PowerWorx Power Distribution Products Select Series Circuit Breaker for ±24 or ±48 Vdc User Manual

Transcription

1 PowerWorx Power Distribution Products Select Series Circuit Breaker for ±24 or ±48 Vdc User Manual ADCP Issue 3 11/ A Circuit Breaker for ±24 or ±48 Vdc Rev C

2 Preface COPYRIGHT All Rights Reserved REVISION HISTORY ISSUE DATE REASON FOR CHANGE 1 6/2009 Original. 2 11/2009 Updated to add optional plastic cover for power terminals. Table 2 specifications were changed for output terminals (lug width and torque). 3 11/2010 Updated to clarify single-pole and dual-pole offerings on Page 7 and Page 9. TRADEMARK INFORMATION ADC is a registered trademark of ADC Telecommunications, Inc. PowerWorx is a registered trademark of ADC Telecommunications, Inc. DISCLAIMER OF LIABILITY 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 , extension (in U.S.A. or Canada) or (outside U.S.A. and Canada), or by to connectivity_tac@adc.com. ADC Telecommunications, Inc. P.O. Box 1101, Minneapolis, Minnesota In U.S.A. and Canada: Outside U.S.A. and Canada: (952) Fax: (952) Page ii

3 Preface TABLE OF CONTENTS Content Page About This Manual v Standards Certification v Admonishments v General Safety Precautions v 1 PRODUCT DESCRIPTION Product Functions and Features Circuit Breaker Panel Components Packaged Hardware Options Accessories Mounting Power Buses Circuit Breakers Input/Output Voltage Input Power Connections Output Power Connections Ground Connections Alarm Operation and Connections LED Indicators Cooling Specifications and Dimensions BEFORE STARTING INSTALLATION General Installation Recommendations Unpacking and Inspection Installation Tools Required Materials Required INSTALLATION Mounting Procedure Chassis Ground Connections External Alarm System Connections Output Power Connections Input Power Connections Protective Cover Installation/Removal Cable Management Bar Installation (Accessory Item) Circuit Designation Card and Voltage Label OPERATION Circuit Breaker Operation Connecting New Equipment MAINTENANCE Inspection Power LED Indicator Replacement Page iii

4 Preface TABLE OF CONTENTS Content Page 5.3 Circuit Breaker Replacement CUSTOMER INFORMATION AND ASSISTANCE A APPENDIX A: ALLOWABLE AMPACITIES OF INSULTATED CONDUCTORS Page iv

5 Preface ABOUT THIS MANUAL This manual describes the PowerWorx Select Series Circuit Breaker Power Distribution Panel, hereinafter called circuit breaker panel or panel, and its available options and accessories. Also provided is the information required to install, test, and operate the circuit breaker panel. The Select Series circuit breaker panel is used to supply dual bus dc power to the ±24 Vdc or ±48 Vdc powered equipment that is typically installed in a central office, multimedia headend, remote site, CEV, or other restricted access location requiring protected dc power. STANDARDS CERTIFICATION The Select Series circuit breaker panel complies with the applicable sections of the following standards: UL, NEC 2002, NEBS Level 3, IEC, and CE. 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 - Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. Warning: Disconnect or turn off the power before connecting the circuit breaker panel input or output wires. This may require turning off the system office battery input at the office distribution panel or turning-off the appropriate circuit breaker at the panel. Page v

6 Preface Caution: Using the wrong circuit breaker may cause damage to the protected equipment or the circuit breaker panel. When replacing a circuit breaker, make sure the replacement breaker is the same current rating as the one being replaced and is the correct rating as required by the protective equipment. Note: Call ADC Technical Assistance Center (TAC) when replacing circuit breakers. For contact information, refer to Section 6 on Page 28. Warning: Wet conditions increase the potential for receiving an electrical shock when installing or using electrically-powered equipment. To prevent electrical shock, never install or use electrical equipment in a wet location or during a lightning storm. Page vi

7 1 PRODUCT DESCRIPTION This section describes the functions and features provided by the PowerWorx Select Series circuit breaker panel and provides a table of product specifications. 1.1 Product Functions and Features The Select Series circuit breaker panel, shown on the cover of this manual, supplies dual-source dc power to the ±24 Vdc and ±48 Vdc powered equipment typically installed in a central office, multimedia headend, remote site, CEV, or other restricted access location. The panel provides the following basic functions and features: Self-configuring voltage (±24 Vdc or ±48 Vdc) capability to simplify installation and allow one panel to fit most dc voltage applications. Ampere ratings and ON/OFF designations clearly marked on each circuit breaker. Eight single pole circuit breaker mounting positions (two-pole breakers require two mounting positions) per bus. Two sets of mounting brackets to permit panel installation in a 19- or 23-inch, WECO or EIA, equipment rack. Mounting within one rack space (1.75 inches). Dual-bus power feeds with a maximum input rating of 100 Amps per bus. Warning: Use of one bus only on a dual bus panel will result in false alarms for the unused bus. Power is required on both buses on a dual bus panel for normal operation. Two-hole compression-lug style terminals for input power connections. Screw-down barrier terminal strips for output power connections. Screw-down or wire-wrap pin terminals (option) for alarm connections. A tripped breaker or loss of power initiates relay operation which opens one set of relay contacts (form C) and closes another set. The alarm contacts may be used to open or close a loop connected to an external alarm system. Two field-replaceable high-brilliance power indicators (green LED s) and two nonreplaceable high brilliance alarm indicators (red LED s). Two grounding studs to ensure reliable ground connectivity. Plastic protective covers mount over the input and output terminal connections to enhance safety. 1.2 Circuit Breaker Panel Components The panel consists of the components shown in Figure 1. Panel components are either mounted on or housed within a putty white powder-painted sheet metal enclosure. The circuit breakers, the power LED indicators, and the breaker alarm LED indicators are mounted on the front side of the enclosure. Unused circuit breaker mounting positions are covered with blanks. Replacement circuit breakers, lug terminals, a cable management bar, and other items are available separately as accessory items. Page 1

