIDE
This guide provides necessary information regarding product safety, installation, and operation for the
following PRG equipment:
• PRG Series 400 400 Amp Disconnect (20.9680.0200)
Familiarizing yourself with this information will help you get the most out of your PRG product.
WARNING: It is important to read ALL accompanying safety and installation instructions to avoid
damage to the product and potential injury to yourself or others.
The PRG Series 400 400 Amp Disconnect is suitable for use in the U.S. and Canada, or any locality
with a 5-wire, 120/208V power grid. It is intended for dry locations only and must be protected from
moisture if used outdoors.
IMPORTANT INFORMATION REGARDING INSTALLATION. PLEASE READ!
This equipment is intended for installation in accordance with the National Electrical Code® and local or
Federal code specifications. To ensure full compliance with all codes and regulations, check with your local
electrical inspector prior to installation. To prevent electrical shock, turn off power at mains before
installation.
This manual has been revised as follows:
Version Release Date Notes
BASIC 27-Sep-06
A 29-Nov-06 Revised Installation steps on page 7.
Added instructions for setting the Inrush Current Limit on page 9.
Additional Documentation
For more information on the Series 400 system, refer to the following PRG manuals:
• PRG Series 400 Power and Data Distribution System User Manual (02.9680.0001)
• PRG Series 400 Power and Data Distribution System Service Manual (02.9680.0010)
02.9680.0200 A 1

PRG SERIES 400 400 AMP DISCONNECT USER MANUAL
Customer Service
Our comprehensive technical services department ensures you get the full benefit of being a PRG
customer. Whether your needs are simple or complex, our full-time staff of experienced professionals
are on-hand to provide support. For assistance, contact your nearest PRG office:
PRG Dallas (International Service)
8617 Ambassador Row, Suite 120
Dallas, Texas 75247
Ph: 1.214.630.1963
Fx: 1.214.630.5867
Service Fx: 214.638.2125
Service Email: orders@prg.com
PRG Los Angeles
9111 Sunland Blvd.
Sun Valley, California 91352
Ph: 1.818.252.2600
Fx: 1.818.252.2620
PRG New York
7777 West Side Avenue
North Bergen, New Jersey 07047
Ph: 1.201.758.4000
Fx: 1.201.758.4312
PRG Canada
2480 Tedlo Street
Mississauga, Ontario L5A 3V3 Canada
Ph: 905.270.9050
Fx: 905.270.2590
PRG Europe
20-22 Fairway Drive
Greenford, Middlesex, UB6 8PW
Ph: +44.208.575.6666
Fx: +44.208.575.0424
PRG Las Vegas
6050 S. Valley Vw Blvd.
Las Vegas, Nevada 89118
Ph: 1.702.942.4774
Fx: 1.702.942.4775
PRG Nashville
8351 Eastgate Blvd.
Mount Juliet, Tennessee 37122
Ph: 1.615.834.3190
Fx: 1.615.834.3192
PRG Orlando
1902 Cypress Lake Dr.
Orlando, Florida 32837
Phone: 1.407.855.8060
Fax: 1.407.855.8059
PRG Asia
Asagami Fukagawa Logistics Center B-4F
2-2-1 Shiohama, Koto-ku, Tokyo, Japan 135-0043
Ph: 81.3.5439.4091
Fx: 81.3.5439.4092
For additional resources and documentation, please visit our website at: www.prg.com
2 02.9680.0200 A

