NTK599BAE5 and NTK599BGE5 Breaker Interface Panel (BIP) Installation Manual

IMK599BAE5 Issue 5 December 2011 NTK599BAE5 and NTK599BGE5 Breaker Interface Panel (BIP) Installation Manual 19981-B 1294798 Rev E

Preface COPYRIGHT All Rights Reserved Printed in the U.S.A. REVISION HISTORY ISSUE DATE REASON FOR CHANGE 1 10/2004 Original. 2 10/2006 NTK599BA product name changed to NTK599BAE5; other small changes. 3 11/2007 Document name on page i changed from IMK955BAE5 (typo) to IMK599BAE5. Global change of product name NTK955BAE5 (typo) to NTK599BAE5. Standard certification entrees changed as follows: 60950 to 60950-1 ; GR-63 to GR-63-CORE ; GR-1089 to GR-1089-CORE. 4 02/2008 Document changed to also include similar product NTK599BGE5. 5 12/2011 Changed to Ciena logo and citations. TRADEMARK INFORMATION Ciena and Optical Multiservice Edge are registered trademarks of Ciena Corporation. DISCLAIMER OF LIABILITY Contents herein are current as of the date of publication. Ciena reserves the right to change the contents without prior notice. In no event shall Ciena be liable for any damages resulting from loss of data, loss of use, or loss of profits and Ciena 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 ii

Preface TABLE OF CONTENTS Content Page About This Manual........................................................................... v Standard Certification......................................................................... v Admonishments............................................................................. v General Safety Precautions..................................................................... v List of Acronyms.............................................................................vi 1 PRODUCT DESCRIPTION.................................................................. 1 1.1 Product Functions and Features........................................................ 1 1.2 User-Accessible Components......................................................... 2 1.3 Schematic...................................................................... 3 1.4 Front Console.................................................................... 4 1.5 Alarm Unit (AU)................................................................... 5 1.5.1 AU Input and Input Connector.................................................. 5 1.5.2 AU Output and Output Connector................................................ 6 1.6 Input/Output Voltage............................................................... 7 1.7 Power Input Connections............................................................ 7 1.8 Power Input Current................................................................ 8 1.9 Ground Connections................................................................ 9 1.10 Power Output Connections........................................................... 9 1.11 Circuit Breakers................................................................. 10 1.12 Dimensions.................................................................... 10 1.13 Mounting...................................................................... 10 1.14 Specifications................................................................... 11 2 BEFORE STARTING INSTALLATION.......................................................... 13 2.1 General Installation Recommendations................................................. 13 2.2 Unpacking and Inspection........................................................... 13 2.3 Installation Tools Required.......................................................... 13 2.4 Materials Required............................................................... 14 3 INSTALLATION........................................................................ 14 3.1 Pre-Installation Testing............................................................ 14 3.2 Mounting Panel on Rack............................................................ 16 3.3 Installing Ground Wire Using 2-Hole Compression Lug....................................... 18 3.4 Installing Ground Contact for Mesh-BN System Bonding Topology............................... 19 3.5 Connecting Alarms............................................................... 20 3.6 Connecting Output................................................................ 22 3.7 Connecting Input................................................................. 22 3.7.1 Standard Configuration..................................................... 23 3.7.2 Four-Feed Configuration..................................................... 24 4 POWER-UP CHECK..................................................................... 26 5 MAINTENANCE........................................................................ 26 5.1 Performing a Routine Inspection...................................................... 26 5.2 Replacing an Alarm Unit............................................................ 27 Page iii

Preface TABLE OF CONTENTS Content Page 6 CUSTOMER INFORMATION AND ASSISTANCE................................................... 28 Page iv

Preface ABOUT THIS MANUAL This manual describes the Ciena NTK599BAE5 and NTK599BGE5 Breaker Interface Panel (BIP) and provides all information required to install and operate this product. The BIP is used to distribute dc power to up to four long-haul optical racks in a telecommunications rack. The BIP provides over-current protection using mid-trip circuit breakers. It collects alarm signals from the optical equipment and indicates alarm status. STANDARD CERTIFICATION The NTK599BAE5 and NTK599BGE5 BIP complies with the applicable sections of the following standards: UL/EN 60950-1, NEC 2002, GR-63-CORE, and GR-1089-CORE. 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 panel uses electrical voltage and current levels that may be considered an energy hazard. 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 panel input or output wires. This may require turning off the system office battery input at the battery distribution fuse bay or removing fuses at the fuse panel. Page v

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. Warning: To prevent the panel from overheating, do not operate it in an area that exceeds the maximum recommended ambient temperature of 55º C. Warning: Stability hazard. The rack stabilizing mechanism must be in place, or the rack must be bolted to the floor before you slide the unit out for servicing. Failure to stabilize the rack can cause the rack to tip over. Warning: Suitable for mounting on concrete or other non-combustible surface only. Warning: Take care when connecting units to the supply circuit so that wiring is not overloaded. Warning: This equipment is intended to be grounded to comply with emission and immunity requirements. Ensure that the switch functional ground lug is connected to earth ground during normal use. LIST OF ACRONYMS ACO -- Alarm Cut Off AWG -- American Wire Gauge AU -- Alarm Unit BIP -- Breaker Interface Panel BN -- Bonding Network BR -- Battery Return DC -- Direct Current EIA -- Electronic Industries Association ETSI -- European Telecommunications Standards Institute EU -- European Union IEC -- International Electro-technical Commission LED -- Light-Emitting Diode L+ -- Positive Line voltage Page vi

Preface L- -- Negative Line voltage MESH-BN -- Mesh Bonding NEBS -- Network Equipment Building System NC -- Normally Closed NO -- Normally Open RTN -- Return SELV -- Safety Extra Low Voltage TNV -- Telecommunications Network Voltage UL -- Underwriters Lab Page vii

