© 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 Confidential Steelers 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 A 3.Tie wrap  Not Included 1.External PLC Signal Cord PN: FIJI-MN-04AFFM-L30FT(02)  Tools needed 1.Ratchet wrench 2.Socket size ½” 3.Flat head screwdriver (0.1” flat head tip) 4.Regular #2 Phillip screwdriver 5.Torque wrench ( in/lbf) 6.Open End Wrench, or deep socket size 1”

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 3 Step 1 Remove the nut from PLC Internal Wiring Harness Step 2 Remove 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

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 4 PLC MODULE INSTALLATION INSTRUCTIONS Step 3 Fish 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

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 5 Step 4 Install the PLC Module into the CGR1240 bottom right slot. Tighten both of the thumbscrews to 15-20inlbs PLC MODULE INSTALLATION INSTRUCTIONS

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 6 Step 5 Install 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 BLUENEU BLACKP1 BROWNP2 GRAYP3 PLC MODULE INSTALLATION INSTRUCTIONS

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 7 Step 6 Using 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

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 8 Step 7 Secure 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

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 9 Step 8 Take 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

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 10 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

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 11 WIRING INSTRUCTIONS FOR CONNECTING EXTERNAL PLC SIGNAL CORD TO THE CUSTOMER’S AC POWER DISTRIBUTION LINES

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 12 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 BLUENEUBLUE BLACKP1BLACK BROWNP2BROWN GRAYP3GRAY

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 13 PLC WIRING CONNECTORS PINOUTS EXTERNAL PLC SIGNAL CORD FIJI-MN-04AFFM-L30FT(02) FRONT VIEW PLC INTERNAL WIRING HARNESS FIJI-MN-04PMMS-SF8(03) FRONT VIEW PINOUT #COLORFUNCTION 4WHITEPHASE 3 3BROWNPHASE 2 2BLACKPHASE 1 1BLUENEUTRAL Longer Pin

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 14 EXTERNAL PLC SIGNAL CORD TYPICAL CONNECTION INSTALLATION INSTRUCTIONS PLC External Power Cord Wiring Color Power Input Polarity BLUENEUTRAL BLACKPhase 1 BROWNPhase 2 GRAYPhase 3  Typical connection diagram for 3-phase Wye AC power distribution shown below:

© 2006 Cisco Systems, Inc. All rights reserved.Cisco Confidential Steelers Mechanical Design Review 15 PLC External Power Cord Wiring Color Power Input Polarity BLUEPhase 1 BLACKPhase 2 BROWNNO CONNECTION GRAYNO CONNECTION EXTERNAL PLC SIGNAL CORD TYPICAL CONNECTION INSTALLATION INSTRUCTIONS  Typical connection diagram for 2-phase differential AC power distribution shown below: