PowerWorx Power Distribution Products Select Series Circuit Breaker Power Distribution Panel User Manual

Transcription

1 ADCP Issue 4 April 2007 PowerWorx Power Distribution Products Select Series Circuit Breaker Power Distribution Panel User Manual A Rev A

2 Preface COPYRIGHT All Rights Reserved Printed in the U.S.A. REVISION HISTORY ISSUE DATE REASON FOR CHANGE 1 09/2002 Original. 2 09/2004 Added warning not to use one bus only (three places). Updated customer information. 3 03/2006 Corrected wire color. 4 04/2007 Added note and illustration explaining mapping from circuit breakers to power outputs. LIST OF CHANGES The technical changes incorporated into this issue are listed below. PAGE IDENTIFIER DESCRIPTION OF CHANGE 18 Section 3.5 Added note and illustration explaining mapping from circuit breakers to power outputs. TRADEMARK INFORMATION ADC and PowerWorx are registered trademarks of ADC Telecommunications, Inc. DISCLAIMER OF LIABILITY Contents herein are current as of the date of publication. ADC reserves the right to change the contents without prior notice. In no event shall ADC be liable for any damages resulting from loss of data, loss of use, or loss of profits and ADC further disclaims any and all liability for indirect, incidental, special, consequential or other similar damages. This disclaimer of liability applies to all products, publications and services during and after the warranty period. This publication may be verified at any time by contacting ADC s Technical Assistance Center at , extension (in U.S.A. or Canada) or (outside U.S.A. and Canada), or by to connectivity_tac@adc.com. ADC Telecommunications, Inc. P.O. Box 1101, Minneapolis, Minnesota In U.S.A. and Canada: Outside U.S.A. and Canada: (952) Fax: (952) Page ii

3 Preface TABLE OF CONTENTS Content Page ABOUT THIS MANUAL v STANDARDS CERTIFICATION v ADMONISHMENTS v GENERAL SAFETY PRECAUTIONS v 1 PRODUCT DESCRIPTION Product Functions and Features Circuit Breaker Panel Components Packaged Hardware Options Accessories Mounting Power Buses Circuit Breakers Input/Output Voltage Input Power Connections Output Power Connections Ground Connections Alarm Operation and Connections LED Indicators Cooling Specifications BEFORE STARTING INSTALLATION General Installation Recommendations Unpacking and Inspection Installation Tools Required Materials Required INSTALLATION Test Continuity Mounting Procedure Chassis Ground Connections External Alarm System Connections Output Power Connections Input Power Connections Protective Cover Installation/Removal Cable Management Bar Installation (Accessory Item) Circuit Designation Card and Voltage Label TESTING Power and Alarm Indication Test Connection Polarity Test Alarm Contacts Test Page iii

4 Preface TABLE OF CONTENTS Content Page 5 OPERATION Circuit Breaker Operation Connecting New Equipment MAINTENANCE Inspection Power LED Indicator Replacement Circuit Breaker Replacement CUSTOMER INFORMATION AND ASSISTANCE Page iv

5 Preface ABOUT THIS MANUAL This manual describes the PowerWorx Select Series Circuit Breaker Power Distribution Panel, hereinafter called circuit breaker panel or panel, and its available options and accessories. Also provided is the information required to install, test, and operate the circuit breaker panel. The Select Series circuit breaker panel is used to supply protected dc power to the 24 Vdc or 48 Vdc powered equipment that is typically installed in a central office, multimedia headend, remote site, CEV, or other restricted access location requiring protected dc power. STANDARDS CERTIFICATION The Select Series circuit breaker panel complies with the applicable sections of the following standards: UL, NEC 2002, NEBS Level 3, IEC, and CE. ADMONISHMENTS Important safety admonishments are used throughout this manual to warn of possible hazards to persons or equipment. An admonishment identifies a possible hazard and then explains what may happen if the hazard is not avoided. The admonishments in the form of Dangers, Warnings, and Cautions must be followed at all times. These warnings are flagged by use of the triangular alert icon (seen below), and are listed in descending order of severity of injury or damage and likelihood of occurrence. Danger: Danger is used to indicate the presence of a hazard that will cause severe personal injury, death, or substantial property damage if the hazard is not avoided. Warning: Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the hazard is not avoided. Caution: Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the hazard is not avoided. GENERAL SAFETY PRECAUTIONS - Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. Warning: Disconnect or turn off the power before connecting the circuit breaker panel input or output wires. This may require turning off the system office battery input at the office distribution panel or turning-off the appropriate circuit breaker at the panel. Page v

6 Preface Caution: Using the wrong circuit breaker may cause damage to the protected equipment or the circuit breaker panel. When replacing a circuit breaker, make sure the replacement breaker does not exceed 50 Amps and is the correct type and correct current rating as required by the protected equipment. Warning: Wet conditions increase the potential for receiving an electrical shock when installing or using electrically-powered equipment. To prevent electrical shock, never install or use electrical equipment in a wet location or during a lightning storm. Page vi

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

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

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

10 One set of 23-inch mounting brackets 5/16-inch long, Phillips drive, 8-32 flat-head thread-forming screws (10 provided which includes 2 spares) - Used to secure the mounting brackets to the panel. 3/8-inch long, combination drive, pan-head screws (4) and #12 flat washers (4) - Used to secure the panel mounting brackets to the equipment rack. 2-hole lugs (4) for #2 AWG wire - Used to attach the BATTERY and RETURN cables to the power input terminals. Also available as an accessory item. #10 ring terminals (2) for AWG wire - Used to connect the grounding cables to the grounding studs. Rear protective input terminal covers (2) and output terminal covers (4) - Used to prevent accidental contact with the power input and output terminals. Voltage label - Used to indicate the voltage of the panel ( 24 or 48 Vdc). Designation cards (2) and card holder - Used to record information about the protected equipment. The card holder has a pressure sensitive adhesive backing to permit attachment to the panel, the rack, or a location close to the panel. The card inserts into the card holder. Two types of cards are provided. Also available as an accessory item. 1.4 Options The following ordering options are available for the Select Series circuit breaker panel: Circuit breaker configurations - Circuit breakers may be specified in any combination of values as long as the total current draw on each bus does not exceed 100 Amps. A maximum of eight 1-pole breakers or four 2-pole breaker may be installed per bus. Circuit breaker ratings - Both 1-pole and 2-pole circuit breakers are used with the panel. The 1-pole breakers are available with 1, 3, 5, 10, 15, or 20 Amp ratings. The 2-pole breakers are available with 26, 30, 36, 40, and 50 Amp ratings. Alarm contact connections - Either screw-down terminals or wire-wrap pin terminals may be specified for the alarm contact connections. 1.5 Accessories The following accessories are available for the Select Series circuit breaker panel: Circuit breakers - 1-pole breakers with a rating of 1, 3, 5, 10, 15, and 20 Amps and 2-pole breakers with a rating of 26, 30, 36, 40, and 50 Amps are available. 2-hole compression lugs - Used to attach the BATT and RTN cables to the power input terminals. Available to fit 2, 4, 6, or 14 AWG wire. Cable management bar - Use to secure the output power wires at the rear of the panel. Designation cards (2) and card holder - Used to record information about the protected equipment. The card holder has a pressure sensitive adhesive backing to permit attachment Page 4

