PowerWorx GMT Series Power Distribution Panel Uninterrupted (C-Source) Power User Manual

Transcription

1 Content PowerWorx GMT Series Power Distribution Panel Uninterrupted (C-Source) Power User Manual Page INTRODUCTION...2 Revision History...5 Trademark Information...5 Admonishments...5 General Safety Precautions GENERAL CHARACTERISTICS AND FEATURES Power Buses Block Diagram Redundant Power Bus Capacity Bus Inputs Bus Outputs Fuses Fuse Holders Fuse Identification Flag Fuse Value Designation Pin Holders Chassis Ground Connection Alarm Contact Closures Fuse Alarm Indicator Power-On Indicator Fuse Designation Card and Holder Voltage Designation Label PHYSICAL CHARACTERISTICS Material and Finish Cooling Protective Cover Weight Mounting Environmental Characteristics Dimensions ACCESSORIES UNPACKING AND INSPECTION INSTALLATION Cable Management Bar (Optional Accessory) Mounting Brackets Wiring Connections Fuse Designation Pin Holders (continued) Rev A Page 1

2 Content Page 5.5 Fuse Designation Card Holder and Card Voltage Designation Label Fuse Installation TESTING THE FUSE PANEL Quality Control Resistance Test Connection Polarity Test Wiring Connections Measurements Power Indication Test Fuse Alarm Test OPERATION MAINTENANCE Inspection Cleaning Adjustments Fuse Removal LED Replacement CUSTOMER INFORMATION AND ASSISTANCE INTRODUCTION This manual describes a GMT type fuse power distribution panel, with uninterrupted output power, designated ADC PowerWorx GMT Series Power Distribution Panel, Uninterrupted (C- Source) Power, hereinafter referred to as the fuse panel. This fuse panel provides GMT type fuse protection and uninterrupted dc output power for telecommunications products used in central offices, multimedia headends, remote sites, and other locations requiring fused power. This fuse panel complies with UL, Telcordia (formerly Bellcore), NEC 1999, CSA, NEBS, and CE standards. The fuse panel design places emphasis on high reliability and simplicity of operation. A description of this fuse panel, with its available options and accessories, is provided herein. The information necessary to install and operate the fuse panel is also provided. Typical PowerWorx GMT type fuse panels with uninterrupted output power are shown in Figure 1 and Figure 2 and are described in the following paragraphs. The fuse panel has two power buses (feeds) with each power bus having ten (10) GMT fuse positions. Custom fuse configurations within minimum limitations are available upon request. Typical dimensions of these fuse panels are: Standard (front and rear access): 1.75 inches (4.45 centimeters) high, inches (43.48 centimeters) wide, and 8.00 inches (20.32 centimeters) deep, or Total front access: 3.5 inches (8.89 centimeters) high, inches (53.97 centimeters) wide, and 5.17 inches (13.12 centimeters) deep. The current capacity of each bus is 60 Amps maximum, which is marked on the fuse panel. Page 2

3 HEAT SINK (PATENT PENDING) VENTS GMT FUSE HOLDER (10 POSITION SHOWN) GMT FUSE HOLDER (10 POSITION SHOWN) FUSE FAILURE INDICATOR (RED LED) FUSE VALUE DESIGNATION PIN HOLDER POWER-ON INDICATOR (GREEN LED) FUSE FAILURE INDICATOR (RED LED) FUSE VALUE DESIGNATION PIN HOLDER POWER-ON INDICATOR (GREEN LED) FRONT VIEW PROTECTIVE COVER IN PLACE OVER INPUT AND OUTPUT POWER, GROUND, AND ALARM CONTACT CONNECTIONS UL/CSA/CE LABEL UNIVERSAL MOUNTING BRACKETS (2) (INSTALLED FOR 23-IN. (58.42 CM) RACK MOUNTING) REAR VIEW A Figure 1. ADC PowerWorx GMT Series Uninterrupted Power (C-Source) Fuse Panel, Standard (Front and Rear Access) Configuration, Dual Power Feed (10/10 Fuse Position Shown) Page 3

4 HEAT SINK (PATENT PENDING) GMT FUSE HOLDER (10 POSITION SHOWN) GMT FUSE HOLDER (10 POSITION SHOWN) FUSE VALUE DESIGNATION PIN HOLDER POWER-ON INDICATOR (GREEN LED) UL/CSA/CE LABEL CABLE RINGS PROTECTIVE COVER IN PLACE OVER OUTPUT POWER, GROUND, AND ALARM CONTACT CONNECTIONS FUSE FAILURE INDICATOR (RED LED) FUSE FAILURE INDICATOR (RED LED) FRONT VIEW FUSE VALUE DESIGNATION PIN HOLDER POWER-ON INDICATOR (GREEN LED) STANDOFF (2) PROTECTIVE COVER IN PLACE OVER INPUT POWER CONNECTIONS REAR VIEW MOUNTING BRACKETS (2) FOR 23 IN. (58.42 CM) RACK (RECESS MOUNT) A Figure 2. ADC PowerWorx GMT Series Uninterrupted Power (C-Source) Fuse Panel, Total Front Access Configuration, Dual Power Feed (10/10 Fuse Position Shown) Page 4