8 1 TO 8 CIRCUIT BREAKERS (BLANK PANEL IF NO CIRCUIT BREAKER) BUS A POWER-ON INDICATOR (GREEN LED) BUS A CIRCUIT BREAKER ALARM INDICATOR (RED LED) BUS B POWER-ON INDICATOR (GREEN LED) BUS B CIRCUIT BREAKER ALARM INDICATOR (RED LED) 1 TO 8 CIRCUIT BREAKERS (BLANK PANEL IF NO CIRCUIT BREAKER) FRONT VIEW DESIGNATION CARD AND CARD HOLDER BUS B INPUT POWER TERMINALS BUS B OUTPUT POWER TERMINALS ALARM TERMINALS CHASSIS GROUNDING STUDS BUS A OUTPUT POWER TERMINALS BUS A INPUT POWER TERMINALS REAR VIEW COVER FOR INPUT POWER TERMINALS COVERS FOR OUTPUT POWER TERMINALS OR COVER FOR INPUT POWER TERMINALS B PLASTIC GUARD Figure 1. Select Series Circuit Breaker Panel (Typical) Page 2

9 The input power terminals, output power terminals, alarm terminals, and grounding studs are mounted on the rear side of the panel enclosure. The plastic protective covers install over the input and output power terminals. The covers prevent accidental contact with the terminals when power is applied to the panel. The internal bus wiring and alarm relay circuit boards are mounted within the enclosure and are not user accessible. 1.3 Packaged Hardware Figure 2 shows hardware components packaged separately and shipped with the basic panel. REAR COVERS FOR OUTPUT POWER/ALARM TERMINAL BLOCK OR REAR COVERS FOR INPUT POWER TERMINAL BLOCK PLASTIC GUARD 2-HOLE LUGS FOR 2 AWG WIRE #10 RING TERMINALS FOR AWG WIRE 5/16-INCH (7.936 MM) 8-32 FLAT-HEAD SCREWS VOLTAGE LABEL ORIENTATION FOR 19-INCH RACK INSTALLATION 3/8-INCH (9.525 MM) SCREWS AND #12 WASHERS ORIENTATION FOR 23-INCH RACK INSTALLATION DESIGNATION CARD AND CARD HOLDER UNIVERSAL MOUNTING BRACKETS AND SCREWS B Figure 2. Packaged Hardware Components Page 3

10 These components include the following items: One set of 19-inch mounting brackets One set of 23-inch mounting brackets 5/16-inch long, Phillips drive, 8-32 flat-head thread-forming screws - Used to secure the mounting brackets to the panel. 3/8-inch long, combination drive, pan-head screws (4) and #12 flat washers (4) - Used to secure the panel mounting brackets to the equipment rack. 2-hole lugs (4) for #2 AWG wire - Used to attach the BATTERY and RETURN cables to the power input terminals. Also available as an accessory item. #10 ring terminals (2) for AWG wire - Used to connect the grounding cables to the grounding studs. Note: Use local practice for any higher level grounding requirement. Use compression lugs across both studs if required for the designated level. Rear protective input terminal covers (2) and output terminal covers (4) or large plastic cover (1) - Used to prevent accidental contact with the power input and output terminals. Voltage label - Used to indicate the voltage of the panel (±24 or ±48 Vdc). Designation cards (2) and card holder - Used to record information about the protected equipment. The card holder has a pressure sensitive adhesive backing to permit attachment to the panel, the rack, or a location close to the panel. The card inserts into the card holder. Two types of cards are provided. Also available as an accessory item. 1.4 Options The following ordering options are available for the Select Series circuit breaker panel: Circuit breaker configurations - Circuit breakers may be specified in any combination of values as long as the total current draw on each bus does not exceed 100 Amps. A maximum of eight 1-pole breakers or four 2-pole breaker may be installed per bus. Circuit breaker ratings - Both 1-pole and 2-pole circuit breakers are used with the panel. The 1-pole breakers are available with 1, 3, 5, 10, 15, 20, or 22 Amp ratings. The 2-pole breakers are available with 25, 26, 30, 36, 40, and 50 Amp ratings. Alarm contact connections - Either screw-down terminals or wire-wrap pin terminals may be specified for the alarm contact connections. 1.5 Accessories The following accessories are available for the Select Series circuit breaker panel: Replacement circuit breakers - 1-pole breakers with a rating of 1, 3, 5, 10, 15, 20, and 22 Amps and 2-pole breakers with a rating of 25, 26, 30, 36, 40, and 50 Amps are available. Please call ADC Technical Assistance Center when replacing circuit brokers. For contact information, refer to Section 6 on Page 28. Page 4

11 2-hole compression lugs - Used to attach the BATT and RTN cables to the power input terminals. Available to fit 2, 4, 6, or 14 AWG wire. Cable management bar - Use to secure the output power wires at the rear of the panel. Designation cards (2) and card holder - Used to record information about the protected equipment. The card holder has a pressure sensitive adhesive backing to permit attachment to the panel, the rack, or a location close to the panel. The cards insert into the card holder. Two types of cards are provided. 1.6 Mounting The Select Series circuit breaker panel can be mounted in either a 19- or 23-inch (482.6 or mm) equipment rack. Two sets of mounting brackets, one set for 19-inch racks and one set for 23-inch racks, are provided with the panel. The panel can be flush mounted or recessed 1, 2, 3, or 4 inches (25.4, 50.8, 76.2 or 91.6 mm). The mounting brackets are slotted to allow the panel to be mounted in racks with WECO 1.0- inch (25.4 mm) or EIA 1.25-inch (31.8 mm) hole spacing. The slots also compensate for vertical rack differences so that the panel can be mounted in either or 2-inch (44.5 or 50.8 mm) rack spaces. The panel requires one open rack space above and below the chassis for heat dissipation. 1.7 Power Buses The Select Series circuit breaker panel has two isolated power bus (power feed) circuits which are designated as the A and B power buses. Each power bus circuit distributes the input power to the corresponding A or B output power circuit. In each bus circuit, current flows from the input power terminals, through the circuit breakers, to the output power terminals. Warning: Use of one bus only on a dual bus panel will result in false alarms for the unused bus. Power is required on both buses on a dual bus panel for normal operation. The maximum current capacity of each power bus circuit is 100 Amps. The total output current capacity of the circuit breakers on each bus must not exceed 100 Amps. The maximum current rating is marked on the circuit breaker panel rear side. The power dissipation of the panel is 160 watts maximum per panel (80 watts per bus). 1.8 Circuit Breakers The circuit breakers are magnetic actuation, manual reset, replaceable, 60 Vdc rated circuit breakers, with finger guard and ampere markings. Both 1- pole and 2-pole breakers are used with the panel. The 1-pole breakers are available with 1, 3, 5, 10, 15, 20, and 22 Amp ratings. The 2-pole breakers are available with 25, 26, 30, 36, 40, and 50 Amp ratings. Page 5

