PowerWorx DSX Series GMT Fuse Panel User Manual

Transcription

1 PowerWorx DSX Series GMT Fuse Panel User Manual ADCP Issue 4 2/ Rev E

2 Preface COPYRIGHT 2011, Tyco Electronics Corporation All Rights Reserved REVISION HISTORY ISSUE DATE REASON FOR CHANGE 1 02/2002 Original 2 11/2005 Corrected technical error. 3 12/2008 Change input torque value from 27 in-lb to 42 in-lb (4.8 Newton Meters), 4 2/2012 Change torque value for input power terminal nuts to 32 in-lb. (3.6 Newton Meters), TRADEMARK INFORMATION TE Connectivity, Tyco Electronics, and TE (logo) are registered trademarks of Tyco Electronics Corporation. DISCLAIMER OF LIABILITY Contents herein are current as of the date of publication. TE Connectivity reserves the right to change the contents without prior notice. In no event shall TE Connectivity be liable for any damages resulting from loss of data, loss of use, or loss of profits and TE Connectivity 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 TE Connectivity s Technical Assistance Center at , extension (in U.S.A. or Canada) or (outside U.S.A. and Canada), or by to connectivity_tac@te.com. Tyco Electronics Corporation 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 Fuse Panel Components Packaged Hardware Options and Accessories Mounting Power Bus Fuses Input/Output Voltage Input Power Connections Output Power Connections Ground Connections Alarm Operation and Connections Specifications BEFORE STARTING INSTALLATION General Installation Recommendations Unpacking and Inspection Installation Tools Required Materials Required INSTALLATION Test Continuity Mounting Procedure Chassis Ground Connections External Alarm System Connections Output Power Connections Input Power Connections Protective Cover Installation/Removal Fuse Designation Card Installation TESTING Power Indication Test Connection Polarity Test Fuse Alarm Test OPERATION Fuse Installation and Replacement Procedure Connecting New Equipment MAINTENANCE Inspection Page iii

4 Preface TABLE OF CONTENTS Content Page 6.2 LED Indicator Replacement CUSTOMER INFORMATION AND ASSISTANCE Page iv

5 Preface ABOUT THIS MANUAL This manual describes the PowerWorx DSX Series GMT fuse panel and provides installation, test, operation, and maintenance procedures. The DSX Series GMT fuse panel is used to supply fused dc power to the 48 Vdc powered equipment that is typically installed in a DSX bay. STANDARDS CERTIFICATION The DSX Series GMT fuse panel complies with the applicable sections of the following standards: UL, NEC 1999, NEBS Level 3, and CSA. 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 fuse 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 fuse panel input or output wires. This may require turning off the system office battery input at the office distribution panel or removing the appropriate output circuit fuse at the fuse panel. Caution: Using the wrong fuse may cause damage to the protected equipment or the fuse panel. When replacing a blown fuse, make sure the replacement fuse is the same type and has exactly the same current rating as the fuse being replaced and does not exceed 3 Amps. Page v

6 Preface 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 provides a complete description of the functions and features provided by the PowerWorx DSX Series GMT fuse panel and a table of specifications. 1.1 Product Functions and Features The DSX Series GMT fuse panel, shown on the cover page of this manual, is used to supply fused dc power to the 48 Vdc powered equipment that is typically installed in a DSX bay. The DSX Series fuse panel provides the following basic functions and features: 20-position GMT fuse holder. Maximum fuse size is 3 Amps. Field-replaceable high-brilliance red LED indicator that lights when an overcurrent condition causes a fuse to open. Universal mounting brackets to permit mounting in a 19- or 23-inch, WECO or EIA, equipment rack. Mounts within a single rack space. 48 Vdc input/output voltage. Single-bus power feed with a maximum input current rating of 60 Amps. Two-hole compression-lug style power input terminals. Wire-wrap pin power output terminals. Normally Open (NO) and Normally Closed (NC) alarm relay contact terminals (wire-wrap pin) for connection to external alarm systems. The alarm relays operate if a fuse opens or if power to the fuse panel is lost. Two grounding studs to ensure reliable ground connectivity. Easy to remove/replace plastic protective covers mount over the input and output terminal connections to enhance safety. 1.2 Fuse Panel Components The DSX Series GMT fuse panel consists of the components shown in Figure 1. All fuse panel components are either mounted on or housed within a powder-painted sheet metal enclosure. The 20-position GMT fuse holder and the fuse alarm LED indicator are mounted on the front side of the enclosure. The fuse holder is equipped with dummy fuses which must be replaced with the required GMT fuses when the fuse panel is installed and connected to the fused equipment. Fuses and other items are available separately as accessory items. The input power terminals, output power terminals, alarm contact terminals, and grounding studs are mounted on the rear side of the enclosure. The plastic protective covers install over the terminals on the rear side of the enclosure. The covers prevent accidental contact with the input and output terminals. The internal bus wiring and alarm relay circuit board (not shown) are mounted within the enclosure. Page 1

