Powerworx® Power Distribution Products Select

Transcript

ADCP-80-531 • Issue 1 • September 2001 PowerWorx® Power Distribution Products Select Series Circuit Breaker Power Distribution Panel User Manual 16755-B Content Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Important Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Standard Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Trademark Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Admonishments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 GENERAL CHARACTERISTICS AND FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1 Power Buses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3 Input Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.4 Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.5 Output Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.6 Chassis Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.7 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.8 Power-On Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 1.9 Circuit Breaker Alarm Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 1.10 Alarm Contact Closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 (continued) 1124636 Rev A Page 1 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 Content Page 1.11 Alarm Contact Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.12 Circuit Breaker Designation Card and Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.13 Voltage Designation Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.14 Material and Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.15 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.16 Protective Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.17 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.18 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.19 Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.20 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.21 Environmental Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4.1 Recommended Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4.2 Use of Screws in Accessories Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4.2.1 Screws to Attach Brackets to Circuit Breaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4.2.2 Screws to Attach Brackets to Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.2.3 Screws to Attach Protective Cover to Circuit Breaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.3 Protective Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.4 Cable Management Bar (Optional Accessory for Circuit Breaker Panels). . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.5 Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.6 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.7 Chassis Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.8 External Alarm Contact Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.9 Output Power Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4.10 Input Power Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4.11 Circuit Breaker Designation Card Holder and Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.12 Voltage Designation Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5.1 Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.2 Connection Polarity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.3 Wiring Connection Torque Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.4 Power Indication Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.5 Circuit Breaker Alarm Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 8 7.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 7.4 Power-On LED Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CUSTOMER INFORMATION AND ASSISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 _________________________________________________________________________________________________________ Page 2 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 INTRODUCTION This manual describes the high current (100 Amps per bus) circuit breaker type power ® distribution platform, designated PowerWorx Select Series Circuit Breaker Power Distribution Panel, hereinafter called “circuit breaker panel” or “panel.” Application: This circuit breaker panel is for telecommunications products used in central offices, multimedia headends, remote sites, and other locations requiring protected dc power. Input Power: This circuit breaker panel contains two buses (feeds) that accept –24 Vdc or –48 Vdc input power of up to 100 Amps per bus (total of 200 Amps per panel). Output Power: This circuit breaker panel provides circuit breaker protected output power with up to 8 circuit breaker positions per bus. The selectable current rating for each circuit breaker can be 1, 3, 5, 10, 15, or 20 Amps (see Subsection 1.7, Circuit Breakers). Standards This circuit breaker panel meets UL, Telcordia (formerly Bellcore), NEC 1999, CSA, NEBS Level 3, IEC, and CE standards. This circuit breaker panel design places emphasis on high reliability and simplicity of operation. Important Features This circuit breaker panel incorporates several important features: • Self-configuring voltage (–24 Vdc or –48 Vdc) capability and up to 100 Amps per bus to simplify installation and allow one panel to fit most dc voltage applications • ON/OFF lettering on each circuit breaker for quick identification of tripped circuit breakers as well as ampere ratings • Eight circuit breaker positions per bus • Alarm contact connections built into the circuit breaker panel for external connection to visual, audio, and remote alarms • Two field-replaceable high-brilliance Power-On green LED indicators and two Alarm red LED indicators (not field-replaceable) • Easily-removable (turn four screws) plastic protective cover over connectors to enhance safety and panel accessibility • Two-post grounding to ensure robust and reliable ground connectivity A complete description of this circuit breaker panel, with its available options and accessories, is provided in this manual. The information necessary to install, test, and operate the circuit breaker panel is also provided herein (see Section 4, Installation; Section 5, Testing; and Section 6, Operation). Standard Configuration The standard configuration circuit breaker panel has two power buses (feeds), with each power bus having multiple circuit