5 The power dissipation of the fuse panel is 108 watts maximum. The fuse panel is capable of sensing the input voltage level and can be used with either 24 Vdc or 48 Vdc. Contacts for external connection to external alarms are also built into the fuse panel. Using the universal mounting brackets included with the fuse panel, the standard (front and rear access) fuse panel can be mounted in 19-inch (48.26-cm) or 23-inch (58.42-cm) racks with WECO or EIA hole spacing. Using the mounting brackets included with the fuse panel, the total front access fuse panel can be mounted in 23-inch (58.42-cm) racks with WECO or EIA hole spacing. Other features include optional types of input connectors, output connectors, and alarm contact connectors, and optional colors. Other fuse capacity configurations are also available by special order. Several accessories for the fuse panels are available: standard value GMT fuses (0.2 to 15.0 Amps), colored fuse value designation pins (rivets), cable management bar kits, GMT fuse pullers, compression lugs, spare GMT fuse value designation pin holders; and spare fuse value designation card holder kits. See Section 3. Revision History ISSUE DATE REASON FOR CHANGE Issue 1 04/2000 Original Trademark Information ADC is a registered trademark of ADC Telecommunications, Inc. PowerWorx is a trademark of ADC Telecommunications, Inc. Admonishments Important safety admonishments are used throughout this manual to warn of possible hazards to persons or equipment. An admonishment identifies a possible hazard and then explains what may happen if the hazard is not avoided. The admonishments in the form of Dangers, Warnings, and Cautions must be followed at all times. These warnings are flagged by use of the triangular safety 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. Page 5

6 Warning: Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the hazard is not avoided. Caution: Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the hazard is not avoided. General Safety Precautions Caution: The fuse panel uses electrical voltage and amperage levels which, per GR-1089, may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with this equipment when the fuse panel is energized. Only insulated tools should be used on energized elements of the fuse panel. Caution: All fuse panel wiring and cabling should be connected with the system office battery input off or disconnected at the office distribution panel. Caution: A replacement fuse must have exactly the same current rating as the fuse being replaced. 1 GENERAL CHARACTERISTICS AND FEATURES The fuse panel has the general characteristics and features defined in the following paragraphs. The two configurations of the fuse panel with the protective covers attached are shown in Figure 1 and Figure 2. Views of the fuse panels, with the protective covers removed to show the external connectors are shown in Figure 3 and Figure 4. Available accessories for the fuse panel are defined in Section Power Buses The fuse panel has two separate power buses. Each bus provides normal power distribution of the input power to 10 output circuits using GMT type fuses and overload protection for the bus. In each bus circuit, current flows from the input to the fuse bus. When a fuse is installed in a fuse holder, the circuit is completed to the output connectors. When a fuse fails, the input power bus is connected through the GMT fuse conducting flag to the fuse alarm board, which causes contact closures which are present at the alarm output connection (using Form C contacts). Each bus has two input power connectors through which input power is applied. The two input power connectors are labeled BATT (battery) and RTN (return). Page 6

7 Each bus has two output power connectors through which the output power of the bus is available for connection to telecommunications equipment. The input power connectors and the output connectors are located on the rear of the standard (front and rear access) fuse panel. The input power connectors and the output connectors are located on the front of the total front access fuse panel. Other fuse capacity configurations are also available by special order. INPUT CONNECTORS (TWO HOLE COMPRESSION LUG STUD TYPE SHOWN) PROTECTIVE COVER MOUNTING STANDOFFS (2 SETS) ALARM CONTACT CONNECTOR (WIRE-WRAP PIN BLOCK TYPE SHOWN) INPUT CONNECTORS (TWO HOLE COMPRESSION LUG STUD TYPE SHOWN) OUTPUT CONNECTORS (SCREW-DOWN BARRIER TERMINAL STRIP TYPE SHOWN) CHASSIS GROUND TERMINALS OUTPUT CONNECTORS (SCREW-DOWN BARRIER TERMINAL STRIP TYPE SHOWN) A Figure 3. Rear View of Standard (Front and Rear Access), Dual Power Feed Fuse Panel with Protective Cover Removed to Show Connections (10/10 Fuse Position Panel with Compression Lug Input Connectors, Screw-Down Barrier Terminal Strip Output Connectors, and Wire-Wrap Pin Alarm Contact Pin Block Shown) PROTECTIVE COVER MOUNTING STANDOFF OUTPUT RETURN CONNECTORS (SCREW-DOWN BARRIER TERMINAL STRIP TYPE SHOWN) ALARM CONTACT CONNECTOR (WIRE-WRAP PIN BLOCK TYPE SHOWN) OUTPUT POWER CONNECTORS (SCREW-DOWN BARRIER TERMINAL STRIP TYPE SHOWN) INPUT CONNECTORS (TWO HOLE COMPRESSION LUG STUD TYPE SHOWN) OUTPUT RETURN CONNECTORS (SCREW-DOWN BARRIER TERMINAL STRIP TYPE SHOWN) PROTECTIVE COVER MOUNTING STANDOFFS (2) CHASSIS GROUND TERMINALS OUTPUT POWER CONNECTORS (SCREW-DOWN BARRIER TERMINAL STRIP TYPE SHOWN) INPUT CONNECTORS (TWO HOLE COMPRESSION LUG STUD TYPE SHOWN) PROTECTIVE COVER MOUNTING STANDOFFS (2) PROTECTIVE COVER MOUNTING STANDOFF A Figure 4. Front View of Total Front Access, Dual Power Feed Fuse Panel with Protective Covers Removed to Show Connections (10/10 Fuse Position Panel with Compression Lug Input Connectors, Screw-Down Barrier Terminal Strip Output Connectors, and Wire-Wrap Pin Alarm Contact Pin Block Shown) Page 7