8 FRONT VIEW FUSE ALARM INDICATOR 20-POSITION GMT FUSE HOLDER OUTPUT POWER TERMINALS ALARM CONTACT TERMINALS DESIGNATION CARDS AND HOLDER REAR VIEW COVER FOR OUTPUT POWER AND ALARM TERMINALS GROUNDING STUDS A COVER FOR INPUT POWER TERMINALS INPUT POWER TERMINALS Figure 1. Fuse Panel Components 1.3 Packaged Hardware The DSX Series GMT fuse panel includes various hardware components that are packaged separately and shipped in the carton with the basic fuse panel. The packaged hardware components are shown in Figure 2 and include the following items: Universal mounting brackets (2) 1/4-inch long, Phillips drive, 6-32 flat-head screws (6) - Used to secure the mounting brackets to the fuse panel. 3/8-inch long, combination drive, pan-head screws (4) and #12 flat washers (4) - Used to secure the fuse panel mounting brackets to the equipment rack. Page 2

9 REAR COVER FOR OUTPUT POWER/ALARM TERMINAL BLOCK REAR COVER FOR INPUT POWER TERMINAL BLOCK 2-HOLE LUGS FOR 6 AWG WIRE #8 RING TERMINALS FOR AWG WIRE 1/4-INCH (6.35 MM) 6-32 FLAT-HEAD SCREWS ORIENTATION FOR 19-INCH RACK INSTALLATION 3/8-INCH (9.525 MM) SCREWS AND #12 WASHERS ORIENTATION FOR 23-INCH RACK INSTALLATION DESIGNATION CARDS, COVER, AND CARD HOLDER UNIVERSAL MOUNTING BRACKETS AND SCREWS A Figure 2. Packaged Hardware Components 2-hole lugs (2) for 6 AWG wire - Used to attach the BATTERY and RETURN cables to the power input terminals. Also available as an accessory item. #8 ring terminals (2) for AWG wire - Used to connect the grounding cables to the grounding studs. Rear protective covers - Used to prevent accidental contact with the power and alarm terminals. Designation cards (2), card holder, and clear cover - Used to record information about the fused equipment. The card holder has a pressure sensitive adhesive backing to permit attachment to the fuse panel, the rack, or a location close to the fuse panel. The card and clear cover insert into the card holder. Two types of cards are provided. Also available as an accessory item. Page 3

10 1.4 Options and Accessories The only ordering option available for the DSX Series GMT fuse panel is the color selection. The fuse panel may be ordered with either a putty white or black powder-paint finish. The following accessories are available: GMT fuses - The following fuse sizes are available: 2/10, 1/4, 3/8, 1/2, 3/4, 1, 1-1/3, 1-1/2, 2, 2-1/2, and 3 Amps. GMT designation pins - Colored pins that are used to indicate the size of GMT fuses. GMT designation pin holder - Hold fuse designation pins. The pin holder has a pressure sensitive adhesive backing to permit attachment to the fuse panel. GMT fuse puller - Use to grip GMT fuse for easy removal from the fuse panel. 2-hole compression lugs - Used to attach the BATTERY and RETURN cables to the power input terminals. Available to fit 2, 4, 6, or 14 AWG wire. Designation cards (2), card holder, and clear cover - Used to record information about the fused equipment. The card holder has a pressure sensitive adhesive backing to permit attachment to the fuse panel, the rack, or a location close to the fuse panel. The card and clear cover insert into the card holder. Two types of cards are provided. 1.5 Mounting The DSX Series GMT fuse panel can be mounted in either a 19- or 23-inch (482.6 or mm) equipment rack. A universal set of mounting brackets is provided with the panel. The fuse panel can be flush mounted or recessed 1, 2, or 3 inches (25.4, 50.8, or 76.2 mm). The mounting brackets are slotted to allow the fuse 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 fuse panel can be mounted in either or 2-inch (44.5 or 50.8 mm) rack spaces. The fuse panel does not require additional rack spaces above or below the chassis for heat dissipation. 1.6 Power Bus The DSX Series GMT fuse panel has one power bus (power feed) circuit. The power bus distributes the input power to the output power circuits. In the bus circuit, current flows from the input power terminals, through the fuse, to the output power terminals. The maximum current capacity of the power bus is 60 Amps. The output fusing of the fuse panel must not exceed 60 Amps. The maximum current rating is marked on the fuse panel rear side. The power dissipation of the fuse panel is 20 watts maximum at 60 Amps. Page 4