breaker positions. The two buses are duplicates of each other in the number and type of circuit breakers. The capacity of each bus is one to eight circuit breakers. Page 3 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 Each bus has Power-On and Alarm indicators on the front of the chassis and input, output, ground, and alarm contact connections on the rear of the chassis. The current capacity of each bus is 100 Amps maximum. The total current of the circuit breaker panel (both buses) is 200 Amps maximum. The power dissipation of the circuit breaker panel is 100 watts maximum at 200 Amps. The dimensions of the circuit breaker panel are 1.75 inches (4.45 centimeters) high, 17.13 inches (43.5 centimeters) wide, and 10 inches (25.41 centimeters) deep. This does not include depth of protective cover and connectors, circuit breakers, and visual indicators that extend beyond the chassis. The circuit breaker panel can be mounted in 19- or 23-inch racks (48.26 or 58.42 cm) with WECO or EIA hole spacing using the mounting brackets provided. Options The circuit breaker panel is available with the following options: • One to eight circuit breakers for each bus installed • Selection of circuit breaker values of 1, 3, 5, 10, 15, and 20 Amperes capacity • Selection of circuit breakers that trip instantly or trip after a short delay • Two types of alarm contact connectors, either a screw-down terminal strip connector or a wire wrap pin block connector • Color of the circuit breaker panel is putty white. Accessories Several accessories for the circuit breaker panels are available (see Section 2, Accessories): • Circuit breakers with capacity values of 1, 3, 5, 10, 15, and 20 Amperes • Cable management bar kit • Compression lugs for connection to the input connectors • Lug terminals to connect #10 AWG wire to earth ground • Spare circuit breaker designation card kit • Contact ADC for circuit breaker replacement Revision History ISSUE DATE Issue 1 09/2001 Page 4 © 2001, ADC Telecommunications, Inc. REASON FOR CHANGE Original ADCP-80-531 • Issue 1 •September 2001 Trademark Information ADC and PowerWorx are registered trademarks of ADC Telecommunications, Inc. Admonishments Important safety admonishments are used throughout this manual to warn of possible hazards to persons or equipment. An admonishment identifies a possible hazard and then explains what may happen if the hazard is not avoided. The admonishments — in the form of Dangers, Warnings, and Cautions — must be followed at all times. These warnings are flagged by use of the triangular alert icon (seen below), and are listed in descending order of severity of injury or damage and likelihood of occurrence. Danger: Danger is used to indicate the presence of a hazard that will cause severe personal injury, death, or substantial property damage if the hazard is not avoided. Warning: Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the hazard is not avoided. Caution: Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the hazard is not avoided. General Safety Precautions - Caution: The circuit breaker panel uses electrical voltage and amperage levels which, per GR-1089, may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with this equipment when the panel is energized. Only insulated tools should be used on energized elements of the panel. Caution: All circuit breaker panel wiring and cabling should be connected with the system office battery input off or disconnected at the office distribution panel. Caution: A replacement circuit breaker must have exactly the same current rating as the circuit breaker being replaced. 1 GENERAL CHARACTERISTICS AND FEATURES The circuit breaker panel have the general characteristics and features defined in the following paragraphs. A typical circuit breaker panel with protective covers in place is shown in Figure 1. A typical circuit breaker panel with the protective cover removed is shown in Figure 2. Configurations and features other than described herein may be available by special order. Available accessories for the circuit breaker panel are listed in Section 2, Accessories. Page 5 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 VENTS UL/CSA/CE LABEL 1 TO 8 CIRCUIT BREAKERS (BLANK PANEL IF NO CIRCUIT BREAKER) BUS A POWER-ON INDICATOR (GREEN LED) BUS A CIRCUIT BREAKER INDICATOR (RED LED) FRONT VIEW BUS B POWER-ON INDICATOR (GREEN LED) BUS B CIRCUIT BREAKER INDICATOR (RED LED) 1 TO 8 CIRCUIT BREAKERS (BLANK PANEL IF NO CIRCUIT BREAKER) 16756-B PROTECTIVE COVER PLACED OVER INPUT AND OUTPUT POWER, GROUND, AND ALARM CONNECTIONS REAR VIEW MOUNTING BRACKETS FOR 23-IN. (58.42 CM) RACK MOUNTING Figure 1. Front and Rear View of ADC PowerWorx Select Series Circuit Breaker Panel with Protective Cover Attached (8/8-Position Panel Shown) Page 6 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 BUS A AND BUS B ALARM CONTACT CONNECTOR (WIREWRAP PIN BLOCK TYPE SHOWN) TO BATTERY B TO RETURN B BUS B INPUT CONNECTORS (TWO-HOLE COMPRESSION LUG-STUD TYPE) 16757-B CHASSIS GROUND TERMINALS BUS B OUTPUT CONNECTORS (SCREW-DOWN BARRIER TERMINAL STRIPS) BUS A INPUT BUS A OUTPUT CONNECTORS CONNECTORS (TWO-HOLE (SCREW-DOWN COMPRESSION BARRIER TERMINAL LUG-STUD TYPE) STRIPS) TO BATTERY A TO RETURN A Figure 2. Rear View of Select Series Circuit Breaker Panel with Protective Cover Removed to Show Connections (Panel with Wire Wrap Alarm Connection Shown) 1.1 Power Buses Each circuit breaker panel has two isolated power feed buses. Each bus provides normal distribution of the input power to the output power circuits. In each bus circuit, current flows from the input power bus, through the circuit breaker, to the output power circuit. The current capacity of each bus is 100 Amps maximum. A typical circuit breaker panel block diagram is shown in Figure 3. Each of the feed buses is available with a capacity of eight circuit breaker positions. Other circuit breaker capacity configurations may be available by special order. When a circuit breaker fails, the input power bus is disconnected from the corresponding output circuit which causes the alarm LED for the bus to light and causes alarm contact closures (using Form C contacts) which are present at the alarm output connection. 