8 1.2 Block Diagram A block diagram of the fuse panel is shown in Figure 5. POWER LED ALARM LED POWER LED ALARM LED POWER OUTPUT POWER OUTPUT FUSE ARRAY POWER/ ALARM MONITOR POWER/ ALARM MONITOR FUSE ARRAY SCHOTTKY RECTIFIER ALARM OUTPUT SCHOTTKY RECTIFIER (3) (3) (3) AUDIO VISUAL REMOTE VOLTAGE RETURN RETURN VOLTAGE BATTERY A OUTPUT RETURN OUTPUT RETURN BATTERY B A Figure 5. PowerWorx GMT Series Uninterrupted Power Fuse Panel (Dual Power Feed) Block Diagram 1.3 Redundant Power The fuse panel provides redundant power to fused equipment through the use of Schottky steering diodes. When power to one bus is interrupted, the Schottky steering diodes enable the other bus (supplied with uninterrupted input power) to supply power to the entire fuse panel and to maintain output power for both buses (bus A and bus B). If bus A loses power, bus B will provide the load of bus A while maintaining its original power load. Likewise, if bus B loses power, bus A will provide the load of bus B while maintaining its original power load. 1.4 Bus Capacity The current capacity of each bus is 60 Amps maximum, which is marked on the fuse panel. The maximum total fuse current capacity for each bus is 30 Amps. When one bus loses input power, the other bus is capable of providing the current for both buses, which is 60 Amps maximum. The power dissipation of the fuse panel is 108 watts maximum. Page 8

9 1.5 Bus Inputs Input Voltage The fuse panel can accommodate 24 Vdc input power on both busses or 48 Vdc input power on both busses. The input voltage used with the fuse panel is required to have the following voltage characteristics: 24 Vdc nominal, within a range of 21 Vdc to 30 Vdc 48 Vdc nominal, within a range of 42 Vdc to 56 Vdc Input Connectors The fuse panel is available with either of two types of input connectors. The two types of input connectors are: Two-hole compression lug (stud type): Two (2) connectors for each bus, each connector having two (2) screws (studs) with nuts mounted on a tin plated copper plate. Each set of two screws can accept different size 2-hole lugs which can be used with a range of wire sizes up to #2 AWG copper wire. Two 2-hole lugs for use with #6 AWG wire are included with the fuse panel for each bus. Set screw barrel connector: Two (2) connectors for each bus, each connector having two (2) barrels. On each connector, the barrel that is closest to the outside of the fuse panel and does not have a cap on it is to be used to connect input power to the fuse panel power bus when installing the fuse panel. The other barrel on each connector that is closest to the center of the fuse panel has a cap over it and is not to be used or accessed. Use of these barrels may render the product warranty void. The set screw barrel input power connectors can accept up to a #6 AWG copper wire. The wire is inserted into the connector, and the connector screw is screwed down, compressing the wire. 1.6 Bus Outputs Output Voltage The output voltage will be the same voltage as the applied input voltage when the fuse does not fail Output Connectors The fuse panel is available with either of two types of output connectors. The two types of output connectors are: Screw-down barrier terminal strip: Terminals with 6-32 screws are mounted in two barrier type terminal blocks per bus. The terminals are on inch (9.525 mm) centers with a distance between barriers of inch (8.255 mm). Page 9

10 The terminals can also accept #12 to #22 AWG copper wire with insulation stripped back. Wires are inserted in the terminal strip, and the screws are screwed down on the wires. Set screw barrel terminal strip. The terminals are on inch (5.004 mm) centers. The terminals can accept #12 to #22 AWG copper wire with insulation stripped back. 1.7 Fuses The fuse panel accommodates industry standard GMT fuses. The fuse panel is rated for the use of any standard GMT fuse from 0.2 Amp to 15.0 Amps in any fuse position, within the maximum capacity of 60 Amps per power bus (total fuse load cannot exceed bus capacity). The maximum fuse value of 15 Amps is marked on the front of the fuse panel. 1.8 Fuse Holders Fuse holders are mounted on the fuse panel such that the fuses install with the fuse identification flags located at the bottom of the fuse holder (upside-down position). When the flags are at the bottom of the fuse holder, they are more visible from below when the fuse panel is installed in a location at or near the top of the rack. The fuse panel is shipped with dummy fuses installed in all positions of the fuse holders. 1.9 Fuse Identification Flag Each fuse has a small color-coded fuse identification flag that identifies the value of the fuse that is installed. When the fuse fails, the flag moves away from the fuse to indicate that the fuse has failed. Since the fuse holders are mounted upside-down, the fuse flags will be facing downward when the fuses fail Fuse Value Designation Pin Holders A fuse designation pin holder is used to house the color-coded pins (rivets) that identify the value of the fuses. A pin holder is intended to be attached to the front of the fuse panel below each fuse holder. See Figures 1 and 2 for location of the pin holders. When the pin holder is in position below the fuse holder, a pin will be located below each fuse to identify the maximum value of current that can flow through the fuse without the fuse failing. The pin holders come with a pressure sensitive adhesive backing for attachment to the fuse panel. A fuse designation pin holder for each fuse holder is provided with the fuse panel (pins are not provided with the fuse panel, but are available as accessories). Page 10