11 1.7 Fuses The DSX Series GMT fuse panel uses standard GMT type fuses which can range in size from 0.2 to 3.0 Amps. The fuses install in a fuse holder that is located on the front side of the fuse panel. The fuse holder has a maximum capacity of twenty fuse positions. The maximum fuse size is 3 Amps which is marked on the front side of the fuse panel. When a fuse fails, the input power bus is disconnected from the corresponding output circuit. This causes the fuse alarm LED for the bus to light and also opens or closes the alarm relay contacts. Fuses are available as an accessory item. 1.8 Input/Output Voltage The DSX Series GMT fuse panel accepts an input voltage of 48 Vdc (nominal) within a range of 42 to 56 Vdc. The voltage level is sensed by the fuse panel alarm relay circuit board. The output voltage is the same value as the applied input voltage. 1.9 Input Power Connections Input power is supplied to the fuse panel through the input terminal block. The input terminal block consists of two pairs of studs that are used for connecting the BATTERY and RETURN input power cables. Each set of studs accepts various size 2-hole compression lugs. Compression lugs for 2, 4, 6, and 14 AWG wire are available as accessory items. Nuts with star washers are included to secure the compression lugs to the studs. The minimum recommended wire size for the input power wiring is 6 AWG. The input terminal block is located on the rear side of the fuse panel Output Power Connections Output power is supplied to the fused equipment through the output terminal block. The output terminal block consists of twenty pairs of wire wrap pins. Each pair of wire wrap pins is used for connecting the BATT (battery ) and RTN (return +) output power wiring to the specified equipment. The recommended wire size for the output power wiring is 22 AWG. The output power terminal block is located on the rear side of the fuse panel Ground Connections Two #8 studs (with nuts and star washers) are provided on the rear side of the fuse panel for grounding the chassis. The ground connection is used to attach grounding cables to the chassis when the fuse panel is mounted in a non-grounded or non-conducting rack or when required by local practice. Two AWG copper wires are recommended for the grounding cables. Two #8 ring terminals for use with AWG wire are provided for connecting the grounding cables to the studs. Page 5

12 1.12 Alarm Operation and Connections The DSX Series GMT fuse panel contains circuitry that opens and closes a set of form C alarm relay contacts when any fuse on the bus fails or when the input power to the bus is lost. These contacts may be used to open or close a loop connected to an external alarm system. During normal operation (power applied and all fuses functional), the normally open (NO) contacts remain open and the normally closed (NC) contacts remain closed. When a fuse fails or power to the 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 each set of alarm relay contacts (two sets are provided) is 125 Volts (ac/dc) maximum voltage, 1.0 Amp maximum current (resistive load). A fuse alarm indicator (red LED) is provided on the front side of the fuse panel. The fuse alarm indicator lights if any fuse fails. The fuse alarm indicator stays off when the fuses are operational. The alarm indicator LED can be field-replaced if it fails. Alarm contact connections are provided through two sets of wire wrap pins located on the rear side of the fuse panel. The wire wrap pin sets are labeled ALARM 1 and ALARM 2 and can accept 22 to 26 AWG copper wire Specifications The specifications for the DSX Series GMT Fuse Panel are listed in Table 1. Table 1. Fuse Panel Specifications PARAMETER SPECIFICATION REMARKS Physical Weight Dimensions (HxWxD) 5 lbs. (2.27 kg) 1.73 x x 4.10 inches (44 x 435 x 129 mm) See Figure 3 Color Putty white or black Option Rack mounting 19- or 23-inch EIA or WECO hole spacing Rack spaces required 1 Electrical Operating voltage 48 Vdc 42 to 56 Vdc tolerance Maximum input current Fuse type Fuse positions 20 Maximum fuse size 60 Amps GMT 3 Amps Input terminal type 2-hole compression lug 6 AWG wire recommended Output terminal type Wire wrap pin 22 AWG wire recommended Alarm terminal type Wire wrap pin AWG wire Page 6