1.2 Input Voltage The dual bus feed circuit breaker panel can accommodate either –24 Vdc on both buses or –48 Vdc on both buses. The voltage level is sensed by the circuit breaker panel circuitry. The input voltage used with the circuit breaker panel can have the following characteristics: • –24 Vdc nominal, within range of –21 Vdc to –30 Vdc • –48 Vdc nominal, within range of –42 Vdc to –56 Vdc Page 7 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 –24V/–48V BATTERY BATTERY A RETURN 1 2 3 4 5 6 7 8 RETURN A BUS A C NO FA NC POWER A LED BREAKER ALARM A LED RETURN A SYSTEM ALARM CONNECTIONS C NO NC BUS B FB POWER B LED BREAKER ALARM B LED RETURN B –24V/–48V BATTERY B RETURN B BATTERY RETURN 1 2 3 4 5 6 7 8 16758-B Figure 3. PowerWorx Circuit Breaker Panel Block Diagram (8/8-Position Panel Shown) Page 8 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 1.3 Input Connectors Each bus has two input connectors on the rear of the fuse panel through which input power is applied. The two input power connectors are labeled “BATT” (battery) and “RTN” (return). The input connectors are two-hole compression lug (stud type) connectors. Each connector has a set of two screws (studs) with nuts mounted on a plated copper plate. Each set of two screws can accept different size 2-hole lugs which can be used with a range of wire sizes up to #2 AWG copper wire. Two 2-hole lugs per bus and one spare lug for use with #2 AWG wire (five total) are included with the circuit breaker panel. Other lugs are available as accessories (see Section 2, Accessories). 1.4 Output Voltage The output voltage will be the same voltage as the applied input voltage when the circuit breaker does not fail. 1.5 Output Connectors Each output circuit has two connectors through which the output power is available for connection to telecommunications equipment. The output connectors are screw-down barrier terminal strips. Eight terminals with 6-32 screws are mounted in each of two barrier type terminal blocks per bus (one block for output and one block for return). The terminals are on 0.375 inch (9.525 mm) centers with a distance between barriers of 0.325 inch (8.26 mm). The terminals can accept #12 to #22 AWG copper wire with crimp-on spade lug or ring connectors, or wires with the insulation stripped back. The connectors or wires are inserted under the screws in the terminal strip, and the screws are tightened down. 1.6 Chassis Ground Connection Two #10 screws and nuts for grounding the circuit breaker panel chassis are mounted on 0.625 inch (15.875 mm) centers. This chassis ground connection can be used to attach a separate grounding conductor when mounting the circuit breaker panel in non-grounded or nonconducting material or when required by local practice. The screws can accommodate 2-hole lugs and up to #6 AWG wire. Two crimp ring lug terminals for use with two #10 AWG wires are provided with the circuit breaker panel. The circuit breaker panel can be properly grounded using only one screw. 1.7 Circuit Breakers The circuit breakers are magnetic actuation, manual reset, single pole, replaceable, 60 Vdc rated circuit breakers, with finger guard and ampere markings. Page 9 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 The circuit breaker panel will accommodate one to eight circuit breakers for each bus (up to eight circuit breakers installed on each side of the panel). Each circuit breaker position that does not have a circuit breaker installed will be filled with a black-colored blank plastic plate. Circuit breaker values of 1, 3, 5, 10, 15, and 20 Amperes capacity are available. The total current rating of all the installed circuit breakers cannot exceed 100 Amps per bus. Two types of circuit breakers are available. One type trips instantly and one type trips after a short delay. The trip times as a function of the percent of rated current are shown in Table 1. The circuit breaker will fail (trip) and the switch will move to the “OFF” position (bottom pushed in) when the circuit current exceeds the capacity of the circuit breaker. To reset the circuit breaker, push the switch to the “ON” position (top pushed in). Table 1. Circuit Breaker Trip Times TRIP TIME in seconds 1.8 DELAY 100% PERCENT OF RATED CURRENT 135% 150% 200% 400% 600% 800% 1000% 1200% Instant NO TRIP MAY TRIP .100 MAX .100 MAX .100 MAX .100 MAX .100 MAX .100 MAX .100 MAX Short NO TRIP .3007.00 .2005.00 .1002.00 .030.500 .008.300 .006.150 .005.100 .005.100 Power-On Indicator A green LED power-on indicator for each power bus is mounted on the front panel of the circuit breaker panel. If the LED indicator is on, power is applied to the bus input connectors. If the green LED indicator is off, power is not applied to the bus input connectors. The Power-On LED can easily be replaced in the field (see Subsection 7.4, Power-On LED Replacement). 1.9 Circuit Breaker Alarm Indicator For each bus, the circuit breaker panel has one visual circuit breaker alarm indicator (red LED) mounted on the front of the panel. The circuit breaker alarm indicator lights if any circuit breaker on the corresponding bus fails. The circuit breaker alarm indicator stays off if all circuit breakers on the corresponding bus are operational. Loss of power to either bus will cause the circuit breaker alarm indicator for the corresponding bus to be off. 1.10 Alarm Contact Closures Each bus contains circuitry that will provide contact closures when any circuit breaker on the bus fails or when input power to the bus is lost. These contact closures may be used as loop closures in alarm systems. The circuitry consists of circuit breaker failure alarm relays with Form C contacts that are terminated at a screw-down barrier terminal strip or a wire wrap pin block on the outside rear of the circuit breaker panel. During normal operation, the normally open (NO) contacts remain Page 10 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 open and the normally closed (NC) contacts remain closed. When a circuit breaker fails or power is lost, the NO contacts close creating a connection from NO to common (C), and the NC contacts open. The current for each circuit breaker failure alarm relay (set of three contacts) is 1.0 Amp maximum. 