Preface Page viii

1 PRODUCT DESCRIPTION This section describes the Ciena NTK599BAE5 and NTK599BGE5 Breaker Interface Panel (BIP). Topics include product function and features, user-accessible components, schematic, front console, Alarm Unit (AU), input/output voltage, power input connections, power input current, ground connections, power output connections, circuit breakers, dimensions, mounting, and specifications. 1.1 Product Functions and Features The Ciena NTK599BAE5 and NTK599BGE5 BIP supplies low-voltage, protected dc power to up to four long haul optical racks in a telecommunications network. The BIP provides the following basic functions and features: Eight power bus circuits, labeled A1 to A4 and B1 to B4. Each circuit is protected by an individual mid-trip circuit breaker. Sixteen compression type power input terminals (eight positive terminals, eight negative terminals). These terminals accept narrow-tongue 2-hole lugs. Narrow tongue lugs are defined as less than 0.5 inches, 1.12 cm wide. Eight D-sub type power output connectors. There is one connector per output. Each connector has a negative terminal (socket) and a positive terminal (pin). Field-replaceable Alarm Unit (AU). The AU receives and reports alarms from the protected equipment and from the BIP itself. It displays alarm status on the front console of the panel and outputs visual and audible alarm signals to the front office or remote device. Front console with alarm indicators. Included are CRITICAL (red), MAJOR (red), and MINOR (amber) LEDs. These alarms may be received from either the load equipment or the BIP itself. A smaller red LED (BIP Fault) indicates an internal fault in the BIP. Lamp Test and Alarm Cut Off (ACO) buttons on front console. Lamp Test button provides a means to test LEDs. ACO button provides ability to turn off major audible alarm signals. Swing-down front cover. Open cover provides access to user-accessible components of the panel including power connectors, alarm connectors, and the AU. Rack-mounting in three types of racks. As shipped, the rack mounts in a 21-inch (533.4 mm) rack per ETSI specifications. Alternate brackets provide mounting per EIA and FibreWorld standards (see Figure 10 on page 11.) Reliable grounding from chassis to office ground. Standard grounding is done using a compression type terminal block on the left side of the BIP chassis. Mesh-BN type grounding can be done using a bus bar (see Section 3.4 on Page 19). Input current of maximum 160 Amps input for the entire BIP, with a maximum of 40 Amps per individual circuit for NTK599BAE5 and 20 Amps per individual circuit for NTK599BGE5. Warning: At least one circuit must be powered on each side of the BIP (at least one A circuit and one B circuit). Otherwise, the BIP will generate a major alarm on power-up. Page 1

1.2 User-Accessible Components The BIP is a total front access panel. Figure 1 shows the user-accessible components of the panel. From bottom center in the figure, going clockwise, they are as follows: CIRCUIT BREAKER (8 X) POWER INPUT TERMINALS (16 X) POWER OUTPUT TERMINALS (8 X) ALARM INPUT AND OUTPUT CONNECTORS (NOT VISIBLE) 19982-A ALARM UNIT (AU) (NOT VISIBLE) FRONT COVER MOUNTING BRACKET (2 PLACES) Figure 1. User-Accessible Components Front Cover swings down to provide access to the components shown in the figure. Connector diagrams printed on the back of the cover identify the connectors and give pin designations. The front cover has a console on the its front side (not visible here). Alarm Unit (AU) collects alarms from protected equipment and from the BIP itself; indicates the alarms on the BIP front console. The AU also forwards alarm status to the front office or to a remote device. The AU is field-replaceable. Alarm Input and Output Connectors provide physical interfaces for alarm indications received from the load equipment (input) and forwarded to the front office or remote device (output). Both are D-sub type connectors. Circuit Breakers one for each output. These are individual, mid-trip circuit breakers. For specifications, see Section 1.14 on Page 11. Power Input Terminals for up to eight inputs (with two terminals per input), arranged from left to right into A1-A4 negative, A1-A4 positive, B1-B4 positive, B1-B4 negative. These are compression-type blocks with two studs per block for use with narrow tongue 2- hole lugs. Narrow tongue lugs are defined as less than 0.5 inches, 1.12 cm wide. Page 2

Power Output Terminals for up to eight power outputs. These are D-sub type, combo (2-position) connectors with a negative terminal (socket) and a positive terminal (pin). Mounting Brackets accommodate ETSI, EIA, or FibreWorld rack mounting. These components are described in more detail in the following topics. 1.3 Schematic Figure 2 is a BIP schematic showing the eight power circuits and indicating how the circuits are tied into the AU and front console. B4 "L-" (B4) B3 B2 "B" OUTPUT CONNECTORS "L-" (B3) "L-" (B2) B1 "B" INPUT CONNECTORS "L-" (B1) "L+" (B4) "L+" (B3) A4 "L+" (B2) "L+" (B1) "L+" (A4) "L+" (A3) A3 A2 "A" OUTPUT CONNECTORS "A" INPUT CONNECTORS "L+" (A2) "L+" (A1) "L-" (A4) A1 "L-" (A3) "L-" (A2) "L-" (A1) 4X "A" ALARM POWER 4X "B" ALARM POWER ALARM UNIT 9-PIN 25-PIN ALARM INPUT CONNECTOR ALARM OUTPUT CONNECTOR FRONT COVER PCB LAMP TEST ACO BIP LED INDICATORS BAY ALARM LED INDICATORS FG TERMINAL 19983-A Figure 2. BIP Schematic Page 3

1.4 Front Console The front console, located on the BIP front cover, provides alarm and status information and operation controls. Figure 3 shows the front console. Its items include the following: 20026-B Figure 3. Front Cover Indicators (NTK599BAE5 Shown) CRITICAL (Red), MAJOR (Red), AND MINOR (Amber) LEDs indicate alarms of the noted severity. An alarm is indicated when an alarm of the same type is received from the equipment protected by the panel. Alarm events in the AU and BIP are also indicated using the same LEDs, as indicated in Table 1. ACO (Alarm Cut Off) Button can be used to turn off the major audible alarm forwarding signals from the AU. Lamp Test Button Can be used to test all of the front console LEDs. When the button is pressed, all of the LEDs illuminate. BIP Fault Lights when the BIP has an internal fault. Alarms in the BIP result from loss of input power, a tripped breaker, or a failed fuse in the AU. For a summary of how these indicators work with respect to one another, refer to Table 1. BIP ALARM LED Table 1. Alarm Outputs Summary A POWER OK LED B POWER OK LED MINOR ALARM LED MAJOR ALARM LED CRITICAL ALARM LED Normal operation Off On On Per inputs Per inputs Per inputs Any breaker trips On On On Per inputs Alarm Per inputs AU fuse fails On A or B off depending on fuse Per inputs Alarm Per inputs Feeder A low power On Off On Per inputs Alarm Per inputs Feeder B low power On On Off Per inputs Alarm Per inputs Both feeders low power Off Off Off Alarm Alarm Alarm Page 4

1.5 Alarm Unit (AU) The Alarm Unit (AU) is a electronic module factory-installed in a compartment in the lower central area of the BIP on the front side. The AU collects bay level alarms from the load equipment and from the BIP itself. It reports any alarm condition on the BIP front console. The alarm condition reported may be critical, major, or minor, per standard industry definitions. For each of these states, there is an LED on the BIP front console. The AU connects to the back side of the front cover by way of an external cable. The AU provides alarm indications for forwarding to the front office or to a remote device. A forwarded alarm indication consists of separate visual and audible signals transmitted through different pins of the AU output connector. The AU is field-replaceable from the front side of the BIP. A slot screwdriver is required to remove or install the AU. Figure 4 is a schematic of the main components of the AU. Minor Vis C, NO, NC Minor Au C, NO, NC Major Vis C, NO, NC ALARM OUTPUTS Major Au C, NO, NC Critical Vis C, NO, NC Critical Au C, NO, NC BIP Vis BIP Au BIP Audio "A" POWER "B" POWER LAMP TEST BIP Visual ACO (AUDIO CUT OFF) TURNS OFF AUDIO BR Minor Vis Minor Au Major Vis Major Au Critical Vis Critical Au 19996-A OPEN = ALARM ALARM INPUTS Figure 4. Alarm Unit Schematic 1.5.1 AU Input and Input Connector The 9-pin input interface from the load equipment to the AU provides direct connections to six normally closed (NC) circuits that switch to an open state when an alarm exists. These six circuits are assigned based on the three levels of alarm severity (critical, major, and minor) plus the two types of indications (audible and visual) forwarded for each alarm to the front office or remote device. Page 5

The alarm input interface is Telecommunications Network Voltage (TNV) 2 for 60V systems and Safety Extra Low Voltage (SELV) for 48V systems. The incoming alarm signals (contacts, connectors, and wiring) must be capable of carrying up to 2 Amps current. The input connector is a 9-pin D-sub receptor located on the front side of the AU. Figure 5 shows the pin configuration. Table 2 gives the pin designations. For an indication of how the received alarms affect the BIP front console LEDs, refer to Table 1 on Page 4. 5 1 9 6 20006-A Figure 5. AU 9-Pin Input Connector Pin Configuration Table 2. AU 9-Pin Input Connector Pin Designations PIN # SIGNAL PIN # SIGNAL 1 Critical Visual NO 6 Major Visual NO 2 Critical Audible NO 7 Major Audible NO 3 BR 8 Minor Visual NO 4 BR 9 Minor Audible NO 5 BR 1.5.2 AU Output and Output Connector The 25-pin output interface from the AU to the front office provides indications of the same alarm states as received on the 9-pin input interface. The output interface also reports the state of the BIP and the AU using the same alarm states. For each single pin on the input interface, three pins are used on the output interface, providing the standard NO-NC-COM configuration of contacts for use by the front office device. The output circuits are normally closed. An open circuit indicates an alarm exists. Figure 6 shows the output connector. Table 3 gives the pin designations. An adapter connector is available that, when plugged into the output connector, provides a wire wrap pin array with the same pin designations. 13 1 25 14 20005-A Figure 6. AU 25-Pin Output Connector Pin Configuration Page 6

Table 3. AU Output Connector Pin Designations PIN # SIGNAL PIN # SIGNAL 1 Minor Audible NO 14 Minor Visual NO 2 Minor Audible COM 15 Minor Visual COM 3 Minor Audible NC 16 Minor Visual NC 4 17 5 Major Audible NO 18 Major Visual NO 6 Major Audible COM 19 Major Visual COM 7 Major Audible NC 20 Major Visual NC 8 21 9 Critical Audible NO 22 Critical Visual NO 10 Critical Audible COM 23 Critical Visual COM 11 Critical Audible NC 24 Critical Visual NC 12 25 13 1.6 Input/Output Voltage The BIP accepts an input voltage of 48 Vdc nominal or 60 Vdc nominal, within an operating range from 40 Vdc to 75 Vdc. The voltage output from a given circuit at any time corresponds to the voltage input to that circuit. The maximum voltage drop between any input terminal and any output terminal is 0.35 V at breaker rated amperage. 1.7 Power Input Connections Power feeds for the eight BIP circuits are connected on the front side of the panel using twohole compression lugs The panel accommodates either straight lugs with wires pointing up or 90 o -angle lugs with wires pointing backward. For each power input, there is one negative (L ) and one positive (L+) terminal, but not side by side. The terminals are arranged as follows (from left front to right front): A1 to A4 negative, A1 to A4 positive, B1 to B4 positive, and B1 to B4 negative. This arrangement allows all eight positive terminals to be grounded together as required for ETSI Mesh-BN system bonding topologies. This is done using an 8x bus bar with a screw-in connection to an unremovable grounding point on the BIP chassis (see Figure 18 on page 20). Each individual terminal has two #10 (0.25-inch, 1.12 cm) studs mounted on 0.625 inch (1.59 cm) centers. The terminals accept narrow-tongue lugs with a maximum lug width of 0.5 inches (1.12 cm). Up to #2 AWG or 35 mm 2 copper wire can be used. In selecting the copper wire size to be used for power input, consider the allowable ampacity as defined by local practice and the National Electrical Code (refer to Appendix A). Page 7

2x (negative terminal) bus bars can be used in combination with 4x (positive terminal bus bars) to reconfigure the power input to use four power feeds per BIP instead of the standard eight power feeds. (In either case, there are eight power outputs.) 8x bus bars can be used for grounding across the eight positive terminals, as required for ETSI Mesh-BN system bonding topologies. Figure 7 shows the input configurations. Note: When eight input feeds are used, use of the 4x bus bar (as shown in Figure 7) is optional. 4 INPUT FEEDERS PER SIDE 2 INPUT FEEDERS PER SIDE ETSI, 4 INPUT FEEDERS PER SIDE ETSI, 2 INPUT FEEDERS PER SIDE "L-" (B4) "L-" (B4) "L-" (B4) "L-" (B4) "L-" (B3) "L-" (B3) "L-" (B3) "L-" (B3) "L-" (B2) "L-" (B2) "L-" (B2) "L-" (B2) "L-" (B1) "L-" (B1) "L-" (B1) "L-" (B1) "L+" (B4) "L+" (B4) "L+" (B4) "L+" (B4) "L+" (B3) "L+" (B3) "L+" (B3) "L+" (B3) "L+" (B2) "L+" (B2) "L+" (B2) "L+" (B2) "L+" (B1) "L+" (B1) "L+" (B1) "L+" (B1) OPTIONAL BONDED TO FG BONDED TO FG "L+" (A4) "L+" (A4) "L+" (A4) "L+" (A4) "L+" (A3) "L+" (A3) "L+" (A3) "L+" (A3) "L+" (A2) "L+" (A2) "L+" (A2) "L+" (A2) "L+" (A1) "L+" (A1) "L+" (A1) "L+" (A1) "L-" (A4) "L-" (A4) "L-" (A4) "L-" (A4) "L-" (A3) "L-" (A3) "L-" (A3) "L-" (A3) "L-" (A2) "L-" (A2) "L-" (A2) "L-" (A2) "L-" (A1) "L-" (A1) "L-" (A1) "L-" (A1) = EXTERNAL JUMPER. 19998-A Figure 7. Input Feed Configurations 1.8 Power Input Current The BIP accommodates a maximum input current of 160 Amps (for the entire panel). At least one circuit on either side of the panel (at least one A and one B circuit) must be used. If one side only (only A or B side) receives current, the BIP will generate a major alarm. Page 8

Two negative input terminals can be linked together using a 2x bus bar. When this is done, the current into the linked inputs is distributed equally between the linked circuits. For example, if 30 Amps is applied to linked circuits A1 (L ) and A2 (L ), the A1 and A2 circuits each wind up with 15 Amps current. 1.9 Ground Connections A compression type grounding block is provided on the left front side of the BIP for attaching a grounding cable to Framework Ground (a.k.a. Protective Earth). The PEM nuts accept a #10, two-hole compression lug with 5/8 inch (1.59 cm) hole spacing. The PEM nuts are suitable for terminating #6 AWG (or equivalent size) wire or a 35 mm 2 (ETSI applications) conductor. An 8x bus bar is available for BR grounding across all eight positive power input terminals in the upper front center side of the BIP (see Figure 7 on page 8). The 8x bus bar fits on the 2-stud compression type input power terminals. It has a screw-down grounding tab used to fasten the bus bar to an unremovable grounding point on the BIP chassis. 1.10 Power Output Connections Output power is supplied to the load equipment through eight D-sub connectors located on the front of the panel. These connectors are labeled A1 to A4 and B1 to B4 corresponding to the power input terminal blocks. Each connector on the panel has one negative (L ) position (socket) and one positive (L+) position (pin). See Figure 8. In addition, each connector has two standoffs for housing screws. For reference purposes, the connector is A0778703 (for example, Conec 302W2CSXX99A10X). Table 4 gives pin designations. These connectors accept copper wire in sizes up to #8 AWG. In selecting wire size to be used for power output, consider the allowable ampacity as defined by local practice and the National Electrical Code (refer to Appendix A). SOCKET PIN L- L+ 19997-R Figure 8. D-Sub Power Output Connector Table 4. Power Output Connector Pin Designations CONTACT SIGNAL COMMENT Socket L ( 48/ 60 Vdc) Protected by raised housing insulator Pin L+ (BR) Exposed. Page 9

1.11 Circuit Breakers The BIP provides eight power circuits, each protected with an individual circuit breaker. The circuit breakers are of the mid-trip type, with an electronically activated middle position in addition to the manually activated ON and OFF positions. The middle position is activated automatically by an electrical overload. When in the middle position, the circuit breaker interrupts power supplied to the protected equipment while allowing an alarm signal to be forwarded. Current in the eight circuits together cannot exceed 160 Amps, the panel maximum. 1.12 Dimensions Figure 9 shows BIP dimensions. 17.12 IN. (43.5 CM) 11.01 IN. (28.0 CM) 3.94 IN. (10.0 CM) (EIA AND FIBREWORLD) 20033-A 1.97 IN. (5.0 CM) (ETSI) Figure 9. BIP Dimensions 1.13 Mounting The BIP is shipped with mounting brackets configured in the factory for a 21-inch (533.4 mm) ETSI rack. The mounting brackets are set at a 1.97 inch (50 mm) recess. If desired, the mounting brackets can be removed and replaced with alternative mounting brackets provided with the BIP. The alternative mounting brackets can be used for mounting the panel in an EIA or FibreWorld rack. Figure 10 shows the mounting options and dimensions. Note: The BIP requires one open rack space or equivalent spacing above and below the chassis for heat dissipation. Page 10

EIA MOUNTING 0.63 IN. (1.6 CM) 3.0 IN. (7.6 CM) 18.31 IN. (46.5 CM) 19.0 IN. (48.3 CM) 1.75 IN. (4.4 CM) 3.47 IN. (8.8 CM) ETSI MOUNTING 0.57 IN. 2.54 IN. (1.4 CM) (6.45 CM) 20.28 IN. (51.5 CM) 21.06 IN. (53.5 CM) 1.39 IN. (3.5 CM) 3.47 IN. (8.8 CM) FIBREWORLD MOUNTING 0.63 IN. (1.6 CM) 3.0 IN. (7.6 CM) 22.31 IN. (56.7 CM) 23.25 IN. (59.0 CM) 1.75 IN. (4.4 CM) 20034-B 3.47 IN. (8.8 CM) Figure 10. Mounting Bracket Dimensions 1.14 Specifications Table 5 lists specifications for the NTK599BAE5 and NTK599BGE5 Breaker Interface Panel. Table 5. Breaker Interface Panel Specifications PARAMETER SPECIFICATION REMARKS Physical Weight Dimensions (HxWxD) Color Rack mounting (three options, each uses separate bracket) 18.55 lbs. (8.41 kg) 3.5 x 17.1 x 11.0 inches (88.9 x 434.3 x 279.4 mm) Platinum white 19-inch (EIA) 21-inch (ETSI) 23-inch (FibreWorld Without mounting brackets (see Figure 9) 19.0 inches (482.6 mm) 21.06 inches (534.9 mm) 23.25 inches (590.1 mm) Page 11

Electrical Operating voltages Input current 48 Vdc nominal or 60 Vdc nominal 160 Amps maximum (entire panel) Input range: 40 Vdc to 75 Vdc At least one A circuit and one B circuit must be powered; if not, BIP generates a major alarm Circuit breaker type Mid-trip 8 circuit breakers per panel Circuit breaker rating 40 Amps maximum NTK599BAE5 Single circuit 20 Amps maximum NTK599BGE5 Single circuit Input terminal type 2-hole compression lug (0.25 inch holes on 0.625 inch centers) Uses narrow gauge lugs (maximum width 0.5 inches, 1.12 cm) Output connector type D-Sub combo 2-position L (socket); L+ (pin) Alarm relay contact voltage 220 Vdc maximum or 250 Vac maximum Alarm relay contact current 2 Amps dc or ac maximum 1 Amp switching current Grounding connection (standard) Grounding connection (Mesh-BN ETSI) 2 #10 PEM nuts on 0.625 centers Ground wires terminated at PEM nuts using 2-hole compression lug Uses 8x bus bar installed across all eight L+ inputs See Section 3.4 on Page 19. Environmental Operating temperature 10º C to +55º C Storage temperature 40º C to +85º C Humidity range 5% to 95% humidity No condensation Altitude range 200 to 13,000 ft. (3.96 km) Acoustic noise 0 dba above ambient Heat dissipation (fully loaded) 48 Vdc, 20 Amp input 75 Vdc, 20 Amp input Compliance Table 5. Breaker Interface Panel Specifications, continued PARAMETER SPECIFICATION REMARKS 4.85 watts/ft. 2 /ft. 4.51watts/ft. 2 /ft. UL, NEC 2002, NEBS, IEC, and CE Torque Mounting bracket chassis screws 15 pound force-inches 1.7 Newton meters Mounting bracket rack screws 25 pound force-inches 2.8 Newton meters Input power terminal nuts 19 pound force-inches 2.1 Newton meters Output power D-sub connector housing screws 4 pound force-inches 0.45 Newton meters Grounding screws 19 pound force-inches 2.1 Newton meters Page 12

2 BEFORE STARTING INSTALLATION This section provides general installation recommendations and unpacking and inspection procedures. Also, this section lists the tools and materials required for installation. 2.1 General Installation Recommendations The Ciena Breaker Interface Panel (BIP) must be installed in a restricted access location in accordance with Articles 110-16, 110-17, and 110-18 of the National Electrical Code, ANSI/ NPFA 70. Mount the BIP in the uppermost area of the rack to reduce the exposure of the power wiring. Route ground, input power, output power, and alarm cables to the BIP according to local practice and procedures. After routing cables, secure them to the rack or to any cable management devices that are in use. When mounting the BIP in the rack, make sure mechanical loading is even to avoid a hazardous condition. The rack shall be capable of supporting the combined weight of all equipment. If the BIP is installed in a closed or multi-rack assembly, the operating temperature of the rack environment may exceed the ambient temperature. Be sure to install the BIP in an environment compatible with the maximum rated ambient temperature. Maintain one rack unit clearance for the bottom and top of the BIP to allow for adequate cooling air flow. Install protective covers on the front side of the power input terminals after all wiring connections are made and tests completed. Do not apply power to the BIP until all wiring and tests are completed. 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. Check the BIP for broken or missing parts. If there is any damage, contact Ciena (refer to Section 6). 2.3 Installation Tools Required The following tools are required to install the BIP: Screwdrivers (both Phillips and flatblade) 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 Compression lug crimper Wire-wrap tool Multimeter Heat gun Page 13

2.4 Materials Required The following materials are required to install the fuse panel: Insulated copper wire for input and output power wires (see Appendix A); 2-hole compression lugs for terminating power input wires and grounding wires (see Section 1.14, Specifications, on page 11). 3 INSTALLATION This section tells how to pre-test and install the BIP. 3.1 Pre-Installation Testing Each panel is thoroughly tested at the Ciena factory before being shipped. However, before the panel is installed, continuity tests should be performed 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 Use the following procedure: 1. Turn the circuit breakers to the ON position. 2. Connect one test probe to the A-1 (L ) input power terminal and the other test probe to the A-1 (L+) input power terminal, as shown in Figure 11. TEST THAT NO CONTINUITY EXISTS BETWEEN NEGATIVE AND POSITIVE INPUT TERMINALS FOR EACH POWER CIRCUIT (A1 - A4, B1 - B4) A1 (L-) A1 (L+) 20041-A Figure 11. Test 1: Input Battery to Input Return Page 14

3. Verify that no continuity exists between the A-1 (L ) and the A-1 (L+) terminals. 4. Repeat the test procedure for each remaining (L )/(L+) pair for the remaining terminals: A2 (L ) and A-2 (L+), A3 (L ) and A-3 (L+), and so on, until the circuits have been tested. Test 2: Input Battery to Output Battery Use the following procedure (Figure 12): Note: Each D-sub type power output connector has one socket and one pin. The socket is the negative (L ) contact. 1. Turn the circuit breakers to the ON position. 2. Connect one test probe to the A-1 (L ) power input terminal and insert the other test probe in the socket on the A-1 power output connector, as shown in Figure 12. TEST THAT CONTINUITY EXISTS BETWEEN NEGATIVE INPUT TERMINAL AND NEGATIVE OUTPUT TERMINAL FOR EACH POWER CIRCUIT (A1 - A4, B1 - B4) L(-) A1 INSERT PROBE IN SOCKET A1 (L-) 20042-A Figure 12. Test 2: Input Battery to Output Battery 3. Verify that continuity exists between the specified terminals. 4. Repeat the test procedure for each remaining input/output pair for the remaining terminals: A2 (L ) and A2 connector socket; A3 (L ) and A-3 connector socket, and so on, until all the circuits have been tested. Page 15

Test 3: Input Return to Output Return Use the following procedure (Figure 13): Note: Each D-sub type power output connector has one socket and one pin. The pin is the positive (L+) contact. 1. Turn the circuit breakers to the ON position. 2. Connect one test probe to the A-1 (L+) power input terminal and the other test probe to the pin on the A-1 power output connector, as shown in Figure 13. TEST THAT CONTINUITY EXISTS BETWEEN POSITIVE INPUT TERMINAL AND POSITIVE OUTPUT TERMINAL FOR EACH POWER CIRCUIT (A1 - A4, B1 - B4) A1 (L+) L(+) A1 CONNECT PROBE TO PIN 20043-A Figure 13. Test 3: Input Return to Output Return 3. Verify that continuity exists between the specified terminals. 4. Repeat the test procedure for each remaining input/output pair for the remaining terminals: A2 (L+) and A2 connector pin; A3 (L+) and A3 connector pin, and so on, until all A and B input and output returns have been tested. 3.2 Mounting Panel on Rack The BIP is shipped with mounting brackets configured in the factory for mounting in a 21-inch (533.4 mm) ETSI rack. If desired, the mounting brackets can be removed and replaced with alternative mounting brackets provided with the BIP. The alternative mounting brackets can be used for mounting the panel in an EIA or FibreWorld rack. Figure 10 on page 11 shows the mounting options and dimensions. Use the following procedure: Caution: When attaching the mounting brackets to the fuse panel, use only the 5/16-inch (7.94 mm) long flathead screws provided with the panel. Use of any other hardware could cause contact with internal parts of the panel. Page 16

1. Determine whether the BIP will be mounted as shipped (ETSI). If it will be mounted as shipped, skip the following step and proceed to step 3. 2. If an alternative mounting option is desired: a. Remove the factory-installed mounting brackets; set aside screws for re-use. b. Select the alternative mounting brackets: EIA (Figure 14) or FibreWorld ( Figure 15). 5/16-INCH (7.94 MM) 10-32 FLAT HEAD SCREWS EIA MOUNTING BRACKETS (2 PLACES) TIGHTEN MOUNTING SCREWS TO 15 POUND-FORCE INCHES (1.7 NEWTON METERS) OF TORQUE 20030-B Figure 14. Installing EIA Mounting Brackets 5/16-INCH (7.94 MM) 10-32 FLAT HEAD SCREWS FIBREWORLD MOUNTING BRACKETS (2 PLACES) TIGHTEN MOUNTING SCREWS TO 15 POUND-FORCE INCHES (1.7 NEWTON METERS) OF TORQUE 20031-B Figure 15. Installing FibreWorld Mounting Brackets Page 17

c. Install the mounting brackets on the BIP, as shown in the appropriate figure, using the screws removed from the original brackets. Tighten the screws to 15 pound forceinches (1.7 Newton meters) of torque. Note: Provide one rack unit of space or equivalent spacing above and below the panel for air circulation. 3. Align the panel with the rack in a top position of the rack (Figure 16). 4. Fasten the BIP to the rack using the four mounting screws provided. (These will be either 3/8-inch (9.53 mm) long, Phillips-drive 12-24 pan head or 8 mm (0.31 inch) M6x1 paint cut metric screws, depending on the rack type.) Install the screws with the provided washers as shown. Tighten the screws to 25 pound force-inches (2.8 Newton meters) of torque. TIGHTEN MOUNTING SCREWS TO 25 POUND-FORCE INCHES (2.8 NEWTON METERS) OF TORQUE USE #12 STAR WASHERS INSTEAD OF FLAT WASHERS IF REQUIRED BY LOCAL PRACTICE 20032-B Figure 16. Installing Panel as Shipped (With ETSI Mounting Brackets) 3.3 Installing Ground Wire Using 2-Hole Compression Lug Standard grounding is accomplished by connecting a compression lug to the grounding point on the left front side of the BIP. The block accepts a 2-hole #10 compression lug with 5/8 inch (1.59 cm) hole spacing. The lug is attached to the block using two Phillips-head grounding screws (with captive washers) provided with the panel. The grounding connection is suitable for terminating a #6 AWG (or equivalent size) wire or a 35 mm 2 (ETSI applications) conductor. Use the following procedure to ground the fuse panel chassis to office ground: Page 18

1. Obtain a length of wire of the specified size for use as the grounding wire. 2. Terminate one end of the wire with a 2-hole compression lug with #10 holes and 5/8 inch (1.59 cm) hole spacing. 3. Locate the grounding location on the left front side of the panel (Figure 17). 4. Place the lug over the mounting holes and secure it to the grounding block using the two screws (with captive washers) provided with the panel. 5. Tighten each screw to 19 pound-force inches (2.1 Newton meters) of torque. 6. Route the free end of the grounding wire to an approved office ground source. Terminate the wire at the ground source. GROUNDING SCREWS 20047-A 2-HOLE LUG Figure 17. Installing Ground Wire 3.4 Installing Ground Contact for Mesh-BN System Bonding Topology Grounding for Mesh-BN system bonding topologies, per ETSI standards, can be accomplished, if desired, using an 8x bus bar (available from Ciena). The 8x bus bar is installed across all eight positive power input terminals in the upper front center side of the BIP. The bus bar is fastened to a grounding block in the top center of the BIP chassis using the two screws provided. Use the following procedure to install the 8x bus bar (see Figure 18): Warning: The 8x bus bar is only used for Mesh-BN system bonding topologies, per ETSI standards. Page 19