13 Alarm contact voltage 125 V ac/dc maximum Resistive load Alarm contact current 1 Amp maximum Resistive load Grounding connections Two #8 studs 10 AWG wire recommended Environmental Operating temperature Storage temperature 5º C to +50º C 45º C to +85º C Humidity range 0% to 95% humidity No condensation Altitude range Fire rating Acoustic noise Heat dissipation (fully loaded) Heat dissipation (no load) Torque Table 1. Fuse Panel Specifications, continued PARAMETER SPECIFICATION REMARKS Up to 13,000 ft. (3.96 km) above sea level All components UL94-V1 or better 0 dba above ambient 20 watts maximum at 60 Amps 1 watt 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 32 pound force-inches 3.6 Newton meters Grounding stud nuts 15 pound force-inches 1.7 Newton meters 4.10 IN. (104.1 mm) IN. (584.2 mm) IN. (566.7 mm) IN. (482.6 mm) IN. (465.1 mm) IN. (28.6 mm) 1.74 IN mm) A Figure 3. Fuse Panel Dimensions Page 7

14 2 BEFORE STARTING INSTALLATION This section provides general installation recommendations, unpacking and inspection procedures, and lists the tools and material required for fuse panel installation. 2.1 General Installation Recommendations The DSX Series GMT fuse panel must be installed in a central office, equipment room, or restricted access location. Mount the fuse panel in the uppermost area of the rack to reduce exposure of the power wiring. Route ground, power, and alarm cables to the fuse 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 fuse panel. Replace the protective covers on the rear side of the fuse panel after all the wiring connections are made and all tests are completed. Do not apply power to the fuse panel until all wiring and tests are completed. Warning: The fuse 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 fuse panel: 1. Open the shipping carton and carefully unpack the fuse panel from the protective packing material. 2. Check the fuse panel for broken or missing parts. If there are any damages, contact ADC (see Section 7, 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 fuse panel: Phillips screwdrivers (#1 and #2) Flat-blade screwdrivers (medium and large Torque screwdriver calibrated in pound-force inches or Newton meters Torque wrench calibrated in pound-force inches or Newton meters 7/16-inch socket (for torque wrench) Page 8

15 2.4 Materials Required 11/32-inch socket (for torque wrench) Wire cutter Wire stripper Compression lug crimper Wire wrap gun Multimeter Heat gun GMT fuse puller The following materials are required to install the fuse panel: 6 AWG insulated copper wire for input power connections 10 AWG copper wire for ground connections 22 AWG insulated copper wire for output power and alarm connections (for power wiring, use black for the RETURN wire and red or blue for the BATTERY wire) Heat-shrink tubing GMT fuses 3 INSTALLATION 3.1 Test Continuity This section provides the installation procedures for the DSX Series GMT fuse panel. Each DSX Series GMT fuse panel is thoroughly tested at the ADC factory before being shipped. However, before the fuse panel is installed, a continuity test should be performed on the fuse panel to verify that no internal damage has occurred during shipping and handling. Using a multimeter that is set to perform a continuity check, perform the following tests. Test 1: Input Battery to Input Return - Connect one test probe to the input power BATTERY ( ) terminal and the other test probe to the input power RETURN (+) terminal (see Figure 4). Verify that no continuity exists between the input power BATTERY and RETURN terminals. Test 2: Input Battery to Output Battery - Remove the dummy fuse from position #1 and install a working GMT fuse (see Section 5.1). Connect one test probe to the input power BATTERY ( ) terminal and the other test probe to the #1 output power BATT ( ) terminal (see Figure 4). Verify that continuity exists between the specified terminals. Repeat the test procedure for each of the remaining (#2 through #20) output power BATT terminals. Remove all fuses from the fuse panel following completion of this test and re-install the dummy fuses. Test 3: Input Return to Output Return - Connect one test probe to the input power RETURN (+) terminal and the other test probe to the #1 output power RTN (+) terminal (see Figure 4). Verify that continuity exists between the specified terminals. Repeat the test procedure for each of the remaining (#2 through #20) output power RTN terminals. Page 9