11 1.11 Chassis Ground Connection Two #8 screws and nuts for grounding the fuse panel chassis are mounted on inch ( mm) centers (see Figures 3 and 4). This chassis ground connection can be used to attach a separate grounding conductor when mounting the fuse panel in non-grounded or nonconducting material or when required by local practice. The screws can accommodate 2-hole lugs and up to #6 AWG wire. Two crimp ring lug terminals for two #10 AWG wires are enclosed with the fuse panel. The fuse panel can be grounded using only one (1) screw Alarm Contact Closures The fuse panel contains circuitry that will provide three contact closures when any fuse in the fuse panel (either bus if dual bus) fails or when input power to the fuse panel (either bus if dual bus) is lost (if power-on indicator (green LED) is present). These contact closures may be used as loop closures in alarm systems. The circuitry consists of fuse failure alarm relays with Form C contacts that are terminated at a connector or wire-wrap pin block on the outside of the fuse panel. During normal operation, the normally open (NO) contacts remain open, and the normally closed (NC) contacts remain closed. When a fuse fails or power is lost (fuse panel with power-on indicator), the NO contacts close, creating a connection from NO to common (C) and the NC contacts open. The current for each fuse failure alarm relay (set of three contacts) is 1.0 Amp maximum Alarm Contact Connection The fuse panel is available with either of two types of alarm contact connections. The two types of alarm contact connections are: Screw-down barrier terminal strip: Terminals with 6-32 screws are mounted in a barrier type terminal block. The terminals are on inch (9.525 mm) centers with a distance between barriers of inch (6.350 mm) to inch (8.255 mm). The alarm terminal strip can have one set of three terminals (NO, C, NC) for use with one alarm system or two sets of three terminals (NO, C, NC), for use with two alarm systems. The screw-down terminal strip with one set of three terminals can accept a inch (4.826 mm) wide crimp-on spade lug or ring connectors. The screw-down terminal strip with two sets of three terminals can accept inch (8.255 mm) wide crimp-on spade lug or ring connectors. The terminals can also accept #12 to #24 AWG copper wire with insulation stripped back. Wires are inserted in the terminal strip, and the screws are screwed down on the wires. Wire-wrap terminal block: Wire-wrap pins are mounted in a terminal block for both buses. The alarm terminal block has three sets of three wire-wrap pins (NO, C, NC), for use with three alarm systems. The wire-wrap pins can accept #22 to #26 AWG copper wire with insulation stripped back. Page 11

12 1.13 Fuse Alarm Indicator A visual fuse alarm indicator (red LED) mounted on the front of the fuse panel lights when any fuse on the corresponding bus fails. The LED is not lighted when all fuses on the bus do not fail. Loss of power to a bus will cause the fuse alarm indicator corresponding to that bus to remain not lighted. The LED can be easily replaced in the field (see section 8.5) Power-On Indicator The power-on indicator (green LED) for each power bus mounts on the front panel of the fuse panel. A lighted LED indicates that power is applied to the bus input connectors. An unlighted LED indicates that power is not applied to the bus input connectors. The LED can easily be replaced in the field (see section 8.5) Fuse Designation Card and Holder Two types of fuse designation cards (see Figure 6) and a card holder are provided with the fuse panel. The card holder is intended to be attached to the fuse panel, to one of the fuse panel mounting brackets, to a part of the rack, or at a location close to the fuse panel, as desired. One of the cards should be filled out with circuit information for each of the fuses that are installed in the fuse holder and inserted in the card holder. The card holder has a pressure sensitive adhesive backing for attachment IN. (4.06 CM) 1.60 IN. (4.06 CM) 2.36 IN. (5.99 CM) 2.36 IN. (5.99 CM) 20 POSITION CARD 10 POSITION A AND B CARD C Figure 6. Fuse Designation Cards 1.16 Voltage Designation Label A voltage designation label (see Figure 7) is provided with the fuse panel. The label is intended to be filled out with the actual voltage present on the buses and placed on the fuse panel. The voltage designation label has a pressure sensitive adhesive backing for attachment. Page 12

13 0.38 IN. (0.96 CM) 1.00 IN. (2.54 CM) A Figure 7. Voltage Designation Label 2 PHYSICAL CHARACTERISTICS 2.1 Material and Finish The fuse panel chassis and brackets are made of 16 gauge cold rolled steel. The fuse panel and brackets are finished with powder paint, and are either black or putty white color. Color should be specified by the customer when ordering. 2.2 Cooling The fuse panel is well ventilated to allow efficient convection cooling of all components without the use of fans or blowers. The fuse panel also contains a 17-1/8 inch (43.50 cm ) by 4 inch (10.16 cm) heat sink (patent pending) on the top of the chassis for optimum heat dissipation. 2.3 Protective Cover A clear, thick polycarbonate cover is mounted over the input power connectors, the output power connectors, the chassis ground terminals, and the external alarm contact connections. To gain access to these connections and terminals, the cover is easily removed. To remove a cover, loosen the screws that attach the cover to the chassis, and pull the cover sideways and over the screws (holes are keyed for easy access). Screws do not need to be completely removed to remove the protective cover. 2.4 Weight The weight of the fuse panel is approximately 10 pounds (4.54 kilograms). Page 13