11 to the panel, the rack, or a location close to the panel. The cards insert into the card holder. Two types of cards are provided. 1.6 Mounting The Select Series circuit breaker panel can be mounted in either a 19- or 23-inch (482.6 or mm) equipment rack. Two sets of mounting brackets, one set for 19-inch racks and one set for 23-inch racks, are provided with the panel. The panel can be flush mounted or recessed 1, 2, 3, or 4 inches (25.4, 50.8, 76.2 or 91.6 mm). The mounting brackets are slotted to allow the panel to be mounted in racks with WECO 1.0-inch (25.4 mm) or EIA 1.25-inch (31.8 mm) hole spacing. The slots also compensate for vertical rack differences so that the panel can be mounted in either or 2-inch (44.5 or 50.8 mm) rack spaces. The panel requires one open rack space above and below the chassis for heat dissipation. 1.7 Power Buses The Select Series circuit breaker panel has two isolated power bus (power feed) circuits which are designated as the A and B power buses. Each power bus circuit distributes the input power to the corresponding A or B output power circuit. In each bus circuit, current flows from the input power terminals, through the circuit breakers, to the output power terminals. Warning: Use of one bus only on a dual bus panel will result in false alarms for the unused bus. Power is required on both buses on a dual bus panel for normal operation. The maximum current capacity of each power bus circuit is 100 Amps. The total output current capacity of the circuit breakers on each bus must not exceed 100 Amps. The maximum current rating is marked on the circuit breaker panel rear side. The power dissipation of the panel is 160 watts maximum per panel (80 watts per bus). 1.8 Circuit Breakers The circuit breakers are magnetic actuation, manual reset, replaceable, 60 Vdc rated circuit breakers, with finger guard and ampere markings. Both 1- pole and 2-pole breakers are used with the panel. The 1-pole breakers are available with 1, 3, 5, 10, 15, and 20 Amp ratings. The 2-pole breakers are available with 26, 30, 36, 40, and 50 Amp ratings. Each 1-pole or 2-pole circuit breaker can be field-replaced by another 1-pole or 2-pole breaker with a different current rating or time delay. A breaker with a higher current rating may be installed as a replacement as long as the total current draw of the affected bus does not exceed 100 Amps. The circuit breaker panel will accommodate from one to eight 1-pole circuit breakers per bus or from one to four 2-pole circuit breakers per bus. Both 1-pole and 2-pole breakers may be combined together on the same bus. Each circuit breaker position that does not have a breaker installed will be filled with a black plastic plate. Any circuit breaker mounting positions that are left blank when the panel is ordered cannot be fitted with field-installed circuit breakers. Page 5

12 The circuit breakers are of the type called short delay. The trip times of short delay circuit breakers are a function of the percent of rated current, as indicated in Table 1. The circuit breaker will trip (open) and the switch will move to the off position (bottom pushed in) when the circuit current exceeds the capacity of the circuit breaker. To reset a circuit breaker, push the switch to the on position (top pushed in). Table 1. Short Delay Trip Times in Seconds PERCENT OF RATED CURRENT 100% 135% 150% 200% 400% 600% 800% 1000% 1200% NO TRIP Circuit breakers are field-replaceable. Please contact ADC Technical Support if replacement is required (refer to Section 7, Customer Information and Assistance, on page 30). 1.9 Input/Output Voltage The Select Series circuit breaker panel accepts an input voltage of either 24 Vdc (nominal) on both buses or 48 Vdc (nominal) on both buses. For 24 Vdc operation, the voltage can fall within 21 to 30 Vdc. For 48 Vdc operation, the voltage can fall within a range of 42 to 56 Vdc. The output voltage is the same value as the applied input voltage Input Power Connections Input power is supplied to the Select Series circuit breaker panel through the A and B input power terminal blocks. Each input terminal block includes two pairs of studs that are used for connecting the BATT (battery ) and RTN (return +) input power cables. Each pair of studs is mounted on inch centers and accepts various size 2-hole compression lugs. Compression lugs for 2, 4, 6, and 14 AWG wire are available as accessory items. Nuts with captive washers are included to secure the compression lugs to the studs. The input terminal blocks are located on the rear side of the panel. The minimum recommended wire size for the input power wiring is 2 AWG Output Power Connections Output power is supplied to the protected equipment through the A and B output power terminal blocks. Screw-down barrier terminal strips are used for the output power terminal blocks. Each terminal block consists of eight pairs of screw down terminals equipped with 8-32 screws. Each pair of terminals is used for connecting the battery (BATT) and return (RTN) output power wiring to the protected equipment. Each terminal will accept a compression-type lug terminal with a maximum width of inches. Copper wire in sizes ranging from #8 16 AWG may be used for the output power wiring. The output power terminal blocks are located on the rear side of the panel. Page 6