12 Note: All circuit breakers, even those not connected to a load, must be placed in the ON position in order to make the BREAKER ALARM indicators go out and to return the alarm contacts to the normal state. The circuit breaker panel will accommodate from one to eight 1-pole circuit breakers per bus or from one to four 2-pole circuit breakers per bus. Both 1-pole and 2-pole breakers may be combined together on the same bus. Each circuit breaker position that does not have a breaker installed will be filled with a black plastic plate. Any circuit breaker mounting positions that are left blank when the panel is ordered cannot be fitted with field-installed circuit breakers. Note: Both power buses must have the same configuration of circuit breakers (same Amp ratings in same order). The circuit breakers are of the type called short delay. The trip times of short delay circuit breakers are a function of the percent of rated current, as indicated in Table 1. The circuit breaker will trip (open) 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 a circuit breaker, push the switch to the on position (top pushed in). Table 1. Circuit Breaker Trip Times TRIP TIME in seconds PERCENT OF RATED CURRENT DELAY 100% 135% 150% 200% 400% 600% 800% 1000% 1200% Instant NO MAY TRIP TRIP MAX MAX MAX MAX MAX MAX MAX Short NO TRIP Circuit breakers are field-replaceable. Please contact ADC Technical Support if replacement is required (refer to Section 6, Customer Information and Assistance, on page 28). 1.9 Input/Output Voltage The Select Series circuit breaker panel accepts an input voltage of either ±24 Vdc (nominal) on both buses or ±48 Vdc (nominal) on both buses. For 24 Vdc operation, the voltage can fall within 21 to 30 Vdc. For 48 Vdc operation, the voltage can fall within a range of 42 to 56 Vdc. The output voltage is the same value as the applied input voltage Input Power Connections Input power is supplied to the Select Series circuit breaker panel through the A and B input power terminal blocks. Each input terminal block includes two pairs of studs that are used for connecting the BATT (battery) and RTN (return) input power cables. Each pair of studs is mounted on inch centers and accepts various size 2-hole compression lugs. Compression lugs for 2, 4, 6, and 14 AWG wire are available as accessory items. Nuts with captive washers are included to secure the compression lugs to the studs. The input terminal blocks are located on the rear side of the panel. Page 6

13 Warning: Use of one bus only on a dual bus panel will result in false alarms for the unused bus. Power is required on both buses on a dual bus panel for normal operation. In selecting wire size, consider the allowable ampacity as determined by local practice and electrical code (see Appendix A: Allowable Ampacities of Insulated Conductors on Page 29) Output Power Connections Output power is supplied to the protected equipment through the A and B output power terminal blocks. Screw-down barrier terminal strips are used for the output power terminal blocks. Each terminal block consists of eight pairs of screw down terminals. Each pair of terminals is used for connecting the battery (BATT) and return (RTN) output power wiring to the protected equipment. Each output terminal will accept a ring/spade crimp lug terminal with a maximum width of inches onto a number 6/32 screw for all single pole only circuit breaker output terminations or inches onto a number 8/32 screw for dual pole or a combination of single and dual poles circuit breaker terminations. A special order single pole only panel is available that accepts a ring/spade crimp lug terminal with a maximum width of inches onto a number 8/32 screw. Note: This panel is pre-wired in the factory. Each circuit breaker (whether single pole or dual pole) and each blank insert, going from left to right on the front of the panel, maps to just one output position, going from left to right on the rear of the panel. For example, if there is a blank insert in circuit breaker position 2 and a dual pole circuit breaker in positions 3 and 4 on the front of the panel, the respective power outputs are at positions 2 and 3 on the rear of the panel. A blank insert, however, is not wired to its output position; it merely claims the position spatially. For an illustration, see Figure 8 on Page Ground Connections Two #10 studs (with nuts and captive washers) are provided on the rear side of the circuit breaker panel for grounding the chassis. The ground connection is used to attach grounding cables to the chassis. Two 10 AWG copper wires are recommended for the grounding cables. Two #10 ring terminals for use with 10 AWG wire are provided for connecting the grounding cables to the grounding studs. Note: Use local practice for any higher level grounding requirement. Use compression lugs across both studs if required for the designated level Alarm Operation and Connections The Select Series circuit breaker panel contains circuitry that opens and closes a set of form C relay alarm contacts when a circuit breaker trips or when power to either power bus is lost. These contacts may be used to open or close a loop connected to an external alarm system. Note: All circuit breakers, even those not connected to a load, must be placed in the ON position in order to make the BREAKER ALARM indicators go out and to return the alarm contacts to the normal state. Page 7