14 2.5 Mounting The standard (front and rear access) fuse panel can be mounted in a 19-inch (48.26-cm) rack or a 23-inch (58.42-cm) rack, using the universal fuse panel mounting brackets shipped with the panel. The mounting brackets can be flush mounted or recessed 1 inch (25.4 mm), 2 inches (50.8 mm), 3 inches (76.2 mm) or 4 inches (101.6 mm) from the front of the panel. The mounting brackets allow mounting with WECO 1.00-inch (2.54 cm) hole spacing or EIA 1.25-inch (3.18 cm) hole spacing. The total front access fuse panel can be mounted in a 23-inch (58.42-cm) rack using the fuse panel mounting brackets shipped with the panel. The total front access fuse panel can be flush mounted or recessed 1 inch (25.4 mm) or 2 inches (50.8 mm) from the front of the panel. The mounting brackets allow mounting with WECO 2.00-inch (5.08 cm) hole spacing or EIA 2.5-inch (6.35 cm) hole spacing. Two mounting brackets, six (6) 1/4-inch (6.350 mm) 6-32 screws for attaching the brackets to the fuse panel, and four (4) 3/8-inch (9.525 mm) screws with washers for attaching the brackets to the rack, are included with the fuse panel. ETSI rack mounting using ETSI mounting brackets is also available. 2.6 Environmental Characteristics Table 1 lists the environmental characteristics of the fuse panel. Table 1. Fuse Panel Environmental Characteristics PARAMETER Operating temperature Storage temperature Humidity range (operating) Altitude range Fire rating Earthquake design Acoustic noise Heat dissipation (fully loaded) Heat dissipation (no load) DESCRIPTION 5 C to +55 C 55 C to +85 C 0% to 95% humidity (non-condensing) 197 ft. to 13,500 ft. above sea level All components UL94-V0. NEBS Level 3 NEBS Level 1, 2, and 3; Zone 4 0 dba above ambient A per bus, A total fuse panel load 1 watt per bus 2.7 Dimensions The dimensions of the fuse panels are shown in Figure 8 and Figure 9. Page 14

15 8.91 IN. (22.63 CM) 7.99 IN. (20.28 CM) IN. (43.51 CM) IN. (56.67 CM) IN. (58.42 CM) 1.75 IN. (4.45 CM) 1.13 IN. (2.87 CM) A Figure 8. Dimensions of PowerWorx GMT Series Uninterrupted Power (C-Source) Fuse Panel, Standard (Front and Rear Access), with Mounting Brackets Attached for Mounting in 19 Inch (48.26 cm) Rack 6.42 IN. (16.30 CM) 5.17 IN. (13.12 CM) IN. (53.97 CM) IN. (58.42 CM) IN. (56.67 CM) 2.75 IN. (6.99 CM) 3.50 IN. (8.89 CM) A Figure 9. Dimensions of PowerWorx GMT Series Uninterrupted Power (C-Source) Fuse Panel, Total Front Access, with Mounting Brackets Attached for Mounting in 23 Inch (58.42 cm) Rack Page 15

16 3 ACCESSORIES The following accessories for the PowerWorx fuse panel are available: GMT fuses. Standard sizes from 0.2 Amp to 15.0 Amps Fuse designation pin (rivet) holder Colored, standard value, fuse designation pins (rivets) Cable management bar with mounting screws. Provides cable tie points. Installed at rear of fuse panel by fastening ends of bar to both sides of fuse panel GMT fuse puller Compression lugs for #2, #4, #6, and #14 AWG wire Fuse designation card holder kit 4 UNPACKING AND INSPECTION Unpack and inspect the various components as follows: 1. Inspect the exterior of the shipping container for evidence of handling that may have damaged the components in the container. 2. Unpack each container while carefully checking the contents for damage and verify with the packing slip. 3. File a claim with the commercial carrier and notify ADC Customer Service if damage is detected or if parts are missing. Save damaged cartons for inspection by the carrier. 4. Refer to the Customer Service section at the back of this manual for repair, replacement, and warranty information. 5. Save all shipping containers for use if the equipment requires return shipment at a future date. 5 INSTALLATION The following guidelines should be used when mounting the fuse panel in a rack. Mount the fuse panel in the upper area of the rack or cabinet to reduce exposure of the powering wiring. A minimum of 1.75 inches (4.45 cm) of air space (one rack space) for cooling shall be provided between the top of the fuse panel and the next item in the rack. Adding a fuse panel to a rack may displace a device which may require relocation. Use common hand tools to install the fuse panel. The use of a power screwdriver to install the self-tapping screws that attach the mounting brackets to the rack is recommended. Caution: This equipment employs electrical voltage and amperage levels which may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with this equipment when the fuse panel is energized. Only insulated tools should be used on energized elements of the fuse panel. Page 16