Overview
Description
OVERVIEW : DESCRIPTION
The PRG Series 400 400 Amp Disconnect is a safety device containing a three-phase, 400 Amp
circuit breaker serving as a Main Breaker for high current AC power distribution systems. A
Disconnect unit is required when 5-wire, 4/0 AWG feeder cables greater than 10 feet in length are
connected from a house service greater than 400 Amps per phase to a portable power distribution
system.
The Series 400 Disconnect interrupts the 3-phase current flow under fault conditions, preventing
dangerous overloads of the feeder cables. The Series 400 Disconnect may be used with the PRG
Series 400 Power and Data Distribution System, other power distribution systems, and with portable
power sources (generators) as long as its ratings are not exceeded and an adequate Earth ground has
been established.
Features:
• Six Cam-Lok Series E1016 high-current
connections for power input.
• Two sets of six Cam-Lok Series E1016
high-current connections for power
output.
• Double Neutral connectors to handle
excessive neutral current generated by
low power factor loads.
• Seven digital LED meters to monitor
power flow - three voltmeters to measure
phase voltages and four current meters to
measure current flowing in each phase
and the neutral.
• Neon indicators to show when feed cable
is energized.
• Adjustable control for setting inrush limit.
• Five color coded, insulated test points for
metering output voltages.
• Multiple local convenience outlets.
• Solid copper rigid bus bars and two thermostatically controlled cooling fans allow operation at
100% of Rated current.
• Suitable for use in the U.S. and Canada, or any locality with a 5-wire, 120/208V power grid.
02.9680.0200 A 3

PRG SERIES 400 400 AMP DISCONNECT USER MANUAL
Controls and Indicators
The Series 400 Disconnect contains the following connections and LED indicators.
MAIN
BREAKER
ON
PUSH
TO
TEST
SWITCH TO OFF
POSITION TO
RESET BREAKER
INPUT VOLTAGES
XØ VOLTS YØ VOLTS ZØ VOLTS
MAIN BREAKER
ON
Type 1 Enclosure
For use in Dry Locations
50 C Max Ambient
For Use in Areas Not Readily Accessible by the General Public
FOR USE BY QUALIFIED PERSONNEL ONLY
WARNING - Risk of Electric Shock.
400 AMP
OFF
2000A 3000A 4000A
INRUSH LIMIT
SETTING
ARC MIXED TUNGSTEN
LOADS LOADS LOADS
Conforms to:
Production Resource Group
UL STD 1640
8617 Ambassador Row
Suite 120
Certified to:
Dallas, TX 75247
CAN/CSA STD C22.2
Made in USA
No. 29
XXXXX
S-400
400 AMP DISCONNECT
MODEL 23-9680-0200
Ø -Ø
Ø -N
600A MAX
NEUT AMPS
120/208V
3ØY/30 A
XØ AMPS
XØ
FOR BRANCH CIRCUIT USE ONLY
120V / 15A 208V / 15A 208V / 20A
120/208V
3ØY/30 A
Figure 1: Series 400 Disconnect Front Panel
4 02.9680.0200 A
GROUND
400A MAX
YØ AMPS
YØ
NEUTRAL
120/208V
3ØY/30 A
ZØ AMPS
ZØ
OUTPUT
VOLTAGES
TEST POINT
FUSES
1A / 250V
AGC1
Voltmeters - measures phase voltages
to ensure supply voltage is correct.
Voltage input to the Cam-Loks is
measured before the breakers and will
show the input voltage even when the
Main Breaker is off.
Voltmeter Rocker Switch - allows
connection of the meters between the
three phases (Ø-Ø) or between each
phase and neutral (Ø-N).
Current Meters - measures current
flowing in each phase and neutral
circuit.
Test Points - to meter the output
voltages after the Main Breaker.
Pilot Light - indicates when Main
Breaker is ON. Provides a Push-To-Test
function.
Main Breaker - provides system
protection.
Convenience Outlet (2) - Edison style
receptacle, which provides power for
optional work lights, test equipment, etc.
Neutrik® Power Outlet (2) -
provides power for control consoles and
support equipment.
L6-20 Power Outlet - provides 208V
power for a single luminaire.
Inrush Limit Setting - adjustment
allows Inrush Limit to be set between
2000 and 4000 Amps.
L21-30R Power Outlet (2) - provides
120/208V 30 Amp, 3-phase power.