16 TEST 2: CONTINUITY (FUSE MUST BE INSTALLED) TEST 1: NO CONTINUITY A TEST 3: CONTINUITY Figure 4. Continuity Tests If the fuse panel fails any of the specified tests, it is defective and must not be installed. Contact ADC (see Section 7, Customer Information and Assistance) for an RMA (Return Material Authorization) and to reorder if replacement is required. 3.2 Mounting Procedure The fuse panel can be mounted in either a 19- or 23-inch wide rack. One set of universal mounting brackets is provided with the fuse panel. Six 1/4-inch (6.35 mm) long, threadforming, Phillips-drive, 6-32 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 fuse panel, use only the 1/4-inch (6.35 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 fuse panel in the equipment rack: 1. Orient the mounting brackets for 19- or 23-inch rack mounting (whichever is required) as shown in Figure Attach the brackets to the sides of the fuse panel chassis using the six 1/4-inch (6.35 mm) 6-32 flathead screws provided. Tighten screws to 15 pound force-inches (1.7 Newton meters) of torque to insure grounding. 3. Place the fuse panel in the specified mounting space within the rack. Page 10

17 19-INCH RACK INSTALLATION 23-INCH RACK INSTALLATION A Figure 5. Fuse Panel Mounting Bracket Installation 4. Secure the panel to the rack as shown in Figure 6 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 to insure grounding. DETAIL DRAWING OF MOUNTING SCREWS AND WASHERS A USE #12 STAR WASHERS INSTEAD OF FLAT WASHERS IF REQUIRED BY LOCAL PRACTICE Figure 6. Typical Fuse Panel Installation in Equipment Rack Page 11

18 3.3 Chassis Ground Connections Mounting the fuse panel on a metal equipment rack using the metal mounting brackets provided with the fuse panel 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 fuse panel is mounted to non-grounded or non-conducting material such as a plastic rack or cabinet. Use the following procedure to connect the CHASSIS GROUND studs to an approved office ground source: 1. Obtain two lengths of 10 AWG wire for use as the chassis grounding wires. 2. Terminate one end of each wire with the #8 ring terminals provided (requires crimper). 3. Locate the CHASSIS GROUND studs at the rear of the fuse panel as shown in Figure A DETAIL DRAWING OF GROUNDING WIRE CONNECTION Figure 7. Chassis Ground Connections 4. Connect the ring terminal end of each wire to one of the studs and secure using the nuts with star washers provided (requires 11/32-inch socket). Tighten the stud nut to 15 poundforce inches (1.7 Newton meters) of torque. 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. 3.4 External Alarm System Connections Two sets of normally open (NO) and normally closed (NC) alarm contacts are provided for connecting the fuse panel to an external alarm system. Alarm contact connections are provided through two sets of wire wrap pins located on the rear side of the fuse panel. The wire wrap pin sets are labeled ALARM 1 and ALARM 2 and can accept 22 to 26 AWG copper wire. Connect the alarm system wires to the fuse panel according to the requirements of the external alarm system and as shown in Figure 8. Page 12

19 17137-A DETAIL DRAWING OF ALARM CONTACT TERMINALS NO C NC Figure 8. Alarm Contact Connections 3.5 Output Power Connections Output power is supplied to the fused equipment through the output terminal block. The output terminal block consists of twenty pairs of wire wrap pins. Each pair of wire wrap pins is used for connecting the BATT (Battery ) and RTN (Return +) power output wiring to the specified fused equipment. The terminal pairs are numbered to correspond with the fuse positions. The recommended wire size for the output power wiring is 22 AWG. Connect the output wires to the fuse panel as shown in Figure PIN ROWS DETAIL DRAWING OF OUTPUT POWER TERMINALS PIN DESIGNATIONS PIN ROW 1: BATT (-) 1-10 PIN ROW 2: BATT (-) PIN ROW 3: RTN (+) 1-10 PIN ROW 4: RTN (+) A Figure 9. Output Power Connections Page 13