14 During normal operation (power applied), the normally open (NO) contacts remain open and the normally closed (NC) contacts remain closed. When a circuit breaker trips or when power to a power bus is lost, the NO contacts close creating a connection between NO and common (C) terminals; and the NC contacts open creating an open circuit between NC and C terminals. The rating for the alarm relay contacts is 110 Vdc/125 Vac maximum voltage, 1.0 Amp maximum switching current. Both screw-down terminals and wire-wrap pin terminals are available (option) for the alarm terminal connections. Two sets of alarm contact connections are provided when the panel is equipped with screw down terminals and three sets of contact connections are provided when the panel is equipped with wire-wrap pins. The alarm terminals are labeled ALARM and are located on the rear side of the panel. The screw-down terminal connections consist of six 3-48 screw terminals mounted in a barrier type terminal block. The screw terminals are mounted on inch (6.350 mm) centers with a maximum distance between barriers of 0.20 inch (5.08 mm). Two sets of three terminals (labeled NO, C, and NC) are provided for connection with external alarm systems. The screwdown terminals will accept #16 to #30 AWG copper wire. For an illustration, refer to Figure 7 on Page 15. The wire wrap pin terminal connections consist of nine wire-wrap pins mounted in a terminal block. Three sets of three wire wrap pins (NO, C, and NC) are provided for connection with external alarm systems. The wire wrap pins will accept #22 to #26 AWG copper wire. For an illustration, refer to Figure 7 on Page LED Indicators Two power indicators (green LED) are provided on the front side of the panel. A separate power indicator is provided for each of the two power output buses (A and B). The power indicators stay on as long as power is supplied to the corresponding power bus. The power indicators turn off when power is turned off to the corresponding power bus. Two breaker alarm indicators (red LED) are provided on the front side of the panel. A separate breaker alarm indicator is provided for each of the two power output buses (A and B). The indicator turns on if any circuit breaker on the corresponding power bus trips. The indicator turns off when the tripped breaker is placed in the on position. Breaker alarm indicators cannot be field-replaced Cooling The Select Series circuit breaker panel relies on convection air flow for cooling. Holes are provided on the top and bottom of the panel to allow heated air to escape from the panel and cool air to enter. At least one rack unit of space must be provided above and below the panel to allow for air circulation Specifications and Dimensions The specifications for the Select Series circuit breaker panel are listed in Table 2. Page 8

15 Table 2. Circuit Breaker Panel Specifications PARAMETER SPECIFICATION REMARKS Physical Weight Dimensions (HxWxD) Color 10 lbs. (4.54 kg) 1.73 x x inches (43.9 x 435 x 282 mm) Putty white See Figure 3 Rack mounting 19- or 23-inch EIA or WECO hole spacing Electrical Operating voltages Input current Breaker type Breaker mounting positions Maximum breaker size ±24 Vdc ±48 Vdc 100 Amps per bus maximum Magnetic actuation, manual reset, replaceable Eight 1-pole per bus (16 total) or Four 2-pole per bus (8 total 50 Amps 21 to 30 Vdc tolerance 42 to 56 Vdc tolerance 1- pole or 2-pole Or any combination of 1- and 2-pole breakers Input terminal type 2-hole compression lug inch between centers. Torque 42 pound-force inches Output terminals Dual pole breaker Screw down terminal (8-32) Max lug width inches Accepts wire without lug #8 to #16 AWG Torque 15 pound-force inches Single pole breaker Screw down terminal (6-32) Max lug width inches Accepts wire without lug #12 to #22 AWG Torque 9 pound-force inches (Note: A special order single pole only panel is available that accepts a ring/spade crimp lug terminal with a maximum width of inches onto a number 8/32 screw.) Combination single/dual pole breaker Screw down terminal (8-32) Max lug width inches Accepts wire without lug #8 to #16 AWG Torque 15 pound-force inches Alarm terminals Screw down terminal (3-48) Max. lug width 0.20 inches Alarm contact voltage Alarm contact current Wire wrap 110 Vac, 125 Vdc maximum 1 Amp maximum #22 to #26 AWG Grounding connections Two #10 studs #10 ring terminals Environmental Operating temperature Storage temperature 5º C to +55º C 45º C to +85º C Humidity range 0% to 95% humidity No condensation Page 9

16 Altitude range Fire rating Acoustic noise Up to 13,000 ft. (3.96 km) All components UL94-V1 or better 0 dba above ambient Heat dissipation (fully loaded) 160 watts max. at 200 Amps 80 watts per bus Torque Table 2. Circuit Breaker Panel Specifications, continued PARAMETER SPECIFICATION REMARKS Mounting bracket chassis screws 15 pound force-inches 1.7 Newton meters Mounting bracket rack screws 27 pound force-inches 3.1 Newton meters Input power terminal nuts 42 pound force-inches 4.8 Newton meters Output power terminal screws 15 pound force-inches 1.7 Newton meters Alarm terminal screws 8 pound force-inches 0.9 Newton meters Grounding stud nuts 23 pound force-inches 2.6 Newton meters INCHES (282 MM) INCHES (254 MM) INCHES (584.2 MM) INCHES (435 MM) 22.3 INCHES (567.7 MM) INCHES (28.6 MM) 1.73 INCHES (43.9 MM) A Figure 3. Dimensions of Select Series Circuit Breaker Panel Page 10