1.11 Alarm Contact Connection The fuse panel is available with either of two types of alarm contact connections. The two types of alarm contact connections are: • Screw-down barrier terminal strip: Six terminals with 3-48 screws are mounted in a barrier type terminal block (see Figure 2). The terminals are on 0.250 inch (6.350 mm) centers with a maximum distance between barriers (maximum connecting terminal width) of 0.200 inch (5.080 mm). The alarm terminal strip has two sets of three terminals labeled (NO, C, and NC), for use with two alarm systems. The terminals can also accept #16 to #30 AWG copper wire (with insulation stripped back). Wires are inserted in the terminal strip, and the screws are screwed down on the wires. • Wire wrap terminal block: Wire wrap pins are mounted in a terminal block for both buses The alarm terminal block has three sets of three wire wrap pins (NO, C, NC), for use with three alarm systems. The wire wrap pins can accept #22 to #26 AWG copper wire with insulation stripped back. 1.12 Circuit Breaker Designation Card and Holder A circuit breaker designation card as shown in Figure 4 and a card holder are provided with the circuit breaker panel. The card holder is intended to be attached to the underside of the panel, one of the panel mounting brackets, to a part of the rack in which the panel is installed, or at a location close to the panel, as desired. The card should be filled out with circuit information for each of the circuit breakers installed in the panel and inserted in the card holder. The card holder has a pressure sensitive adhesive backing for attachment. 1.60 IN. (4.06 CM) 2.36 IN. (5.99 CM) 16753-A 10 POSITION A AND B CARD Figure 4. Circuit Breaker Designation Card Page 11 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 1.13 Voltage Designation Label A voltage designation label as shown in Figure 5 is provided with the circuit breaker panel. The label is intended to be filled out with the actual voltage present on the buses and placed on the panel. The voltage designation label has a pressure sensitive adhesive backing for attachment. 0.38 IN. (0.96 CM) 14228-A 1.00 IN. (2.54 CM) Figure 5. Voltage Designation Label 1.14 Material and Finish The circuit breaker panel chassis and brackets are made of 16-gauge cold rolled steel. The panel and brackets are finished with powder paint. 1.15 Cooling The circuit breaker panel is well ventilated to allow efficient convection cooling of all components without the use of fans or blowers. Holes are provided in the top and bottom of the panel to allow heated air to escape from the panel and cool air to enter. 1.16 Protective Cover A thick plastic protective cover is mounted over the input power connectors, the output power connectors, the chassis ground terminals, and the external alarm contact connections. Access to these connectors and terminals is obtained by removing the cover. The cover is easily removed by loosening (but not removing) four screws that attach the cover to the chassis. The holes in the cover are keyed to allow it to be pulled to the side and then lifted clear of the screws. 1.17 Dimensions The dimensions of a typical circuit breaker panel are shown in Figure 6. Page 12 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 17.13 IN. (43.51 CM) 10.93 IN. (27.75 CM) 10.00 IN. (25.41 CM) 23.00 IN. (58.42 CM) 1.75 IN. (4.45 CM) 22.31 IN. (56.67 CM) 16762-B 1.13 IN. (2.86 CM) Figure 6. Dimensions of Circuit Breaker Panel (8/8-Position Panel with Mounting Brackets Attached for 23-Inch [58.42 cm] Rack Mounting Shown) 1.18 Weight The weight of the circuit breaker panel is approximately 10 pounds (4.54 kilograms). The actual weight is dependent upon the configuration of the panel. 1.19 Color The color of the circuit breaker panel and mounting brackets is putty white. 1.20 Mounting The circuit breaker panel can be mounted in a 19- or 23-inch rack (48.26 or 58.42 cm) using the mounting brackets shown in Figure 7. The panel can be flush mounted or recessed 1, 2, 3, or 4 inches (25.4, 50.8, 76.2, or 101.6 mm) from the front of the rack. The mounting holes are slotted to permit installation in racks with WECO 1.00-inch (2.54 cm) hole spacing or EIA 1.25-inch (3.18 cm) hole spacing. Page 13 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 The following mounting brackets and screws are enclosed with the circuit breaker panel: • Two brackets for 19-inch rack installations • Two brackets for 23-inch rack installations • Eight 5/16-inch (7.936 mm) long, 8-32 chromate finish, thread-forming, flathead screws for attaching the brackets to the circuit breaker panel • Four 3/8-inch (9.525 mm) long, 12-24 thread-forming screws and washers for attaching the brackets to the rack Caution: Use only the 5/16-inch (7.936 mm) long, chromate finish, flathead, thread forming screws for attaching the mounting brackets to the circuit breaker panel. Use of any other hardware could cause contact with internal parts of the panel. If parts are missing, please contact ADC. USE 5/16-INCH (7.936 MM) 8-32 THREAD-FORMING FLAT-HEAD SCREWS TO SECURE MOUNTING BRACKETS TO PANEL 19-INCH RACK MOUNTING BRACKET INSTALLATION 23-INCH RACK MOUNTING BRACKET INSTALLATION USE 3/8-INCH (9.525 MM) 12-24 THREAD-FORMING SCREWS AND WASHERS TO SECURE MOUNTING BRACKETS TO RACK 16965-A Figure 7. Mounting Brackets for Mounting Circuit Breaker Panel in 19- and 23-Inch (48.26 or 58.42 cm) Racks The slotted mounting hole pattern in the mounting brackets compensates for vertical rack differences and allows mounting the circuit breaker panel in either 1.75- or 2-inch (4.45 or 5.08 cm) rack spaces. Rack mounting instructions are contained in Section 4, Installation. 1.21 Environmental Characteristics Table 2 lists the environmental characteristics of the PowerWorx Select Series circuit breaker panel. Page 14 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 Table 2. PowerWorx Select Series Circuit Breaker Panel Environmental Characteristics PARAMETER DESCRIPTION Operating temperature –5° C to +50° C Storage temperature –45° C to +85° C Humidity range 0% to 95% humidity (non-condensing) Altitude range –197 ft. (0.06 km) to 13,000 ft. (3.96 km) above sea level Fire rating All components UL94-V1 Earthquake design NEBS Level 3, Zone 4 Acoustic noise 0 dBA above ambient Heat dissipation (fully loaded) 50 watts @ 100 Amps per bus, 100 watts @ 200 Amps total circuit breaker panel load Heat dissipation (no load) 2 1 watt per bus ACCESSORIES The following accessories for the PowerWorx Select Series circuit breaker panel are available: • Circuit breakers. Current capacity of 1, 3, 5, 10, 15, 20 Amps with choice of two delay values (instant and short). • Cable management bar with mounting screws. Provides cable tie points. Installed at rear of circuit breaker panel by fastening ends of bar to both sides of the panel • Three sizes of two-hole compression lugs for #2, #4, and #6 AWG wire for input power connection • Lug terminals to connect #10 AWG wire to earth ground • Circuit breaker designation card kit • Spare circuit breakers (contact ADC) 3 UNPACKING AND INSPECTION Unpack and inspect the various components as follows: 1. Inspect the exterior of the shipping container for evidence of handling that may have damaged the components in the container. 