17 Warning: Never install telephone equipment in a wet location or during a lightning storm. When installing or modifying telephone lines, disconnect lines at the network interface before working with uninsulated lines or terminals to prevent electrical shock. Warning: Do not install fuses in fuse panel or power source until you have completed the power wiring connections. 5.1 Cable Management Bar (Optional Accessory) Before installing the fuse panel in the rack, mount the cable management bar (not supplied with fuse panel) on the rear of the fuse panel as shown in Figure 10. Use the 1/4-inch (6.350 mm) long 4-40 screws that are supplied with the cable management bar. The cable management bar can be recess mounted by using the mounting holes closest to the front of the fuse panel. UNINTERRUPTED POWER FUSE PANEL ATTACH TO EITHER SET OF 3 HOLES CABLE MANAGEMENT BAR B Figure 10. Cable Management Bar Installation, Standard (Front and Rear Access), Dual Power Feed Fuse Panel Shown 5.2 Mounting Brackets Two 1-3/4-inch (4.45-cm) high universal mounting brackets are used to mount the standard (17.12-inch (43.48-cm) wide) fuse panel in either a 19-inch (48.26-cm) rack or a 23-inch (58.42-cm) rack. The brackets, mounting screws, and washers are provided with the fuse panel (see 2.5). See Figure 11. Two 3-1/2-inch (8.89-cm) high mounting brackets are used to mount the total front access (21.25-inch (53.97-cm) wide) fuse panel in a 23-inch (58.42-cm) rack. The brackets, mounting screws, and washers are provided with the fuse panel (see 2.5). Page 17

18 The slotted mounting hole pattern in the mounting brackets compensates for vertical rack differences and allows mounting the standard (front and rear access) 1-3/4-inch (4.45-cm) high fuse panel in either 1-3/4-inch (4.45 cm) high or 2-inch (5.08-cm) high rack spaces and allows mounting the inch (53.97-cm) wide fuse panel in either 3-1/2-inch (8.89-cm) high or 3-3/4-inch (9.53 cm) high rack spaces. Note: ETSI mounting brackets are also available. 19-IN. (48.26 CM) RACK, MOUNT ON FRAME, USE 3/8-IN. (9.525 MM) LONG SCREWS AND WASHERS 23-IN. (58.42 CM) RACK, MOUNT ON FUSE PANEL, USE 1/4-IN. (6.350 MM) LONG FLATHEAD SCREWS 23-IN. (58.42 CM) RACK, MOUNT ON FRAME, USE 3/8-IN. (9.525 MM) LONG SCREWS AND WASHERS 19-IN. (48.26 CM) RACK, MOUNT ON FUSE PANEL, USE 1/4-IN. (6.350 MM) LONG FLATHEAD SCREWS C Figure 11. Universal Mounting Brackets for Mounting Standard (Front and Rear Access) Fuse Panel in 19-Inch (48.26-cm) Rack or 23-Inch (58.42-cm) Rack Caution: When attaching the mounting brackets to the fuse panel, use only the hardware supplied with the fuse panel. The flathead screws are for attaching the mounting brackets to the fuse panel. Use of any other hardware could cause contact with internal parts of the fuse panel. Install the fuse panel in the rack as shown in Figure 12 and as follows: 1. Mount the brackets to the fuse panel chassis using the six 1/4-inch (6.350 mm) 6-32 flathead screws. Mount the bracket marked L on the left side of the panel and the bracket marked R on the right side of the panel (viewed from front of panel). 2. Secure the fuse panel to the rack using the four 3/8-inch (9.525 mm) screws and washers supplied with the fuse panel. 5.3 Wiring Connections Note: Before connecting the input and output power wires, measure the resistance as defined in 6.2. Remove the protective cover from the fuse panel by loosening the four screws that attach the cover, sliding the cover to the right, and pulling it over the screws. Route and connect ground cables, power cables, and alarm cables to the fuse panel connectors according to local practice and the following subparagraphs. An example of the connections to the fuse panel is shown in Figure 13. After routing the cables, tie them to the cable management bar (if optional accessory ordered). Page 18

19 13956-B Figure 12. Typical Fuse Panel Installation in Equipment Rack, Rear View of Rack and Cable Management Bar (Standard Fuse Panel Shown) Caution: Connect only the input voltage wire (wire labeled BATTERY or BATT, or labeled with the voltage polarity and/or the voltage value) to the connector on the fuse panel labeled BATT (battery). Connect only the input return wire (wire labeled RTN, RETURN, or BATTERY GROUND ) to the connector on the fuse panel labeled RTN (return). If the wires are reversed, voltage could be present on the fuse panel chassis and current could flow through the unfused return wiring in the fuse panel. This condition causes damage to equipment in the rack in which the fuse panel is installed and to equipment in adjacent frames! Replace the protective cover on the fuse panel after all the wiring connections are made and before power is applied to the fuse panel. Page 19