17 2 BEFORE STARTING INSTALLATION This section provides general installation recommendations, unpacking and inspection procedures, and lists the tools and material required for panel installation. 2.1 General Installation Recommendations The Select Series circuit breaker panel must be installed in a central office, equipment room, CEV or other restricted access location. Mount the panel in the uppermost area of the rack to reduce the exposure of the power wiring. Route ground, power, and alarm cables to the panel according to local practice and procedures. After routing the cables, secure them to the equipment rack or to any cable management devices that are in use. Follow the instructions provided in this manual when connecting the cables to the panel. Install the protective covers on the rear side of the panel after all the wiring connections are made and all tests are completed. Do not apply power to the panel until all wiring is completed. Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. Warning: Wet conditions increase the potential for receiving an electrical shock when installing or using electrically-powered equipment. To prevent electrical shock, never install or use electrical equipment in a wet location or during a lightning storm. 2.2 Unpacking and Inspection Before starting the installation, always open the shipping boxes and verify that all parts have been received and that no shipping damage has occurred. Use the following procedure to unpack and inspect the circuit breaker panel: 1. Open the shipping carton and carefully unpack the circuit breaker panel from the protective packing material. 2. Check the panel for broken or missing parts. If there are any damages, contact ADC (see Section 6, Customer Information and Assistance, at the end of this manual) for an RMA (Return Material Authorization) and to reorder if replacement is required. 2.3 Installation Tools Required The following tools are required to install the circuit breaker panel: Phillips screwdrivers (#1 and #2) Torque screwdriver calibrated in pound-force inches or Newton meters Torque wrench calibrated in pound-force inches or Newton meters 3/8-inch and 7/16-inch sockets (for torque wrench) Wire cutter Wire stripper Page 11

18 Compression lug crimper Multimeter Heat gun 2.4 Materials Required The following materials are required to install the circuit breaker panel: Note: In selecting wire size, consider the allowable ampacity as determined by local practice and electrical code (refer to Appendix A: Allowable Ampacities of Insulated Conductors on Page 29). #2 AWG insulated copper wire for input power wires #10 AWG copper wire for ground connections #8 16 AWG insulated copper wire for the output power wires (use black for the RTN wire and red for the BATT wire) #22 26 AWG insulated copper wire for the wire-wrap pin terminal alarm wires or #16 30 AWG insulated copper wire for the screw-down terminal alarm wires. Heat-shrink tubing 3 INSTALLATION This section provides the installation procedures for the Select Series circuit breaker panel. 3.1 Mounting Procedure The circuit breaker panel can be mounted in either a 19- or 23-inch wide rack. Two sets of mounting brackets are provided with the panel. Eight 5/16-inch (7.94 mm) long, threadforming, Phillips-drive, 8-32 flat-head screws are provided for attaching the mounting brackets to the panel. Four 3/8-inch (9.53 mm) long, Phillips-drive, pan-head screws and four #12 flat washers are provided for attaching the mounting brackets to the equipment rack. Caution: When attaching the mounting brackets to the circuit breaker panel, use only the 5/16- inch (7.94 mm) long, thread forming, flathead screws provided with the panel. Use of any other hardware could cause contact with internal parts of the panel. If parts are missing, contact ADC to order replacement parts. Use the following procedure to install the circuit breaker panel in the equipment rack: 1. Select the 19- or 23-inch mounting brackets (whichever set is required) and orient for installation as shown in Figure Attach the brackets to the sides of the circuit breaker panel chassis using the eight 5/16- inch (7.94 mm) 8-32 flathead thread-forming screws provided. Tighten screws to 15 pound force-inches (1.7 Newton meters) of torque to insure grounding. 3. Place the panel in the specified mounting space within the rack as shown in Figure 5. Page 12

19 Note: Provide one rack unit of space above and below the panel for air circulation. 4. Secure the panel to the rack using the four 3/8-inch (9.525 mm) long pan-head screws and #12 flat washers provided (use star washers when required by local practice). Tighten the screws to 27 pound-force inches (3.1 Newton meters) of torque. 19-INCH RACK MOUNTING BRACKETS TIGHTEN MOUNTING SCREWS TO 15 POUND-FORCE INCHES (1.7 NEWTON METERS) OF TORQUE 5/16-INCH (7.94 MM) 8-32 FLAT-HEAD THREAD-FORMING SCREWS 23-INCH RACK MOUNTING BRACKETS A Figure 4. Circuit Breaker Panel Mounting Bracket Installation TIGHTEN MOUNTING SCREWS TO 27 POUND-FORCE INCHES (3.1 NEWTON METERS) OF TORQUE DETAIL DRAWING OF MOUNTING SCREWS AND WASHERS USE #12 STAR WASHERS INSTEAD OF FLAT WASHERS IF REQUIRED BY LOCAL PRACTICE A Figure 5. Typical Circuit Breaker Panel Installation in Equipment Rack Page 13

20 3.2 Chassis Ground Connections Use the following procedure to connect the panel to an approved office ground source using the #10 ring terminals provided: Note: Use local practice for any higher level grounding requirement. Use compression lugs across both studs if required for the designated level. 1. Obtain two lengths of #10 AWG wire for use as the chassis grounding wires. 2. Terminate one end of each wire with the #10 ring terminals provided (requires crimper). 3. Locate the C GND (chassis ground) studs at the rear of the panel as shown in Figure Connect the ring terminal end of each wire to one of the studs and secure using the nuts with captive star washers provided (requires 3/8-inch socket). Tighten each stud nut to 23 pound-force inches (2.6 Newton meters) of torque. DETAIL DRAWING OF GROUNDING WIRE CONNECTION B TIGHTEN STUD NUT TO 23 POUND-FORCE INCHES (2.6 NEWTON METERS) OF TORQUE Figure 6. Chassis Ground Connections 5. Route the free end of each chassis grounding wire to an approved office ground source. 6. Cut each chassis grounding wire to length and connect it to the office ground source as required by local code or practice. Page 14

21 3.3 External Alarm System Connections Normally open (NO) and normally closed (NC) alarm contacts are provided for connecting the circuit breaker panel to an external alarm system. Alarm connections are provided through either screw-down terminals or wire-wrap pins (option) located on the rear side of the panel as shown in Figure 7. One set of terminals, labeled ALARM, is provided for reporting either a power failure or tripped circuit breaker alarm A WIRE-WRAP PIN CONNECTIONS FOR AUDIO, VISUAL, AND REMOTE ALARMS SCREW-DOWN TERMINAL CONNECTIONS FOR REMOTE ALARMS TIGHTEN TO 8 POUND-FORCE INCHES (0.9 NEWTON METERS) OF TORQUE WIRE-WRAP PIN ALARM CONNECTIONS SCREW-DOWN TERMINAL ALARM CONNECTIONS Figure 7. Alarm Contact Connections The screw-down type terminal strip can accept #16 to #30 AWG copper wire. Screw-down terminal alarm wires may be terminated with spade/ring crimp lugs (maximum width 0.20 inches/5.08 mm) or the wire insulation may be stripped back from the wire end and the bare wire looped under the screw head. Use a torque screw driver to tighten the terminal screws to 8 pound-force inches (0.9 Newton meters). The wire-wrap terminal strip can accept #22 to #26 AWG solid copper wire. Strip back the insulation approximately 1.5 inches (38.1 mm) before inserting the wire into the wire-wrap tool. Page 15