2. Unpack each container while carefully checking the contents for damage and verify with the packing slip. 3. File a claim with the commercial carrier and notify ADC Customer Service if damage is detected or if parts are missing. Save damaged cartons for inspection by the carrier. 4. Refer to Section 8, Customer Information and Assistance at the back of this manual, for repair, replacement, and warranty information. 5. Save all shipping containers for use if the equipment requires return shipment at a future date. Page 15 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 4 INSTALLATION Circuit Breaker panels must be installed in a central office, equipment room, or restricted access location. The following guidelines should be used when mounting the circuit breaker panel in a rack. • Mount the circuit breaker panel in the uppermost area of the rack to reduce exposure of the power wiring. • Provide a minimum of 1.75 inches (4.45 cm) of air space (one rack space) between the top of the circuit breaker panel and the next item in the rack for cooling. • Adding a circuit breaker panel to a rack may displace a device which may require relocation. Caution: This equipment employs electrical voltage and amperage levels which may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with this equipment when the circuit breaker panel is energized. Only insulated tools should be used on energized elements of the circuit breaker panel. Warning: Never install telephone equipment in a wet location or during a lightning storm. When installing or modifying telephone lines, disconnect lines at the network interface before working with uninsulated lines or terminals to prevent electrical shock. 4.1 Recommended Installation Tools Use common hand tools, such as a Phillips screwdriver, a wire wrap gun and bits, a wire stripper, and a wire lug crimper to install the circuit breaker panel. In addition to these tools, the following tools are recommended: • Power screwdriver with bits for Phillips and slotted head screws PHILLIPS SCREW HEAD BIT 16776-A Page 16 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 • Set of sockets and driver 12504-A • Set of open end or box end wrenches 12506-A • Torque screwdriver calibrated in pound-force inches or Newton meters and equipped with bits for Phillips and slotted head screws 4.2 Use of Screws in Accessories Package Caution: When installing the circuit breaker panel, use only the hardware supplied with the panel. Use of any other hardware could cause damage to the panel. If parts are missing, please contact ADC. The circuit breaker panel accessories kit contains three types of screws. The screws used with the rack-mounting brackets are thread-forming screws which will provide a solid ground path between the panel chassis and the rack. Use the power screwdriver to install these screws. 4.2.1 Screws to Attach Brackets to Circuit Breaker Panel To fasten the mounting brackets (ears) to the circuit breaker panel, use the 5/16-inch (7.936 mm) long, chromate finish 8-32 screws as shown in Figure 8 (4 for each bracket). Eight screws are in the package. THREAD FORMING SCREW, FLAT HEAD UNDERCUT, PHILLIPS DRIVE 5/16-IN. (7.936 mm) 8 - 32 THREAD 16977-A Figure 8. Screw for Attaching Bracket to Circuit Breaker Panel Page 17 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 4.2.2 Screws to Attach Brackets to Rack To fasten the brackets to the rack, use the nickel plated 12-24 screws as shown in Figure 9 (2 for each bracket). Four screws are in the package. PAINT CUTTING, TAPPING SCREW, PAN HEAD, COMBINATION DRIVE 3/8-IN. (9.53 mm) 12 - 24 THREAD 16592-A Figure 9. Screw for Attaching Bracket to Rack 4.2.3 Screws to Attach Protective Cover to Circuit Breaker Panel To fasten the plastic protective cover over the power connections, use the four tin plate finish screws as shown in Figure 10. Four screws are in the package. MACHINE SCREW, PAN HEAD, PHILLIPS DRIVE 3/8-IN. (9.53 mm) 6 - 32 THREAD 16593-B Figure 10. Screw for Attaching Protective Cover to Circuit Breaker Panel 4.3 Protective Cover To attach the plastic protective cover over the connectors on the rear of the circuit breaker panel, insert the four screws (defined in Subsection 4.2.3, Screws to Attach Protective Cover to Circuit Breaker Panel) into the standoffs located on each output power screw-down barrier strip. Rotate each screw approximately two turns to get it threaded. Hold the cover so the lettering is oriented properly and then place the cover over the screw heads. Slide the cover to the left and then tighten the screws to 9 pound-force inches (1 Newton meter). To remove the protective cover, loosen but do not remove the four screws that secure the cover to the panel. Slide the cover to the right and then pull the cover directly outward and away from the panel. The screws do not need to be completely removed to remove the protective cover. Page 18 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 4.4 Cable Management Bar (Optional Accessory for Circuit Breaker Panels) Before installing the circuit breaker panel in the rack, mount the cable management bar (accessory item, not supplied with panel) on the rear of the panel as shown in Figure 11, using the 0.25-inch (6.35 mm) long 4-40 screws that are supplied with the cable management bar. The cable management bar can be recess mounted by using the mounting holes closest to the front of the panel. Caution: When attaching the cable management bar to the circuit breaker panel, use only the hardware supplied with the cable management bar. Use of any other hardware could cause contact with internal parts of the circuit breaker panel. If parts are missing, please contact ADC. Note: A circuit breaker panel with the cable