S-400
400 AMP
DISCONNECT
INPUT CONNECTIONS
MUST BE MADE
IN THE FOLLOWING
ORDER:
1) CONNECT GROUND
2) CONNECT NEUTRAL
3) CONNECT PHASES
DISCONNECT IN
REVERSE ORDER
GND
GND
GND
120/208V 3Ø OUTPUTS 400A PER Ø MAX
NEUT
NEUT
NEUT XØ
Figure 2: Series 400 Disconnect Rear Panel
OVERVIEW : CONTROLS AND INDICATORS
02.9680.0200 A 5
YØ
YØ
120/208V 3Ø INPUTS 400A PER Ø MAX
XØ YØ
NEUT
NEUT
NEUT
XØ
XØ
YØ
ZØ
ZØ
ZØ
ZØ
Power Output Connectors -
Two sets of six Cam-Lok
connectors for power output
to power distribution systems.
Neon Phase Lamps -
Indicate presence of AC
voltage for each of three
phases.
Power Input Connectors -
Six 400 Amp Cam-Lok
connectors for house power
feed.

PRG SERIES 400 400 AMP DISCONNECT USER MANUAL
Proper Use and Operation
Please observe the following safety, use and operational guidelines:
• The Disconnect is intended for dry locations only and must be protected from rain and other
moisture if used outdoors.
• Two Disconnect racks may be stacked on top of each other. The upper rack’s casters will nest on
top of the lower rack. When stacking racks, use a strap to tie them together for stability.
• The Disconnect may be operated with the front cover in place for security or weather protection.
The fans draw and exhaust to the rear of the rack.
• The cooling fans turn on automatically when the internal bus bar temperatures exceed 135°F. This
only happens when the rack is in the sun on a hot day or when it is loaded to its maximum. The fan
may cycle on and off during normal operation.
6 02.9680.0200 A

Installation
Installing Series 400 Disconnect
INSTALLATION : INSTALLING SERIES 400 DISCONNECT
The Series 400 Disconnect is installed between the house service and a portable power distribution
system, such as the Series 400 Power and Data Distribution System. It may also be used to protect a
dimmer installation.
CAUTION: Before installing, refer to "Proper Use and Operation" on page 6.
WARNING: Ensure house service main breaker and Series 400 Disconnect breaker are OFF before
connecting mains power cables. Ground should always be connected first.
To install:
Step 1. At house service main breaker, turn power OFF.
Step 2. Meter voltage at the input of the house disconnect to ensure that all voltages are correct.
Phase-to-phase voltages should be 208 Volts +/- 8 Volts. The voltage between Neutral and
Ground should be less than 5 Volts.
CAUTION: If the house breaker has a capacity greater than 400 Amps per phase, the pigtails
connecting the S400 Disconnect cannot be longer than 10 feet.
Step 3. Connect Cam-Lok 5-wire pigtails to house breaker output terminals. Ensure connections are
tight to avoid heating of the connections.
Step 4. Place Disconnect in desired location and remove front and back covers (Figure 3).
NOTE: Two racks may be stacked on top of
each other. The upper rack’s casters will nest
on top of the lower rack. When stacking racks,
use a strap to tie them together for stability.
Figure 3: Removing Disconnect Rack Covers
02.9680.0200 A 7