22 3.4 Output Power Connections Output power is supplied to the protected equipment through the output power terminal blocks. Each terminal block consists of eight pairs of screw-down terminals. The screw-down terminals are used for connecting the BATT (battery) and RTN (return) output power wiring to the protected equipment. The output power wires may be terminated with spade/ring crimp lugs or the insulation may be stripped back and the bare wire looped under the screw head. The panel has two output power terminal blocks, one for power bus A and one for power bus B. Each terminal block has terminals numbered1-8 from left to right. For torque specifications, see Table 2 on Page 9. Note: This panel is pre-wired in the factory. Each circuit breaker (whether single pole or dual pole) and each blank insert, going from left to right on the front of the panel, is assigned to just one output position, going from left to right, on the rear of the panel. Blank inserts are not wired to the output; they merely claim one output position. Figure 8 shows a wiring example. The single pole circuit breaker in position 1 on the front of the panel maps to output 2 on the rear of the panel. The blank insert in position 2 on the front of the panel maps to output 2 on the rear of the panel (dashed line indicates this mapping is not wired). The dual pole circuit breaker in positions 3 and 4 on the front of the panel maps to output 3 on the rear of the panel. The dual pole circuit breaker in positions 5 and 6 on the front of the panel maps to output 4 on the rear of the panel. And so on. In the example shown, outputs 7 and 8 are not used. FRONT BREAKERS (BUS A) POLE BLANK 2 POLE 2 POLE BLANK 1 POLE REAR OUTPUT TERMINALS (BUS A) A Figure 8. Hard-Wiring Pattern of Output Terminals Page 16

23 Note: In selecting wire size, consider the allowable ampacity as determined by local practice and electrical code (refer to Appendix A: Allowable Ampacities of Insulated Conductors on Page 29). Note: When a panel is preconfigured such that some of the output terminals are not used, the extra screw terminals are not connected to the bus and cannot be used. Caution: Connecting the protected equipment to the wrong circuit may cause damage to the equipment or the circuit breaker panel. Make sure the circuit breaker is the correct type and has the correct current rating as specified by the protected equipment manufacturer. Note: The continuous output load of the equipment during normal operation should not exceed 80% of the rated value of the circuit breaker. This allows some room for manufacturing tolerances and voltage fluctuations in the plant power mains. Note: Both power buses must have the same configuration of circuit breakers (same Amp ratings in same order). Connect each pair of output wires to the panel as shown in Figure 9. Use a torque screwdriver to tighten the terminal screws. For torque specifications, see Table 2 on Page 9. POWER FEED TERMINALS DETAIL DRAWING OF OUTPUT TERMINAL BLOCK CONNECTIONS POWER RETURN TERMINALS TIGHTEN TERMINAL SCREWS TO 15 POUND-FORCE INCHES (1.7 NEWTON METERS) OF TORQUE A POWER BUS B OUTPUT TERMINALS POWER BUS A OUTPUT TERMINALS Figure 9. Output Power Connections Page 17

24 3.5 Input Power Connections Input power is supplied to the circuit breaker panel through the A and B input terminal blocks. Each input terminal block consists of two pairs of studs that are used for connecting the BATT (battery) and RTN (return) input power cables. Each set of studs accepts various size 2-hole compression lugs. Nuts (with captive locking washers) are provided to secure the compression lugs to the studs. Caution: Connect only the input voltage wire [the wire labeled BATTERY or BATT, or labeled with the voltage value to the connector on the circuit breaker panel labeled BATTERY. Connect only the input return wire [the wire labeled RTN, RETURN, or BATTERY RETURN) to the connector on the circuit breaker panel labeled RETURN. Caution: Caution should be taken to not reverse the input wires to the circuit breaker panel. Within the panel, the internal return wiring is not protected by circuit breakers. If the wires are reversed, current will flow through the unprotected return wiring in the panel to the equipment. This condition can cause damage to the equipment in the frame in which the panel is installed and to equipment in adjacent frames Warning: Use of one bus only on a dual bus panel will result in false alarms for the unused bus. Power is required on both buses on a dual bus panel for normal operation. Use the following procedure to connect the input power cables to the circuit breaker panel: 1. Obtain four lengths of wire for use as the input power cables. 2. Strip back 7/8 inches of insulation from one end of each wire as shown in Figure HOLE LUG TERMINAL HEAT SHRINK TUBING (2-INCH LENGTH) #2 AWG COPPER WIRE STRIP BACK 7/8 INCH OF INSULATION A Figure Hole Lug Terminal Installation 3. Slide a 2-inch length of heat shrink insulation over the end of each wire. 4. Terminate one end of each wire with the 2-hole lug terminals provided (requires crimper). Page 18