1. Install the 8x bus bar across the center eight positive input power terminals on the front side of the BIP. When looking at the BIP from the front side, these terminals start at A1 (L+) on the left and and continue across to the right to B4 (L+). 2. Fasten the bus bar grounding tab to the BIP grounding point, as shown in the figure, using the two screws provided. MOUNTING SCREWS AND WASHERS GROUNDING BLOCK GROUNDING TAB A1 A2 A3 A4 B1 B2 B3 B4 8 x BUS BAR (POSITIVE) 20053-A Figure 18. Installing 8x Bus Bar 3.5 Connecting Alarms The Alarm Unit (AU) on the front side of the BIP has an input and output connector. Both connectors are D-sub receptors. Connections to them are made using a 9-pin D-sub plug for input and a 25-pin D-sub plug for output. The current rating for the alarm relay contacts is 2 Amps ac or dc maximum, 220 Vdc or 250 Vac maximum, with 1 Amp switching current. Page 20

If desired, a PCB adapter plug (Figure 19) can be connected to the 25-pin connector to covert the AU output interface to a 25-pin wire wrap. FRONT VIEW REAR VIEW 20077-A Figure 19. PCB Adapter Plug Use the following procedure to connect an external alarm system to the alarm terminals on the panel: 1. Obtain AWG wire of the specified size and connect it to the specified connector types if the connectors are not already prepared. Note: In most cases, the connectors will be standard types already wired to the bay alarm system and the front office device. If additional specifications are required for the AU input and output connectors, refer to Section 1.5, Alarm Unit (AU), on page 5. 2. Connect the connectors to the input and output connectors, as shown in Figure 20. 20048-A FROM LOAD EQUIPMENT TO FRONT OFFICE Figure 20. AU Input and Output Connectors 3. Terminate the input and output wires to the load equipment alarm system and front office alarm reporting device, respectively, following local procedures. Page 21

3.6 Connecting Output Output power is supplied to the load equipment through D-sub connectors labeled A1 to A4 and B1 to B4 on the right front side of the panel. Each connector has a socket (negative terminal) and a pin (positive terminal). For a diagram, refer to Figure 4 on page 9. The output power terminals accept copper wire in sizes ranging from #8 to #16 AWG. In selecting wire size, follow local code and refer to Appendix A. 1. Obtain AWG wire of the specified size and connect it to the specified connector types if the connectors are not already prepared. Note: In most cases, the connectors will be standard types already wired to the load equipment. If additional specifications are required for the output power connectors, refer to Section 1.10, Power Output Connections, on page 9. 2. Connect the connectors to the BIP power output terminals (Figure 21). POWER OUTPUT TERMINALS (8 PLACES) 20049-A Figure 21. Power Output Terminals 3. Tighten the connector housing screws to 4 pound force-inches (0.5 Newton-meters) of torque. 4. Route the free end of each output power wire to the equipment for connection. 3.7 Connecting Input The power input terminals accept #10 two-hole compression lugs with 0.25 inch holes on 0.625 inch centers. The tongues must be narrow gauge with a maximum width of 0.5 inches (1.12 cm). Nuts with captive washers are provided to secure the lugs to the terminal block. The lugs may be either straight or angled (90 o ), providing for power wire entry from either above or behind the BIP, respectively. Up to #2 AWG or 35 mm 2 copper wire can be used. In selecting the copper wire size to be used for power input, consider the allowable ampacity as defined by local practice and the National Electrical Code (refer to Appendix A). Page 22

The standard power input configuration uses eight power feeds, each with a negative lug and a positive lug. This configuration uses all 16 terminals, with one lug per terminal. An alternative arrangement uses 2x and 4x bus bars (provided) to configure the BIP for four power feeds. The four 2x bus bars are installed on the eight (L ) terminals; the two 4x bus bars are installed on the eight (L+) terminals. For illustrations of these configurations, see the following procedures. 3.7.1 Standard Configuration To connect input power wires in a standard condiguration, use the following procedure: 1. Obtain 16 lengths of copper wire for use as the input power wires. 2. Strip back 7/8 inches of insulation from one end of each wire. 3. Slide a 2-inch length of heat shrink insulation over the end of each wire. 4. Terminate one end of each wire with 2-hole lugs (customer provided; requires crimper). The lugs may be either straight (top entry, Figure 22) or right-angled (rear entry, Figure 23). COVER MOUNTING SCREW 20045-A PROTECTIVE COVER NUT AND WASHER (2 PLACES) 2-HOLE COMPRESSION LUG POWER INPUT TERMINALS LUGS AND COVER INSTALLED Figure 22. Installing Lugs (Top Entry) 5. Slide the heat shrink insulation down to the lug terminal so the barrel end of the terminal is covered. Use a heat gun to apply heat to the heat shrink insulation until it tightens around the wire and barrel end of the terminal. Page 23

COVER MOUNTING SCREW 20046-A PROTECTIVE COVER NUT AND WASHER (2 PLACES) 2-HOLE COMPRESSION LUG POWER INPUT TERMINALS LUGS AND COVER INSTALLED Figure 23. Installing Lugs (Rear Entry) 6. Secure the lugs to the terminals using the nuts (with captive washers) provided. Connect the negative lugs to the negative (L ) terminals. Connect the positive lugs to the positive (L+) terminals. For top entry, refer to Figure 22 on page 23. For rear entry, refer to Figure 23 above. 7. Use a torque wrench (with a 7/16-inch socket) to tighten the input power terminal block nuts to 19 pound-force inches (2.1 Newton meters) of torque. 8. Route the free ends of the input power cables to the office battery source. Connect the input power cables to the office battery power source in accordance with applicable local electrical codes and National Electrical Codes. Do not apply power to the fuse panel until instructed to do so for testing (see Section 4). 3.7.2 Four-Feed Configuration To connect input power wires using a four-feed configuration, use the following procedure: 1. Install lugs on the input power wires, as described in the previous procedure. 2. Orient the bus bars with the power input terminals as shown in Figure 24 (top). 3. Install the lugs as shown in Figure 24 (bottom). Page 24

2 x BUS BARS (NEGATIVE) 20052-A A1 A3 A2 A4 A1 A2 A3 A4 4 x BUS BAR (POSITIVE) 2-HOLE COMPRESSION LUG (TYPICAL) 20052-A NUT AND WASHER (TYPICAL) 2 x BUS BAR (NEGATIVE) 2 x BUS BAR (NEGATIVE) 4 x BUS BAR (POSITIVE) Figure 24. Installing Lugs on Bus Bars Page 25