PRG SERIES 400 400 AMP DISCONNECT USER MANUAL
Step 5. Ensure that Main Breaker is switched OFF (Figure 4).
Step 6. At INPUTS, connect input power cable Cam-Loks in the following order:
1) Ground, 2) Neutral 3) X Phase, 4) Y Phase, and 5) Z Phase.
Pilot
Light
Main
Breaker
MAIN
BREAKER
ON
PUSH
TO
TEST
SWITCH TO OFF
POSITION TO
RESET BREAKER
INPUT VOLTAGES
XØ VOLTS YØ VOLTS ZØ VOLTS
400 AMP
MAIN BREAKER
ON
OFF
2000A 3000A 4000A
INRUSH LIMIT
SETTING
ARC MIXED TUNGSTEN
LOADS LOADS LOADS
Type 1 Enclosure
For use in Dry Locations
50 C Max Ambient
For Use in Areas Not Readily Accessible by the General Public
FOR USE BY QUALIFIED PERSONNEL ONLY
WARNING - Risk of Electric Shock.
Conforms to:
Production Resource Group
UL STD 1640
8617 Ambassador Row
Suite 120
Certified to:
Dallas, TX 75247
CAN/CSA STD C22.2
Made in USA
No. 29
XXXXX
S-400
400 AMP DISCONNECT
MODEL 23-9680-0200
Ø -Ø
Ø -N
600A MAX
NEUT AMPS
120/208V
3ØY/30 A
FRONT VIEW
XØ AMPS
XØ
GROUND
FOR BRANCH CIRCUIT USE ONLY
120V / 15A 208V / 15A 208V / 20A
120/208V
3ØY/30 A
400A MAX
YØ AMPS
YØ
NEUTRAL
120/208V
3ØY/30 A
Figure 4: Turning Off Main Breaker and Connecting Cam-Loks
Step 7. At OUTPUTS, connect output power cable Cam-Loks from power distribution equipment in
the following order: 1) Ground, 2) Neutral 3) X Phase, 4) Y Phase, and 5) Z Phase.
Note: Two complete sets of OUTPUT Cam-Lok connectors are provided in order to connect two
separate power distribution systems.
Note: A double set of Neutral connections are provided in the INPUT and OUTPUT Cam-Lok sets for
use with low power factor loads, such as dimmers. Since low power factor loads cause large neutral
currents, the Disconnect is designed to handle up to 600 Amps of Neutral current if the input and
Output cable sets have two Neutral conductors each. The double set of Neutral cables must be 4/0.
8 02.9680.0200 A
ZØ AMPS
ZØ
OUTPUT
VOLTAGES
TEST POINT
FUSES
1A / 250V
AGC1
CONNECTION
ORDER:
1) Ground
2) Neutral
3) X Phase
4) Y Phase
5) Z Phase
Cam-Lok Input
Connectors
WARNING: RISK OF ELECTRICAL SHOCK!
Ensure house service main breaker and Disconnect
breaker are OFF before connecting mains power
cables. Ground should always be connected first.
Cam-Lok Output Connectors (Two Sets)
S-400
400 AMP
DISCONNECT
INPUT CONNECTIONS
MUST BE MADE
IN THE FOLLOWING
ORDER:
1) CONNECT GROUND
2) CONNECT NEUTRAL
3) CONNECT PHASES
DISCONNECT IN
REVERSE ORDER
GND
GND
GND
120/208V 3Ø OUTPUTS 400A PER Ø MAX
NEUT
NEUT
NEUT XØ
REAR VIEW
YØ
YØ
120/208V 3Ø INPUTS 400A PER Ø MAX
XØ YØ
NEUT
NEUT
NEUT
XØ
XØ
YØ
ZØ
ZØ
ZØ
ZØ