25 5. Slide the heat shrink insulation down to the lug terminal so the barrel end of the terminal is covered. 6. Use a heat gun to apply heat to the heat shrink insulation until it tightens around the wire and barrel end of the terminal. 7. Use the nuts (with captive locking washers) and flat washers provided to secure the input power wires to the specified terminals and as shown in Figure 11: BATT wires: Connect to BATT terminals on A and B input power terminal blocks. RTN wires: Connect to RTN terminals on A and B input power terminal blocks. 8. Use a torque wrench (with a 7/16-inch socket) to tighten the input power terminal block nuts to 42 pound-force inches (4.8 Newton meters) of torque. 9. Route the free end of each input power cable to the office battery and return sources. 10. Connect the input power cables to the office battery power source in accordance with applicable local electrical codes and/or National Electrical Codes A TIGHTEN INPUT TERMINAL NUTS TO 32 POUND FORCE INCHES (3.6 NEWTON METERS) OF TORQUE DETAIL DRAWING OF INPUT POWER CABLE CONNECTIONS Figure 11. Input Power Connections Page 19

26 3.6 Protective Cover Installation/Removal Install the rear protective covers, shown in Figure 12, when all the wiring and tests are completed. Both the input and output terminal covers snap into place over the terminals. If the protective covers are lost or damaged, contact ADC for replacement (refer to Section 6, Customer Information and Assistance) B COVER FOR INPUT POWER TERMINALS COVERS FOR OUTPUT POWER TERMINALS OR PLASTIC GUARD COVER FOR INPUT POWER TERMINALS Figure 12. Protective Cover Installation/Removal To provide access to the input and output power terminals, it may sometimes be necessary to remove the protective rear covers. To remove a cover, pull outward on the cover until it comes free of the terminal block. 3.7 Cable Management Bar Installation (Accessory Item) The cable management bar is an accessory item that may be attached to the rear side of the circuit breaker panel as shown in Figure 13. Align the cable management bar with the holes on the sides of the chassis. The bar can be recess mounted by using the holes that are closest to the front of the panel. Use the six 1/4-inch (6.35 mm) long 4-40 thread-forming screws provided to secure the cable management bar to the sides of the circuit breaker panel chassis. Caution: When attaching the cable management bar to the circuit breaker panel, use only the 1/ 4-inch (6.35 mm) long, 4-40 thread-forming screws provided with the panel. Use of any other hardware could cause contact with internal parts of the panel. If parts are missing, contact ADC to order replacement parts. Page 20

27 MOUNTING BRACKET INSTALLED FOR 23-IN. (58.42 CM) RACK MOUNTING ATTACH TO EITHER SET OF 3 HOLES CABLE MANAGEMENT BAR A Figure 13. Cable Management Bar Installation 3.8 Circuit Designation Card and Voltage Label A circuit designation card holder and card (2), shown in Figure 14, are provided with the circuit breaker panel. Fill out one of the designation cards with the required circuit information and insert it into the card holder. Attach the card holder to the circuit breaker panel or to any convenient location that is close to the panel. The card holder has a pressure sensitive adhesive back for attachment. A voltage designation label (see Figure 14) is also provided with the circuit breaker panel. Enter the voltage level for the panel (24 or 48 Vdc) in the spaces provided. Attach the voltage label to any convenient mounting point on the panel. The voltage label has a pressure sensitive adhesive back for attachment. DESIGNATION CARD AND CARD HOLDER VOLTAGE LABEL A Figure 14. Circuit Designation Card and Voltage Label Page 21

28 4 OPERATION Operation of the Select Series circuit breaker panel consists of placing circuit breakers in either the ON or OFF position, replacing breakers that fail or that need upgrading, and connecting new equipment to the output power circuits. If a breaker trips, the alarm LED indicator for the corresponding power bus lights and the external alarms are activated (if present). Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. 4.1 Circuit Breaker Operation Each circuit breaker is equipped with a rocker-type ON/OFF switch handle. To turn on the power to the protected equipment, place the circuit breaker handle in the ON position. To turn off the power to the protected equipment, place the circuit breaker handle in the OFF position. The circuit breaker will automatically trip (turn off) when the load current exceeds the current rating of the breaker Note: All circuit breakers, even those not connected to a load, must be placed in the ON position in order to make the BREAKER ALARM indicators go out and to return the alarm contacts to the normal state. When a circuit breaker trips, the BREAKER ALARM indicator on the corresponding power bus will light and the handle on the tripped breaker will move to the OFF position. To determine which breaker tripped, locate the breaker handle that is in the OFF position. Determine what caused the breaker to trip and take the appropriate corrective action. When the problem has been corrected, place the breaker handle in the ON position. The BREAKER ALARM indicator should go out and the alarm contacts should return to the normal state. Page 22

29 4.2 Connecting New Equipment New equipment may be connected to unused circuit breakers following installation and testing of the circuit breaker panel. Use the following procedure for connecting the output power wires for new equipment to an unused output circuit: Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. Caution: Each circuit breaker (whether single pole or dual pole) and each blank insert, going from left to right on the front of the panel, maps to just one output position, going from left to right, on the rear of the panel. Thus, a circuit breaker in a certain numbered position on the front of the panel may not map to the output terminal in the same numbered position on the rear of the panel. For more information, refer to Figure 8 on Page Remove the plastic protective covers from the rear side of the output power terminal blocks (refer to Section 3.6, Protective Cover Installation/Removal). 2. Locate an unused pair of output power terminals and verify that a circuit breaker of the recommended size and type (as specified by the equipment manufacturer) is installed the corresponding breaker mounting position. 3. Place the circuit breaker handle in the OFF position. Note: Placing the circuit breaker in the OFF position will cause the BREAKER ALARM indicator for the corresponding power bus to light and will cause the alarm contacts to move to the alarm state. 4. Connect the output power wiring to the power output terminals as described in Section 3.4, Output Power Connections. Warning: Use care to avoid shorting out adjacent terminals when connecting new output power wiring to a powered circuit breaker panel. Shorting may cause injury and damage the panel or the connected equipment. 5. Re-install the plastic protective covers over the output power terminal block (refer to Section 3.6, Protective Cover Installation/Removal). 6. Place the circuit breaker handle in the ON position and verify that the voltage level and polarity are correct (refer to Section 4.1, Circuit Breaker Operation). Page 23