20 SCREW-DOWN BARRIER TERMINAL STRIP TYPE CONNECTORS SHOWN CONNECT TO OUTPUT POWER CONNECT TO CONNECT RETURN TO OUTPUT POWER CONNECT TO RETURN SCREW-DOWN BARRIER TERMINAL STRIP TYPE CONNECTORS SHOWN TO BATTERY BUS B* TO RETURN BUS B** COMPRESSION LUG TYPE CONNECTORS SHOWN WIRE-WRAP PINS NO C NC AUDIO VISUAL REMOTE ALARM C.GND C.GND COMPRESSION LUG TYPE CONNECTORS SHOWN TO RETURN BUS A** TO BATTERY BUS A* *NOTE: CONNECT INPUT VOLTAGE WIRE LABELED "BATTERY" OR "BATT," OR LABELED WITH THE VOLTAGE POLARITY AND/OR THE VOLTAGE VALUE TO THE "BATT" CONNECTOR ("HOT" WIRE). **NOTE: CONNECT INPUT RETURN WIRE LABELED "RTN," "RETURN," OR "BATTERY GROUND" TO THE "RTN" CONNECTOR. Figure 13. Fuse Panel Cabling; Rear View (Standard Fuse Panel with Compression Lug Input Connectors, Screw-Down Barrier Terminal Strip Output Connectors, and Wire-Wrap Pin Alarm Contact Pin Block Shown) A Chassis Ground Connection Mounting the fuse panel on a metal equipment rack using metal mounting brackets as described in 5.2 provides a sufficient return path to meet equipment grounding requirements. However, often a separate grounding conductor is 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, e.g., a plastic rack or cabinet. When the fuse panel requires separate chassis grounding, the chassis grounding conductor is sized to match the upstream protection device feeding the fuse panel. This provides an adequate return path capable of allowing the fuse to fail in the unlikely event of a battery wire to chassis fault. Connect one or both of the chassis ground connectors (labeled C. GND ) to the equipment rack ground using the following chassis grounding recommendations: Chassis ground conductor: Use two #10 AWG wires if using both chassis ground connectors or one #6 AWG wire if using one chassis ground. Chassis grounding conductor connection point: Use provided #8 screws and nuts on inch ( mm) centers. Two #10 crimp ring terminals, for use with #10 AWG wires, are provided. Page 20

21 5.3.2 Output Power Connectors Connect the output BATT and RTN terminals for each fused circuit on each set of terminal strips. Screw-down barrier terminal strip: Use #12 to #22 AWG wire. Wire leads should be equipped with crimp-on spade lugs or ring connectors that have a maximum width of inches (8.255 mm). The terminals also accommodate copper wire without lugs (insulation stripped back). Torque the screws to approximately 9 pound-inches (1 Newton-meter). Set screw barrel terminal strip: Use #12 to #22 AWG wire. Torque the screws to approximately 4.5 pound-inches (0.5 Newton-meter) External Alarm Contact Connections Connect the external alarm contacts as desired to the system alarms. Screw-down barrier terminal strip: Use #12 to #24 AWG wire. Wire leads should be equipped with spade lug or crimp-on ring connectors that have a maximum width of inch (8.255 mm). The following sizes of crimp-on spade lugs or ring connectors are recommended: Screw-down terminal strip with one set of three terminals = inch (4.826 mm) wide connector Screw-down terminal strip with two sets of three terminals (six terminals) = inch (8.255 mm) wide connector The terminals also accommodate copper wire without lugs (insulation stripped back). Torque the screws to approximately 9 pound-inches (1 Newton-meter). Wire-wrap terminal block: Use #22 to #26 AWG copper wire with insulation stripped back Input Power Connectors Connect input power wires to the input power connectors labeled BATT and connect return wires to the return connectors labeled RTN for both buses in the fuse panel. Connect input power to the appropriate power sources in accordance with applicable local electrical codes and/or National Electrical Codes. Caution: Caution should be taken to not reverse input wires to the fuse panel. In the fuse panel, the internal battery (positive or negative voltage) wiring is fused, and the internal return wiring is not fused. Compression lug connector: Use the included 2-hole lugs with #6 AWG copper wire (insulation stripped back) or appropriate optional 2-hole lugs available as accessories (see Section 3) with appropriate AWG copper wire. Tighten the nuts to approximately 16 pound-inches (2 Newton-meters). Page 21

22 Set screw barrel connector: Use only the barrel connectors on each connector assembly that are closest to the outside of the fuse panel. Use up to #6 AWG copper wire with insulation stripped back. Tighten the set screws to approximately 16 pound-inches (2 Newton-meters). Note: Do not loosen the set screws in the two barrel connectors that are closest to the center of the fuse panel. Accessing these connectors may render the warranty void. 5.4 Fuse Designation Pin Holders Attach the fuse designation pin holder(s) to the front of the fuse panel below each fuse holder and install color-coded pins (accessory item, not supplied) in the holder as required. See the installation drawing for the location of the pin holder(s). 5.5 Fuse Designation Card Holder and Card Attach the fuse designation card holder to the fuse panel, to one of the fuse panel mounting brackets, or to a part of the rack as desired by removing the backing from the back of the card holder and pressing the card holder against the mounting surface. Fill out one of the cards (see Figure 6) with circuit information as desired and insert it in the card holder. 5.6 Voltage Designation Label Write the voltage used in the fuse panel on the voltage designation label (see Figure 7) and attach the label to the back of the fuse panel. 5.7 Fuse Installation Replace the dummy fuses in the fuse holder(s) with the appropriate value GMT fuses. Leave the dummy fuses in unused fuse positions. 6 TESTING THE FUSE PANEL Caution: This equipment employs electrical voltage and amperage levels which may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with this equipment when the fuse panel is energized. Only insulated tools should be used on energized elements of the fuse panel. 6.1 Quality Control Each unit is thoroughly tested at the ADC Telecommunications factory. The following tests are recommended, however, to assure that no damage has occurred during shipping or handling. Both bus A and bus B input circuits need to be tested. Page 22