management bar attached may exceed the 12-inch (3.05 mm) overall depth objective described in GR-63 CORE, 02-14. MOUNTING BRACKET INSTALLED FOR 23-IN. (58.42 CM) RACK MOUNTING ATTACH TO EITHER SET OF 3 HOLES CABLE MANAGEMENT BAR 16759-B Figure 11. Cable Management Bar Installation 4.5 Rack Mounting The circuit breaker panel can be mounted in either a 19- or 23-inch (48.26 or 58.42 cm) wide rack using the 1.75-inch high (4.45 cm), 19- or 23-inch rack mounting brackets. The brackets, mounting screws, and washers are provided with the panel. Caution: When attaching the mounting brackets to the circuit breaker panel, use only the 5/16-inch (7.935 mm) long, chromate finish, flathead, thread forming screws supplied with the panel. Use of any other hardware could cause contact with internal parts of the circuit breaker panel. If parts are missing, please contact ADC. Install the circuit breaker panel in the rack as shown in Figure 12 and as follows: 1. Mount the brackets to the panel chassis using the eight 5/16-inch (7.936 mm) 8-32 flathead screws. 2. Secure the panel to the rack using the four 3/8-inch (9.525 mm) 12-24 screws and washers. Page 19 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 TO PROVIDE SUFFICENT AIR CIRCULATION FOR COOLING, ALLOW A MINIMUM OF 1.75 INCHES (4.45 CM) OF AIR SPACE BETWEEN THE CIRCUIT BREAKER PANEL AND THE NEXT ITEM IN THE RACK 16760-B Figure 12. Rear View of Typical Circuit Breaker Panel Installation in Equipment Rack (Panel with Protective Cover and Cable Management Bar Shown) 4.6 Wiring Connections Note: Before connecting the input and output power wires, measure the resistance as defined in Subsection 5.1, Resistance Test. Remove the protective cover from the rear of the circuit breaker panel by loosening the four screws that attach the cover, sliding the cover to the right, and pulling it over the screws, and away from the panel. Route and connect ground cables, power cables, and alarm cables to the panel connectors according to local practice and the following subparagraphs. An example of the connections to the circuit breaker panel is shown in Figure 13. After routing the cables, tie them to the cable management bar (if optional accessory ordered). Caution: Connect both buses of the circuit breaker panel to only –24 Vdc or –48 Vdc. Page 20 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 Caution: Connect only the input voltage wire (labeled BATTERY, BATT, NEGATIVE, NEG, or – and/or the voltage value) to the connector on the circuit breaker panel labeled BATT (battery). Connect only the input return wire (labeled RTN, RETURN, POSITIVE, POS, +, or BATTERY GROUND) to the connector on the circuit breaker panel labeled RTN (return). If the wires are reversed, voltage could be present on the circuit breaker panel chassis and current could flow through the unprotected return wiring in the circuit breaker panel. This condition causes damage to equipment in the frame in which the circuit breaker panel is installed and to equipment in adjacent frames! CONNECT OUTPUT POWER TERMINALS TO OUTPUT POWER CIRCUITS CONNECT REMOTE ALARM TERMINALS TO REMOTE ALARMS CONNECT TO BUS B BATTERY* OUTPUT POWER CONNECTORS CONNECT TO BUS B RETURN** OUTPUT RETURN CONNECTORS CONNECT OUTPUT POWER TERMINALS TO OUTPUT POWER CIRCUITS OUTPUT POWER CONNECTORS CONNECT INPUT CONNECTOR TO BUS A BATTERY* 16763-B LANCE FOR SECURING INPUT CABLES CONNECT OUTPUT RETURN TERMINALS TO OUTPUT RETURN CIRCUITS OUTPUT RETURN CONNECTORS CONNECT TO EQUIPMENT RACK LANCE FOR SECURING INPUT CABLES CONNECT INPUT CONNECTOR TO BUS A RETURN** CONNECT OUTPUT RETURN TERMINALS TO OUTPUT RETURN CIRCUITS *NOTE: CONNECT INPUT VOLTAGE WIRE LABELED "BATTERY," "BATT," "NEGATIVE," "NEG," OR "-" AND/OR THE VOLTAGE VALUE TO THE "BATT" CONNECTOR ("HOT" WIRE). **NOTE: CONNECT INPUT RETURN WIRE LABELED "RTN," "RETURN," "BATTERY GROUND," "POSITIVE," "POS," OR "BATTERY GROUND" TO THE "RTN" CONNECTOR. Figure 13. Rear View of Circuit Breaker Panel Cabling (Panel with Wire Wrap Alarm Connection Shown) Replace the protective cover on the circuit breaker panel after all the wiring connections are made and before power is applied to the panel. 4.7 Chassis Ground Connection Mounting the circuit breaker panel on a metal equipment rack using metal mounting brackets as described in Section 4.5, Rack Mounting, provides a sufficient return path to meet equipment grounding requirements. However, a separate grounding conductor is often required by local practice or local inspectors. A separate chassis grounding conductor is always needed when the circuit breaker panel is mounted to non-grounded or non-conducting material, e.g., a plastic rack or cabinet. When the panel requires separate chassis grounding, the chassis grounding conductor is sized to match the upstream protection device feeding the panel. This provides an adequate return path capable of allowing the circuit breaker to fail in the unlikely event of a battery wire to chassis fault. Page 21 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 Connect one or both of the chassis ground connectors (labeled “C. GND”) to the equipment rack ground (see Figure 14 and Figure 15), using the following chassis grounding recommendations: • Chassis grounding conductor connection point: #10 screws and nuts on 0.625 inch (15.875 mm) centers. Two #10 crimp ring terminals, for use with #10 AWG wires, are provided. • Chassis ground conductor: Use two #10 AWG wires if using both chassis ground connectors or one #6 AWG wire if using one chassis ground connector from connector(s) to equipment rack. • Torque the nuts to approximately 15 pound-force inches (1.7 Newton meters). CONNECT TO ALARMS USING #22 TO #26 AWG COPPER WIRE WITH INSULATION STRIPPED BACK. CONNECT TO CORRESPONDING ALARM CONNECTORS CONNECT TO AUDIO ALARMS CONNECT TO VISUAL ALARMS CONNECT TO REMOTE ALARMS GROUND SCREWS AND NUTS (CONNECT TO EQUIPMENT RACK) USE TWO #10 AWG WIRES IF USING BOTH CHASSIS GROUND CONNECTORS OR ONE #6 AWG WIRE IF USING ONLY ONE CHASSIS GROUND CONNECTOR. TWO #10 CRIMP RING TERMINALS FOR ATTACHING THE #10 WIRES TO THE CHASSIS CONNECTORS ARE PROVIDED WITH THE FUSE PANEL. MAXIMUM WIDTH OF CONNECTORS IS 0.625 INCH (15.875 MM). PLACE THE RING TERMINALS OVER THE CHASSIS SCREWS AND TIGHTEN THE NUTS DOWN ON THE TERMINALS TO APPROXIMATELY 15 POUND-FORCE INCHES (1.7 NEWTON METERS). CONNECT THE