30 5 MAINTENANCE Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. 5.1 Inspection Inspect the circuit breaker panel periodically (every six months is recommended) for damage to the breakers and for damaged or broken wires at the power and external alarm connections. If excessive dirt is found during the inspection, brush or wipe dust and dirt from the panel with a soft bristle brush or soft cloth. Take care to avoid damaging the breakers or wiring. Broken or damaged circuit breakers should be replaced (see Section 5.3, Circuit Breaker Replacement). If a circuit is not operating properly, contact ADC Customer Assistance (see Section 6, Customer Information and Assistance). 5.2 Power LED Indicator Replacement The power LED indicators may be field-replaced if they fail. Use the following procedure to replace a failed LED indicator: 1. Pull the LED indicator slowly out from the front of the panel. Note: The LED indicator uses a snap-in type retainer to hold it in place on the front side of the panel. 2. Use a needle-nose pliers to disconnect the lead wire terminals (quick-connects or fastons) from the metal tabs on the rear side of the LED indicator as shown in Figure 15. Note: The lead wire terminals are insulated and can generally be removed without turning off the power to the circuit breaker panel. If any part of the terminal is not covered by insulation, make sure the exposed portion does not come into contact with the panel chassis or the other terminal. 3. On the replacement LED indicator, connect the red wire to the tin tab and the black wire to the brass tab. 4. Push the LED indicator back into the panel until it snaps into place. Page 24

31 METAL TABS A Figure 15. LED Indicator 5.3 Circuit Breaker Replacement Any existing circuit breaker may be field-replaced with an identical circuit breaker or with a breaker that has a different current rating or time delay. However, a breaker with a higher current rating may only be used as a replacement if the total current draw of the affected bus will not exceed 100 Amps. A circuit breaker mounting position that does not have an existing breaker (blank) cannot be used for installation of a replacement breaker because positions with blank inserts are not wired to the output terminals. Note: Call ADC Technical Assistance Center (TAC) when replacing circuit breakers. Note: Both power buses must have the same configuration of circuit breakers (same Amp ratings in same order). Use the following procedure to replace an existing circuit breaker with a new breaker: Note: Previous versions of the Select Series Circuit Breaker Panel were not equipped with field-replaceable circuit breakers. If the panel does not have a slot above the circuit breakers as shown in Figure 16, then it does not have field-replaceable circuit breakers and this procedure does not apply. 1. Turn-off or disconnect the power from the power bus (either A or B) that supplies current to the circuit breaker to be replaced. Danger: During normal operation, the terminal connections on the circuit breakers are electrically energized. Failure to disconnect the power from the power bus that supplies current to the circuit breaker being replaced may cause severe personal injury to the installer and/or equipment damage. Page 25

32 1.INSERT SCREWDRIVER INTO SLOT AND DEPRESS TO RELEASE LOCKING TAB. 2.TILT BREAKER FORWARD B Figure 16. Releasing Circuit Breaker Lock Tab 2. Insert a flat-bladed screwdriver into the slot above the circuit breaker (see Figure 16). 3. Push down and forward on the upper circuit breaker lock tab until the top of the circuit breaker is released from the panel. 4. Hold the top edge of the circuit breaker to keep the circuit breaker from snapping back into the panel when the screwdriver is withdrawn from the slot. 5. Insert a flat-bladed screwdriver into the slot below the circuit breaker. 6. Push down and forward on the lower circuit breaker lock tab until the bottom of the circuit breaker is released from the panel. 7. Pull the circuit breaker forward and out of the panel to expose the wiring connections on the rear side of the circuit breaker. 8. Disconnect the power and load wires (large black and white wires) and the alarm wires (small black wires) from the terminals on the rear side of the circuit breaker. Refer to Figure 17 when replacing a single pole breaker. Refer to Figure 18 when replacing a twopole breaker. 9. Connect the power and load wires to the specified terminals on the rear side of the replacement circuit breaker (see Figure 17 or Figure 18). Note that with the circuit breaker oriented as shown, the black load wire(s) connect to the top terminal(s) and the white power wire(s) connect to the bottom (LINE) terminal(s). Page 26

33 LOCKING TAB LOAD (BLACK) NOT USED BREAKER ALARM CONNECTIONS LINE C POWER (WHITE) FRONT VIEW LOCKING TAB SIDE VIEW Figure 17. Single-Pole Circuit Breaker Wiring Connections LOAD (BLACK) BREAKER ALARM CONNECTIONS LOAD (BLACK) LOCKING TAB TOP VIEW LOAD (BLACK) NOT USED BREAKER ALARM CONNECTIONS LINE POWER (WHITE) FRONT VIEW LOCKING TAB SIDE VIEW C Figure 18. Two-Pole Circuit Breaker Wiring Connections 10. Connect the two alarm wires to the specified terminals on the rear side of the replacement circuit breaker (see Figure 17 or Figure 18). Note: Do not connect any wires to the center terminal on the circuit breaker. 11. Insert the replacement circuit breaker into the opening in the panel and push inward until it locks into place. 12. Reconnect the power to the power bus. Page 27

34 6 CUSTOMER INFORMATION AND ASSISTANCE PHONE: U.S.A. or CANADA Sales: Extension Technical Assistance: Connectivity Extension: Wireless Extension: EUROPE Sales Administration: Technical Assistance: EUROPEAN TOLL FREE NUMBERS Germany: UK: Spain: France: Italy: ASIA/PACIFIC Sales Administration: Technical Assistance: ELSEWHERE Sales Administration: Technical Assistance: WRITE: Q ADC Telecommunications (S PORE) PTE, LTD; 100 Beach Road, #18-01, Shaw Towers. Singapore ADC Telecommunications, INC PO Box 1101, Minneapolis, MN , USA ADC European Customer Service, INC Belgicastraat 2, 1930 Zaventem, Belgium PRODUCT INFORMATION AND TECHNICAL ASSISTANCE: REPRINTS: PDF copies of manuals are available for downloading at the following link: ADCP Number: 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. Page 28