23 6.2 Resistance Test Caution: Before performing this test, verify that the input and output power is not connected to the fuse panel connectors. Measure the resistance at each bus input with a multimeter connected to the BATT and RTN input terminals. A resistance of at least 500 ohms should be read on the meter (some meters will indicate a resistance of several Megohms because their input voltage is not high enough to break down the forward conductance of the diodes used in the alarm circuit). Any resistance higher than 500 ohms is acceptable. 6.3 Connection Polarity Test To verify that the input power wires are connected to the correct terminals, measure the voltage between the input return connector (RTN) and the chassis ground using a multimeter. The voltage should be less than 2.0 Vdc. If the voltage is more than 2.0 Vdc, reverse the input power wires and measure the voltage between the input return connector (RTN) and the chassis ground again to determine that the voltage is less than 2.0 Vdc. 6.4 Wiring Connections Measurements Measure the torque of all input, output, chassis ground and fuse failure alarm relay contact connections stated in the Wiring Connections paragraphs above using a torque screwdriver that is calibrated in pound-inches (Newton-meters). 6.5 Power Indication Test After checking input resistance according to the Resistance Test above, the input power wires can be connected to the fuse panel. Upon power application, the fuse alarm indicators will not light unless a fuse that has failed is in the fuse holder. The fuse failure alarm relay should indicate an open circuit between the common (C) contact and the normally open (NO) contact at the alarm contacts. When input power is not applied, a short will be indicated between these contacts. 6.6 Fuse Alarm Test Place a fuse that has failed in one of the fuse positions on each bus. The visual fuse alarm indicator(s) will change from unlighted to a red light, and the fuse failure alarm relay will operate. 7 OPERATION Caution: This equipment employs electrical voltage and amperage levels which may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with this equipment when the fuse panel is energized. Only insulated tools should be used on energized elements of the fuse panel. Page 23

24 All fuse panel circuits are operational as soon as power is applied to the input connectors. The alarm indicator should not light when power is applied. Operation of the fuse panel consists of removing and replacing fuses when a fuse fails. If a fuse fails, the alarm indicator lights, and the external and remote alarms are activated (if present). 8 MAINTENANCE Caution: This equipment employs electrical voltage and amperage levels which may be considered an electrical hazard. Care should be exercised to assure that only qualified personnel are allowed to install, operate, maintain, or otherwise come in contact with this equipment when the fuse panel is energized. Only insulated tools should be used on energized elements of the fuse panel. 8.1 Inspection Inspect the fuse panel periodically (every six months is recommended) for damage to the fuses, damaged or broken wires on the power outputs and the external alarm connections. Inspect for excessive dust and dirt that block the vents. 8.2 Cleaning 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. Care should be taken to not damage the fuses or any wiring. 8.3 Adjustments No adjustments in the field are indicated or required. If a circuit is not operating properly, contact ADC customer assistance (see Section 9). 8.4 Fuse Removal The GMT fuses can be removed with the aid of a wire hook or tweezers-type fuse puller. A fuse puller is an available accessory. 8.5 LED Replacement The LEDs may be replaced as follows: 1. Pull LED out slowly from the front of the fuse panel. 2. Disconnect both mating terminals (quick-connects or fastons) on the wires from the tabs on the LED. 3. On the replacement LED, connect the mating terminal on the red wire to the tin tab and connect the mating terminal on the black wire to the brass tab. Page 24

25 9 CUSTOMER INFORMATION AND ASSISTANCE For customers wanting information on ADC products or help in using them, ADC offers the services listed below. To obtain any of these services by telephone, first dial the central ADC telephone number, then dial the extension provided below. The central number for calls originating in the U.S.A. or Canada is For calls originating outside the U.S.A. or Canada, dial country code 1 then dial Sales Assistance Extension 3000 Systems Integration Extension 3000 BCG Technical Assistance Center Extension technical@adc.com Product Return Department Extension repair&return@adc.com Quotation Proposals Ordering and Delivery General Product Information Complete Solutions (from Concept to Installation) Network Design and Integration Testing System Turn-Up and Testing Network Monitoring (Upstream or Downstream) Power Monitoring and Remote Surveillance Service/Maintenance Agreements Systems Operation Technical Information System/Network Configuration Product Specification and Application Training (Product-Specific) Installation and Operation Assistance Troubleshooting and Repair ADC Return Authorization number and instructions must be obtained before returning products. Product information may also be obtained using the ADC web site at or by writing ADC Telecommunications, Inc., P.O. Box 1101, Minneapolis, MN , U.S.A. Contents herein are current as of the date of publication. ADC reserves the right to change the contents without prior notice. In no event shall ADC be liable for any damages resulting from loss of data, loss of use, or loss of profits and ADC further disclaims any and all liability for indirect, incidental, special, consequential or other similar damages. This disclaimer of liability applies to all products, publications and services during and after the warranty period. This publication may be verified at any time by contacting ADC s Technical Assistance Center at , extension 3475 (in U.S.A. or Canada) or (outside U.S.A. and Canada), or by writing to ADC Telecommunications, Inc., Attn: Technical Assistance Center, Mail Station #71, P.O. Box 1101, Minneapolis, MN , U.S.A. 2000, ADC Telecommunications, Inc. All Rights Reserved Printed in U.S.A. Page 25

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