WIRE(S) TO THE EQUIPMENT RACK. 16764-B Figure 14. Chassis Ground Connection and Alarm Contact Connection (Wire Wrap Alarm Connection Shown) 4.8 External Alarm Contact Connectors Connect each set of external alarm contacts to a system alarm as desired: • Wire wrap terminal block (see Figure 14): Wrap terminal block pins using #22 to #26 AWG copper wire with insulation stripped back. • Screw-down barrier terminal strip (see Figure 15): Terminal screw size is 3-48. Use wire leads with crimp-on spade lug or ring connectors that have a maximum width of 0.200 inches (5.080 mm) on #16 to #30 AWG wire or use #16 to #30 AWG wire without lugs (insulation stripped back). Torque the nuts to approximately 9 pound-force inches (1 Newton-meter). Page 22 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 CONNECT TO ALARMS USING CRIMP-ON SPADE LUGS OR RING CONNECTORS THAT HAVE A MAXIMUM WIDTH OF 0.200 INCH (5.080 MM) ON #16 TO #30 AWG WIRE OR USING #16 TO #30 AWG COPPER WIRE WITHOUT LUGS WITH INSULATION STRIPPED BACK. TIGHTEN NUTS TO APPROXIMATELY 9 POUND-FORCE INCHES (1 NEWTON METER). CONNECT TO CORRESPONDING ALARM CONNECTORS CONNECT TO REMOTE ALARMS GROUND SCREWS AND NUTS (CONNECT TO EQUIPMENT RACK) CONNECT TO REMOTE ALARMS USE TWO #10 AWG WIRES IF USING BOTH CHASSIS GROUND CONNECTORS OR ONE #6 AWG WIRE IF USING ONLY ONE CHASSIS GROUND CONNECTOR. TWO #10 CRIMP RING TERMINALS FOR ATTACHING THE #10 WIRES TO THE CHASSIS CONNECTORS ARE PROVIDED WITH THE FUSE PANEL. MAXIMUM WIDTH OF CONNECTORS IS 0.625 INCH (15.875 MM). PLACE THE RING TERMINALS OVER THE CHASSIS SCREWS AND TIGHTEN THE NUTS DOWN ON THE TERMINALS TO APPROXIMATELY 15 POUND-FORCE INCHES (1.7 NEWTON METERS). CONNECT THE WIRE(S) TO THE EQUIPMENT RACK. 16765-A Figure 15. Chassis Ground Connection and Alarm Contact Connection (Screw-Down Barrier Terminal Strip Connection Shown) 4.9 Output Power Connectors Connect the output BATT and RTN terminals for each circuit breaker circuit on each set of terminal strips as follows (see Figure 16): • Use #12 to #22 AWG wire. Wire leads should be equipped with crimp-on spade lugs or ring connectors that have a maximum width of 0.325 inches (8.255 mm). • The terminals also accommodate copper wire without lugs (insulation stripped back). • Torque the screws to approximately 9 pound-force inches (1 Newton meter). Page 23 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 CONNECT USING CRIMP-ON SPADE LUGS OR RING CONNECTORS THAT HAVE A MAXIMUM WIDTH OF 0.325 IN. (8.255 MM) ON #12 TO #22 AWG WIRE OR USING #12 TO #22 AWG WIRE WITH INSULATION STRIPPED BACK. TORQUE THE SCREWS TO APPROXIMATELY 9 POUND-FORCE INCHES (1 NEWTON METER). CONNECT TO OUTPUT POWER CIRCUITS CONNECT TO OUTPUT RETURN CIRCUITS 16766-A Figure 16. Output Power Connection 4.10 Input Power Connectors Connect input power wires to the input power connectors labeled “BATT” and connect return wires to the return connectors labeled “RTN” for both buses in the circuit breaker panel as shown in Figure 17. Connect input power to the appropriate power sources in accordance with applicable local electrical codes and/or National Electrical Codes. Caution: Connect only the input voltage wire (labeled BATTERY, BATT, NEGATIVE, NEG, or – and/or the voltage value) to the connector on the circuit breaker panel labeled BATT (battery). Connect only the input return wire (labeled RTN, RETURN, POSITIVE, POS, +, or BATTERY GROUND) to the connector on the circuit breaker panel labeled RTN (return). Caution: Caution should be taken to not reverse input wires to the circuit breaker panel. In the circuit breaker panel, the internal battery (negative voltage) wiring is protected and the internal return wiring is not protected by circuit breakers or fuses. Use the included 2-hole lugs with #2 AWG copper wire (insulation stripped back) or optional 2hole lugs available as accessories (see Section 2, Accessories) with appropriate AWG copper wire. Tighten the nuts to approximately 16 pound-inches (1.8 Newton meters). Page 24 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 USE THE INCLUDED 2-HOLE LUGS WITH #6 AWG COPPER WIRE WITH INSULATION STRIPPED BACK OR USE APPROPRIATE OPTIONAL 2-HOLE LUGS AVAILABLE AS ACCESSORIES WITH APPROPRIATE SIZE AWG COPPER WIRE. TORQUE THE NUTS TO APPROXIMATELY 16 POUND-FORCE INCHES (1.8 NEWTON METERS). CONNECT INPUT VOLTAGE WIRE LABELED "BATTERY" OR "BATT," OR LABELED WITH THE VOLTAGE POLARITY AND/OR THE VOLTAGE VALUE ("HOT" WIRE) CONNECT INPUT RETURN WIRE LABELED "RTN," "RETURN," OR "BATTERY GROUND" CAUTION: CAUTION SHOULD BE TAKEN TO NOT REVERSE INPUT WIRES TO THE FUSE PANEL. IN THE FUSE PANEL, THE INTERNAL BATTERY (NEGATIVE VOLTAGE) WIRING IS FUSED, BUT THE INTERNAL RETURN WIRING IS NOT FUSED. 16761-A Figure 17. Input Power Connection 4.11 Circuit Breaker Designation Card Holder and Card Attach the circuit breaker designation card holder to the underside of the circuit breaker panel, to one of the panel mounting brackets, to part of the rack, or to a location close to the panel. Remove the backing from the back of the card holder and press the card holder against the mounting surface. Fill out one of the cards (see Figure 4) with circuit information as desired and insert it in the card holder. 4.12 Voltage Designation Label Write the voltage used in the circuit breaker panel on the voltage designation label (see Figure 5) and attach the label to the back of the panel. 5 TESTING Caution: This equipment employs electrical voltage and amperage levels which may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with the circuit breaker panel when it is energized. Only insulated tools should be used on energized elements of the panel. Each unit is thoroughly tested at the ADC factory. The following tests are recommended, however, to assure that no damage has occurred during shipping or handling. Both bus A and bus B input circuits need to be tested. The tests in Subsections 5.1, 5.2, and 5.24 must be performed without power applied (before input power and output power is connected) to the circuit breaker panel. Page 25 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 5.1 Resistance Test Caution: Before performing this test, verify that the input and output power is not connected to the circuit breaker panel connectors. Measure the resistance at each bus input with a multimeter connected to the BATT and RTN input terminals. A resistance of at least 500 ohms should be read on the meter (some meters will indicate a resistance of several Megohms because their input voltage is not high enough to break down the forward conductance of the diodes used in the alarm circuit). Any resistance higher than 500 ohms is acceptable. 