INSTALLATION : INSTALLING SERIES 400 DISCONNECT
Set the Inrush Current Limit:
Some loads, such as incandescent lamps or electric motors, can draw a large surge of current through
the Main Breaker when they are quickly energized with voltage. When the Inrush Current Limit of the
Main Breaker is exceeded, the Breaker will trip within a half cycle of the AC line. It is important that
the Inrush Current Limit be properly adjusted so that these normal, but large surges do not cause
nuisance tripping of the Main Breaker.
CAUTION: 1) If the Inrush Current Limit is set too high, the Main Breaker may not respond quickly
enough to a hard fault in the output cables feeding the load resulting in excessive damage to the cables.
2) DO NOT adjust the Inrush Setting while the unit is under load.
Recommended Settings...
• For loads consisting mainly of arc lamp power supplies, set the Inrush Limit to its minimum of
2000 Amps.
• For loads consisting mainly of high wattage incandescent lamps, set the Inrush Limit to 4000
Amps.
• For mixed loads, try an intermediate setting near 3000 Amps.
Note: It is important to note that this setting applies to INRUSH and not OVERALL amperage. For
example, setting the inrush to 2000 amps does not mean that the switch will now trip at a normal load
of 200 amps-per-leg instead of 400 amps-per-leg.
Once the load system is installed, connected and ready to test, "bump" the entire cold load to make
sure the Main Breaker does not trip. If it trips, increase the Inrush setting moderately, then wait 5
minutes for the lamps to cool and "bump the system again.
Step 1. Set Inrush Current Limit considering the type of load that the Disconnect will be protecting
(refer to guidelines above). The Inrush Current Limit adjustment is located directly below
the Main Breaker handle (Figure 5) and is adjusted by inserting a flat blade screwdriver into
the vertical slot of the curved, recessed control. Moving the control to the left reduces the
Main Breaker's tolerance of inrush current and moving it to the right increases the Main
Breaker's tolerance.
XØ VOLTS
MAIN
BREAKER
ON
PUSH
TO
TEST
MAIN CIRCUIT BREAKER IS SUITABLE
FOR CONTINUOUS OPERATION AT
400 AMPERES.
DISJONCTEUR DU CIRCUIT PRINCIPAL
A MOINS QU'IL NE CONVIENNE POUR
SERVICE CONTINU A 400 AMPERES.
SWITCH TO OFF
POSITION TO
RESET BREAKER
INPUT VOLTAGES
YØ VOLTS ZØ VOLTS
400 AMP
MAIN BREAKER
ON
INRUSH LIMIT
SETTING
ARC MIXED TUNGSTEN
LOADS LOADS LOADS
S-400
400 AMP DISCONNECT
MODEL 23-9680-0200
OFF
2000A 3000A 4000A
Ø -Ø
Ø -N
600A MAX
NEUT AMPS
120V / 15A 208V / 15A 208V / 20A
120/208V
Y/30 A
X Ø AMPS
XØ
GROUND
FOR BRANCH CIRCUIT USE ONLY
120/208V
3ØY/30 A
400A MAX
YØ AMPS
YØ
NEUTRAL
ZØ
120/208V
3ØY/30 A
ZØ AMPS
OUTPUT
VOLTAGES
TEST POINT
FUSES
1A / 250V
AGC1
INRUSH LIMIT
SETTING
2000A 3000A
ARC
LOADS
Figure 5: Inrush Limit Setting Switch
02.9680.0200 A 9
4000A
MIXED TUNGSTEN
LOADS LOADS

PRG SERIES 400 400 AMP DISCONNECT USER MANUAL
Power Up Sequence
Use the following procedure to power up unit:
Step 1. At house service main breaker, turn power ON.
Step 2. At rear of Disconnect, verify all phase indicators are lit (Figure 6).
DISCONNECT
INPUT CONNECTIONS
MUST BE MADE
IN THE FOLLOWING
ORDER:
1) CONNECT GROUND
2) CONNECT NEUTRAL
3) CONNECT PHASES
DISCONNECT IN
REVERSE ORDER
GND
NEUT XØ
120/208V 3Ø INPUTS 400A PER Ø MAX
NEUT
NEUT
XØ YØ
XØ
Figure 6: Phase Indicators Location
Step 3. At front of Disconnect, check AC voltmeters. Voltages should read as follows:
Voltmeter Connection Voltage
Neutral to X 120V ± 5V
Neutral to Y 120V ± 5V
Neutral to Z 120V ± 5V
X to Y 208V ± 8V
Y to Z 208V ± 8V
Z to X 208V ± 8V
Step 4. If meter readings are nominal, switch Main Breaker to the ON position (Figure 4).
Step 5. Verify that test point readings match LED meter readings for proper voltage. Note: Since the
test points are after the Main Breaker, their voltages may be slightly lower than those
indicated by the digital meters when the Disconnect is under load. This is due to the internal
resistance of the breaker causing a slight voltage drop when current flows through it.
Note: The Pilot Light indicates when Main Breaker is energized (Figure 4). Press to test LED before
Main Breaker is "ON."
10 02.9680.0200 A
YØ
ZØ
ZØ
ZØ
Phase Indicators