4 POWER-UP CHECK Use the following procedure to check that the BIP for correct operation: 1. Verify that the input power cables are connected to the correct terminals. 2. Verify that the circuit breakers for all circuits are ON. 3. Apply power to the BIP. 4. Verify that the Power OK (green) LEDs on the front console are lit. 5. Verify that the BIP Fault (red) LED on the front console is not lit. 6. Verify that the CRITICAL (red), MAJOR (red), and MINOR (amber) LEDs on the front console are not lit. 7. Depress the Lamp Test button and verify that all the LEDs are working correctly (they should all illuminate). 8. Using a multimeter set to measure dc voltage, measure the voltage between each input return (L+) terminal and chassis ground. The voltage level should be less than 2.0 Vdc. If the voltage on the (L+) terminal is much higher, and reads out in the 40 to 60 Vdc range, the lugs are probably reversed. If this appears to be true, power down the panel. Disconnect the (L+) and (L ) lugs and switch them around. Power up the panel and check again to verify that the higher voltage is on the (L ) lug. 9. If any problem occurs that cannot be resolved, consult Ciena for technical assistance. 5 MAINTENANCE This section provides maintenance procedures for the BIP. 5.1 Performing a Routine Inspection 1. Inspect the panel for damage to the circuit breakers and for damaged or broken wires at the power and external alarm connections. 2. If excessive dirt is found during the inspection, brush or wipe dust from the panel with a soft bristle brush or soft cloth. 3. Depress the Lamp Test button on the front console; verify that all LEDs illuminate. Page 26

5.2 Replacing an Alarm Unit If the Alarm Unit (AU) malfunctions, it can be replaced in the field. Use the following procedure to replace the AU (see Figure 25): 1. Power down the BIP. 2. Remove the front cover fasteners and swing down the front cover. 3. Disconnect the 16-pin connectors that connects the AU cable to the AU main unit and the front cover. 4. Unscrew the mounting screws on either side of the AU. BIP ALARM UNIT (AU) 20044-A CABLE AND CONNECTORS PULL TAB (2 PLACES) GUIDE (2 PLACES) AU SLOT (NOT VISIBLE) Figure 25. Replacing an Alarm Unit 5. Grasp hold of the AU pull tabs and pull the AU straight out to the front of the BIP. 6. Orient the new AU within the AU slot. Note that the AU has guides that hold it in position in the slot. Orient the guides and slide the AU into the slot. 7. Screw in mounting screws on either side of the board. 8. Press back on the AU to seat it firmly into the internal connectors within the BIP. 9. Connect the AU cable to the 16-pin connectors on the AU main unit and on the back of the front cover. 10. Close the front cover and secure it with the fasteners. Page 27

6 CUSTOMER INFORMATION AND ASSISTANCE For technical assistance, consult Ciena. Page 28

APPENDIX A: ALLOWABLE AMPACITIES OF INSULATED CONDUCTORS This appendix provides guidelines for selecting AWG wire size based on the temperature rating of the conductor and the anticipated load. The information contained is from Table 310-16 of the National Electrical Code document, ANSI/NFPA 70 (1978). Note: Information for aluminum conductors has been omitted from the table here because copper conductors only are recommended for use with the Ciena panel. Table 310-16 (NEC): Allowable Ampacities of Insulated Conductors, Rated O Through 2000 Volts, 60 to 90 C (140 to 194 F), Not More Than Three Current-Carrying Conductors in Raceway or Cable or Earth (Directly Buried), Based on Ambient Temperature of 30 C (86 F) SIZE AWG KCMIL 60 C (114 F) TYPES TW*, UF* TEMPERATURE RATING OF CONDUCTOR 60 C (114 F) TYPES FEPW*, RH*, RHW*, THHW*, THW*, THWN*, XHHW*, USE*, ZW* 60 C (114 F) TYPES TBS, SA, SIS, FEP*, FEPB*, MI, RHH*, RHW-2, THHN*, THHW*, THW-2*, THWN-2*, USE-2, XHH, XHHW* XHHW-2 ZW-2 18...... 14 16...... 18 14 20* 20* 25* 12 25* 25* 30* 10 30 35* 40* 8 40 50 55 6 55 65 75 4 70 85 95 3 85 100 110 2 95 115 130 1 110 130 150 1/0 125 150 170 2/0 145 175 195 3/0 165 200 225 4/0 195 230 260 250 215 255 290 300 240 285 320 350 260 310 350 400 280 335 380 500 320 380 430 Page 29

Table 310-16 (NEC): Allowable Ampacities of Insulated Conductors, Rated O Through 2000 Volts, 60 to 90 C (140 to 194 F), Not More Than Three Current-Carrying Conductors in Raceway or Cable or Earth (Directly Buried), Based on Ambient Temperature of 30 C (86 F) SIZE AWG KCMIL 60 C (114 F) TYPES TW*, UF* TEMPERATURE RATING OF CONDUCTOR 60 C (114 F) TYPES FEPW*, RH*, RHW*, THHW*, THW*, THWN*, XHHW*, USE*, ZW* 60 C (114 F) TYPES TBS, SA, SIS, FEP*, FEPB*, MI, RHH*, RHW-2, THHN*, THHW*, THW-2*, THWN-2*, USE-2, XHH, XHHW* XHHW-2 ZW-2 600 355 420 475 700 385 460 520 750 400 335 380 800 410 490 555 900 435 520 585 1000 455 545 615 1250 495 590 665 1500 520 625 705 1750 545 650 735 2000 560 665 750 CORRECTION FACTORS For ambient temperatures other than 30C (86F), multiply the allowable ampacities shown by the appropriate factor shown below. 21-25 1.08 1.05 1.04 26-30 1.00 1.00 1.00 31-35.91.94.96 36-40.82.88.91 41-45.71.82.87 46-50.58.75.82 51-55.41.67.76 56-60....58.71 61-70....33.58 71-80.......41 * Unless otherwise specifically permitted in the code, as defined in the NEC document cited (ANSI/NEC 70), the overcurrent protection for conductor types marked with an asterisk (*) shall not exceed 15 amperes for No. 14, 20 amperes for No. 12, and 30 amperes for No. 10 copper, after any correction factors for ambient temperature have been applied. Page 30