20 3.6 Input Power Connections Input power is supplied to the fuse panel through the input terminal block. The input terminal block consists of two pairs of studs that are used for connecting the BATTERY and RETURN input power cables. Each set of studs accepts various size 2-hole compression lugs. Nuts with 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 negative ( ) voltage polarity and/or the voltage value] to the connector on the fuse panel labeled BATTERY. Connect only the input return wire [the wire labeled RTN, RETURN, or BATTERY GROUND, or labeled with the positive (+) voltage polarity] to the connector on the fuse panel labeled RETURN. Caution: Caution should be taken to not reverse the input wires to the fuse panel. Within the fuse panel, the internal return wiring is not protected by fuses. If the wires are reversed, current will flow through the unprotected return wiring in the fuse panel to the equipment. This condition can cause damage to equipment in the frame in which the fuse panel is installed and to equipment in adjacent frames Use the following procedure to connect the input power cables to the fuse panel: 1. Obtain two lengths of 6 AWG wire for use as the input power cables. Note: For power wiring, use black for the RETURN (+) wire and red or blue (blue is used for international applications) for the BATTERY ( ) wire. 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) 6 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. Page 14

21 4. Terminate one end of each wire with the 2-hole lug terminals provided (requires crimper). 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. Using the nuts with locking washers provided, connect the red or blue wire to the input power BATTERY ( ) terminal and the black wire to the input power RETURN (+) terminal as shown in Figure A APPLY NO-OX GEL TO BOTH SIDES DETAIL DRAWING OF INPUT POWER CABLE CONNECTIONS Figure 11. Input Power Connections 8. Use a torque wrench (with a 7/16-inch socket) to tighten the 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 source. 10. Connect the input power cables to the office battery power source in accordance with applicable local electrical codes and/or National Electrical Codes. Do not apply power to the fuse panel until instructed to do so for testing (see Section 4, Testing). Page 15

22 3.7 Protective Cover Installation/Removal Install the rear protective covers, shown in Figure 12, when all the wiring and tests are completed. To install the output power/alarm contact terminals cover, locate the two hex-rod stand-offs on the rear side of the panel. Back out each stand-off screw two or three turns. Hold the cover so the lettering is oriented properly and then place the cover over the stand-off screw heads. Slide the cover to the left and then tighten the screws. To install the input power terminals cover, hold the cover over the input power terminals and press inward until it snaps into place. If the protective covers are lost or damaged, contact ADC for replacement (refer to Section 7, Customer Information and Assistance). OUTPUT POWER/ALARM CONTACT TERMINALS COVER HEX ROD STAND-OFF INPUT POWER TERMINALS COVER A Figure 12. Protective Cover Installation/Removal To provide access to the input power, output power, and alarm system terminals, it may sometimes be necessary to remove the protective rear covers. To remove the output power/alarm contact terminals cover, loosen but do not remove the two screws that secure the cover to the stand-offs. The screws do not need to be completely removed to remove the protective cover. Slide the cover to the right and then pull the cover directly outward and away from the panel. To remove the input power terminals cover, pull outward on the cover. Page 16

23 3.8 Fuse Designation Card Installation The fuse designation card holder may be attached to the fuse panel, as shown in Figure 13, or to any convenient location that is close to the fuse. Remove the paper from the back of the card holder and press the card holder against the mounting surface. Fill out one of the designation cards with the required circuit information and insert it in the card holder. DESIGNATION CARD HOLDER B Figure 13. Fuse Designation Card and Voltage Label Installation Page 17

24 4 TESTING Following installation, perform the following tests to verify that the fuse panel is correctly wired and that the fuse alarm system is functioning properly. Warning: The fuse 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 Power Indication Test Remove any fuses (except dummy fuses) that may have been installed in the fuse panel during installation and then turn on the power to the fuse panel. With the power turned on and all fuses removed, the fuse alarm LED indicator should not light. With power applied, the alarm relay contacts should provide an open circuit between the common (C) terminals and the normally open (NO) terminals and a closed circuit between the common (C) and normally closed (NC) terminals. Using a multimeter that is set to test for continuity, connect the probes alternately between the C and NC terminals and the C and NO terminals. Verify that continuity exists between the C and NC terminals and that no continuity exists between the C and NO terminals. 4.2 Connection Polarity Test Verify that the input power cables are connected to the correct terminals. Using a multimeter that is set to measure dc voltage, measure the voltage between the input power RETURN terminal and chassis ground. The voltage level should be less than 2.0 Vdc. If the voltage is more than 2.0 Vdc, disconnect the power from the fuse panel and reverse the input power wires. Reconnect the power and again measure the voltage between the input RETURN terminal and the chassis ground. Verify that the voltage level is less than 2.0 Vdc. 4.3 Fuse Alarm Test Place a fuse that has failed in one of the fuse positions. The fuse alarm LED indicator will change from off to red and the fuse failure alarm relay will operate. Using a multimeter that is set to test for continuity, connect the probes alternately between the C and NC terminals and the C and NO terminals. Verify that no continuity exists between the C and NC terminals and that continuity exists between the C and NO terminals. Remove the failed fuse from the fuse panel. The fuse alarm LED indicator will go off and the alarm relay contacts will return to their normal state. Page 18