Maintenance
Cleaning/Replacing Rack Air Filters
MAINTENANCE : CLEANING/REPLACING RACK AIR FILTERS
The air filters, located in the interior rack assembly, will require periodic cleaning. The frequency will
depend on the amount of use and/or exposure to dusty environments.
Parts:
40.7155.0120.0 FILTER, FAN 120MM, MESH ALUMINUM
Tools:
#2 slotted screwdriver
WARNING: Remove power from rack before performing any maintenance procedures.
To clean/replace rack air filters:
Step 1. Disconnect power to rack.
Step 2. Remove rack assembly from rolling rack case by removing ten 10-32 x 1/2" PTB black zinc
screws.
Step 3. Using screwdriver, free filter from enclosure.
Step 4. Clean filter with soap and water. Dry thoroughly.
Step 5. Re-install filter.
Step 6. Re-install rack assembly into rolling rack case.
10-32 x 1/2" PTB
Black Zinc Screw (10)
Rack Assembly
Rolling Rack Case
Rack Assembly
Figure 7: Removing Rack Air Filters
Fan Filter
02.9680.0200 A 11

PRG SERIES 400 400 AMP DISCONNECT USER MANUAL
Specifications
Technical Specifications
RATINGS and AMPACITY
Voltage Rating: 120/208V 3-phase wye with Neutral and Ground
Line Frequency: 50 - 60 Hz
Current Rating, Phases: 400 Amps per phase continuous
Current Rating, Neutral: 600 Amps continuous
Current Rating, Ground: 400 Amps
Fault Current Interrupting Capacity: 42,000 Amps
Fault Current Interrupt Time: Circuit clears in less than one line cycle
MAIN BREAKER
Type: Thermal-Magnetic, Square D Model LAL36400
Number of Poles: 3
Voltage Rating: 600V AC
Current Rating: 400 Amps
Inrush Overload Limit: Adjustable from 2000A to 4000A
DIGITAL LED METERS (7)
Update Rate: 2.5 samples/sec.
Display: 3-digit reading
INPUT VOLTMETERS (3)
Accuracy: ± 1 Volt
Input Range: 85 - 264 Volts AC
Overload Protection: 300V AC
OUTPUT AMMETERS (4)
Phase Current Meters full scale reading: 400 Amps
Neutral Current Meter full scale reading: 600 Amps
Overcurrent Rating: 1.5X rated full scale reading
Accuracy (sine wave): ±0.15% of full scale or ±6 counts
ENVIRONMENTAL
Operational Temperature Range: -20° C to +50° C
Cooling: Two thermostatically controlled fans
For Dry Locations Only
12 02.9680.0200 A

DIMENSIONS and WEIGHT
Unit in Rolling Rack: 22.5"(L) x 22.5"(W) x 30.5"(H)
Stand-Alone Panel Without Rack: 8.5"(D) x 19"(W) x 23.5"(H)
Weight: 153 lbs. with Rack / 79 lbs. without Rack
COMPLIANCE
UL Standard 1640
Canadian Standard CAN/CSA STD C22.2 No.29
Intertek ETL Safety Mark
SPECIFICATIONS : TECHNICAL SPECIFICATIONS
02.9680.0200 A 13

PRG SERIES 400 400 AMP DISCONNECT USER MANUAL
Notes
14 02.9680.0200 A