Initial setup of Power chassis

Initial setup of Power chassis

Setting up power chassis for initial installation

The power chassis can be set up either to directly power the power supply or to power
the power supply and a second connection to an auxiliary power panel. This step can be
skipped if you intend to connect the power lead directly to the power supply.

This section will cover the initial setup and wiring for both available switch types


AC Mains Power can kill or seriously injure

DO NOT plug in your equipment while you are working on it

Parts Required

Supplied Parts

1 x Power Chassis

1 x 240v Switch

2 or 3 x 4.8mm Spade connector and cover

1 x AC wire set (Live wire only)

1 x 240v Fuse

Parts to be sourced

No additional parts required.

Recommended tools

Wire stripper

Wire cutter

Crimping tool

Soldering iron (optional)

Parts Overview

Power chassis switches

There are two switch types that can be supplied with your kit. The first type
 “Type 1” has two individual power circuits consisting of 2 input terminals and
2 output terminals. “Type 2” is a single circuit switch consisting of 1 input
terminal and 2 output terminals

Power Chassis parts and pin outs

  1. Power Switch (installed in Chassis)
  2. Power Chassis
  3. Fuse Holder
  4. “Live” pin 240v AC
  5. “Ground/Earth” pin 240v AC
  6. “Neutral” pin 240v AC
  7. “Live” input pin(s) on switch, 240v AC
  8. “Live” output pins on switch, 240v AC

Assembly/Installation process

Make sure your power lead is not plugged into a wall socket.

Installing Fuse

The first step is to install a fuse in the Power chassis. Without a fuse the circuit in
the Power chassis is not complete and a current will not flow through it.

Locate the Fuse holder

Slide Fuse holder forward

Once the Fuse holder is pulled forward it should come away from the chassis freely
and you should be able to see the fuse terminals inside the chassis

Rotate the Fuse holder and you should be able to see the fuse clip on the back

Check the filament in the fuse to make sure it is intact and the glass tube of the fuse
has no cracks

Press the fuse into the fuse clip from underneath and make sure the fuse is central
on the clip

Insert the fuse holder and fuse back into chassis

Press the fuse holder into place, the holder should sit flat with the face of the Power

Initial wiring

The Power chassis and Power switch are two separate components and must be wired
together to work. The images below will show wiring both types of switches, please
identify your switch (duel or single circuit) and use the instructions appropriate for it.

For switch type 1 cut 2 65mm lengths of 240v AC “Live” wire. For switch type 2 cut
1 65mm length of 240v AC “Live” wire.

Strip approx 10mm of insulation of each end of the wire(s)

For switch type 1 join 2 lengths together while side by side and holding them together,
give one end a twist. The twist is to bind all the individual strands of wire together.
For switch type 2 only a single wire is required, twist each end to bind all the strands

Slip a spade connector cover (not pictured) over each end of the wires and then
solder a 4.8mm spade terminal to each end (terminals can be crimped but soldering
will provide a stronger connection). Once the spade terminals are attached pull the
rubber covers over them.

Attach the wire to the “Live” output pin on the back of the Power chassis. The fit
should be tight and may take some wriggling to get them on. Avoid removing and
reattaching them repetitively as they will become loose (loose fit) quickly.

Connect the other end of the wire(s) to the AC input terminals on the Power switch

Actual picture to show spade connector covers (had a few goes at drawing them,
never worked out)

You are now ready to move onto the next step, Mounting the power chassis.