5.2 Connection Polarity Test To verify that the input power wires are connected to the correct terminals, measure the voltage between the input return connector (RTN) and the chassis ground using a multimeter. The voltage should be less than 2.0 Vdc. If the voltage is more than 2.0 Vdc, reverse the input power wires and measure the voltage between the input return connector (RTN) and the chassis ground again to verify that the voltage is less than 2.0 Vdc. 5.3 Wiring Connection Torque Measurements Measure the torque of all input, output, and circuit breaker failure alarm relay contact connections referenced in the non-powered testing sections using a torque screwdriver that is calibrated in pound-force inches or Newton meters. 5.4 Power Indication Test After checking input resistance according to the Resistance Test above, the input power wires can be connected to the circuit breaker panel. Upon power application, the alarm indicators will not light unless there is a circuit breaker that has failed. The circuit breaker failure alarm relay should indicate an open circuit between the common (C) contact and the normally open (NO) contact at the alarm contacts. When input power is not applied, a short will be indicated between these contacts. 5.5 Circuit Breaker Alarm Test Operate a circuit breaker switch on each bus to the “OFF” position (bottom pushed in). The visual circuit breaker alarm indicator (LED) for the bus will change from unlighted to a red light, and the circuit breaker failure alarm relay will operate. Reset the circuit breakers. 6 OPERATION Caution: This equipment employs electrical voltage and amperage levels which may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with the circuit breaker panel when it is energized. Only insulated tools should be used on energized elements of the panel. Page 26 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 •September 2001 All circuit breaker panel circuits are operational as soon as power is applied to the input connectors. The alarm indicator should not light when power is applied. Operation of the circuit breaker panel consists of resetting circuit breakers when they trip. If a circuit breaker trips, the alarm LED indicator lights for the bus and the external and remote alarms are activated (if present). 7 MAINTENANCE Caution: This equipment employs electrical voltage and amperage levels which may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with the circuit breaker panel when it is energized. Only insulated tools should be used on energized elements of the panel. 7.1 Inspection Inspect the circuit breaker panel periodically (every six months is recommended) for damage to the circuit breakers, damaged or broken wires on the power outputs and the external alarm connections. Inspect for excessive dust and dirt that block the vents. 7.2 Cleaning If excessive dirt is found during the inspection, brush or wipe dust and dirt from the circuit breaker panel with a soft bristle brush or soft cloth. Care should be taken to not damage the circuit breakers or any wiring. 7.3 Adjustments No adjustments in the field are indicated or required. If a circuit is not operating properly, contact ADC customer assistance (see Section 8, Customer Information and Assistance). 7.4 Power-On LED Replacement The circuit breaker power-on indicator LEDs may be replaced as follows: 1. Pull the LED out slowly from the front of the circuit breaker panel. 2. Disconnect both tabs on the LED from the mating terminals (quick-connects or fastons) on the wires. 3. On the replacement LED, connect the tin tab to the mating terminal on the red wire, and connect the brass tab to the mating terminal on the black wire. 4. Push the LED back into the panel. Page 27 © 2001, ADC Telecommunications, Inc. ADCP-80-531 • Issue 1 • September 2001 8 CUSTOMER INFORMATION AND ASSISTANCE For customers wanting information on ADC products or help in using them, ADC offers the services listed below. To obtain any of these services by telephone, first dial the central ADC telephone number, then dial the extension provided below. The central number for calls originating in the U.S.A. or Canada is 1-800-366-3891. For calls originating outside the U.S.A. or Canada, dial country code “1” then dial 952-946-3000. Sales Assistance Extension 63000 • Quotation Proposals • Ordering and Delivery • General Product Information Systems Integration Extension 63000 • • • • • • • Complete Solutions (from Concept to Installation) Network Design and Integration Testing System Turn-Up and Testing Network Monitoring (Upstream or Downstream) Power Monitoring and Remote Surveillance Service/Maintenance Agreements Systems Operation BCG Technical Assistance Center Extension 63475 E-Mail: [email protected] • • • • • • Technical Information System/Network Configuration Product Specification and Application Training (Product-Specific) Installation and Operation Assistance Troubleshooting and Repair Product Return Department Extension 63748 E-Mail: [email protected] • ADC Return Authorization number and instructions must be obtained before returning products. Product information may also be obtained using the ADC web site at www.adc.com or by writing ADC Telecommunications, Inc., P.O. Box 1101, Minneapolis, MN 55440-1101, U.S.A. Contents herein are current as of the date of publication. ADC reserves the right to change the contents without prior notice. In no event shall ADC be liable for any damages resulting from loss of data, loss of use, or loss of profits and ADC further disclaims any and all liability for indirect, incidental, special, consequential or other similar damages. This disclaimer of liability applies to all products, publications and services during and after the warranty period. This publication may be verified at any time by contacting ADC’s Technical Assistance Center at 1-800-366-3891, extension 63475 (in U.S.A. or Canada) or 952-946-3475 (outside U.S.A. and Canada), or by e-mail to [email protected]. © 2001, ADC Telecommunications, Inc. All Rights Reserved Printed in U.S.A. Page 28