25 5 OPERATION Operation of the DSX Series GMT fuse panel consists of installing fuses, replacing fuses when they fail, and connecting new equipment to the output power circuits. If a fuse fails, the alarm LED indicator lights and the external and remote alarms are activated (if present). Warning: The fuse 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 Fuse Installation and Replacement Procedure Remove the dummy fuses from the fuse positions that will supply power to equipment. Install a GMT fuse of the recommended size and type (as specified by the fused equipment manufacturer) in each fuse position. The current rating of the fuse (in Amperes) is indicated on the side of the fuse. The color of the indicator also corresponds to the fuse size. Refer to the color code chart provided with replacement fuses to identify the fuse size by color. Orient each fuse so the indicator is on the top as shown in Figure 14. Caution: Using the wrong fuse may cause damage to the protected equipment or the fuse panel. When replacing a blown fuse, make sure the replacement fuse is the same type and has exactly the same current rating as the fuse being replaced and does not exceed 3 Amps. INDICATOR A Figure 14. GMT Fuse When a fuse fails, the fuse alarm LED indicator will light (red) and the fuse alarm relay contacts will operate. The indicator on the failed fuse will spring outward and should be visible on the top side of the fuse. Use a GMT fuse puller to remove the failed fuse from the fuse panel. The fuse alarm LED indicator should go out and the fuse alarm relay contacts should return to the normal state as soon as the failed fuse is removed. Determine the problem that caused the fuse to fail and take the appropriate corrective action. When the problem has been corrected, install a replacement GMT fuse that is the same current rating and type as the original fuse. Page 19

26 5.2 Connecting New Equipment New fused equipment may be connected to unused output power circuits following installation and testing of the fuse panel. Use the following procedure for connecting the output power wires for new fused equipment to a previously installed fuse panel: Warning: The fuse 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. 1. Remove the plastic protective cover from the output power/alarm contacts terminal block (refer to Section 3.7, Protective Cover Installation/Removal). 2. Locate an unused pair of wire wrap pin terminals on the output terminal block and verify that a fuse is not installed the corresponding fuse position. 3. Connect the output power wiring to the fuse panel output terminals as described in Section 3.5, Output Power Connections. The recommended wire size for the output power wiring is 22 AWG. Warning: Use care to avoid shorting out adjacent terminals when connecting new output power wiring to a powered fuse panel. Shorting may cause injury and damage the fuse panel or the connected fused equipment. 4. Install the plastic protective cover over the output power/alarm contacts terminal block (refer to Section 3.7, Protective Cover Installation/Removal). 5. Install a fuse of the recommended size (as specified by the fused equipment manufacturer) in the appropriate fuse position (refer to Section 5.1, Fuse Installation and Replacement Procedure). Page 20

27 6 MAINTENANCE Warning: The fuse 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. 6.1 Inspection Inspect the fuse panel periodically (every six months is recommended) for damage to the fuses 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 fuse panel with a soft bristle brush or soft cloth. Take care to avoid damaging the fuses or wiring. No adjustments are required. If a circuit is not operating properly, contact ADC Customer Assistance (see Section 7, Customer Information and Assistance). 6.2 LED Indicator Replacement The fuse alarm LED indicator may be field-replaced if it fails. Use the following procedure to replace the fuse alarm LED indicator: 1. Pull the LED indicator slowly out from the front of the fuse panel. Note: The LED indicator uses a snap-in type retainer to hold it in place on the front side of the fuse panel. 2. 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. METAL TABS A Figure 15. Fuse Alarm LED Indicator 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 21

28 7 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: ADC Telecommunications (S PORE) PTE, LTD; 100 Beach Road, #18-01, Shaw Towers. Singapore Tyco Electronics Corporation PO Box 1101, Minneapolis, MN , USA TE 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: Publication Number: ADCP Contents herein are current as of the date of publication. TE reserves the right to change the contents without prior notice. In no event shall TE be liable for any damages resulting from loss of data, loss of use, or loss of profits and TE 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 T Page 22