13 1.12 Ground Connections Two #10 studs (with nuts and captive washers) are provided on the rear side of the circuit breaker panel for grounding the chassis. The ground connection is used to attach grounding cables to the chassis. Two 10 AWG copper wires are recommended for the grounding cables. Two #10 ring terminals for use with 10 AWG wire are provided for connecting the grounding cables to the grounding studs Alarm Operation and Connections The Select Series circuit breaker panel contains circuitry that opens and closes a set of form C relay alarm contacts when a circuit breaker trips or when power to either power bus is lost. These contacts may be used to open or close a loop connected to an external alarm system. During normal operation (power applied), the normally open (NO) contacts remain open and the normally closed (NC) contacts remain closed. When a circuit breaker trips or when power to a power bus is lost, the NO contacts close creating a connection between NO and common (C) terminals; and the NC contacts open creating an open circuit between NC and C terminals. The rating for the alarm relay contacts is 110 Vdc/125 Vac maximum voltage, 1.0 Amp maximum switching current. Both screw-down terminals and wire-wrap pin terminals are available (option) for the alarm terminal connections. Two sets of alarm contact connections are provided when the panel is equipped with screw down terminals and three sets of contact connections are provided when the panel is equipped with wire-wrap pins. The alarm terminals are labeled ALARM and are located on the rear side of the panel. The screw-down terminal connections consist of six 3-48 screw terminals mounted in a barrier type terminal block. The screw terminals are mounted on inch (6.350 mm) centers with a maximum distance between barriers of 0.20 inch (5.08 mm). Two sets of three terminals (labeled NO, C, and NC) are provided for connection with external alarm systems. The screwdown terminals will accept #16 to #30 AWG copper wire. The wire wrap pin terminal connections consist of nine wire-wrap pins mounted in a terminal block. Three sets of three wire wrap pins (NO, C, and NC) are provided for connection with external alarm systems. The wire wrap pins will accept #22 to #26 AWG copper wire LED Indicators Two power indicators (green LED) are provided on the front side of the panel. A separate power indicator is provided for each of the two power output buses (A and B). The power indicators stay on as long as power is supplied to the corresponding power bus. The power indicators turn off when power is turned off to the corresponding power bus. Each power indicator LED can be field-replaced if it fails. Page 7

14 Two breaker alarm indicators (red LED) are provided on the front side of the panel. A separate breaker alarm indicator is provided for each of the two power output buses (A and B). The breaker alarm indicator turns on if any circuit breaker on the corresponding power bus trips. The breaker alarm indicator turns off when the tripped breaker is placed in the on position. The breaker alarm indicators cannot be field-replaced Cooling The Select Series circuit breaker panel relies on convection air flow for cooling. Holes are provided on the top and bottom of the panel to allow heated air to escape from the panel and cool air to enter. At least one rack unit of space must be provided above and below the panel to allow for air circulation Specifications The specifications for the Select Series circuit breaker panel are listed in Table 2. Table 2. Circuit Breaker Panel Specifications PARAMETER SPECIFICATION REMARKS Physical Weight 10 lbs. (4.54 kg) Dimensions (HxWxD) 1.73 x x inches See Figure 3 (43.9 x 435 x 282 mm) Color Putty white Rack mounting 19- or 23-inch EIA or WECO hole spacing Electrical Operating voltages 24 Vdc 48 Vdc 21 to 30 Vdc tolerance 42 to 56 Vdc tolerance Input current 100 Amps per bus maximum Breaker type Magnetic actuation, manual reset, replaceable 1- pole or 2-pole Breaker mounting positions Eight 1-pole per bus (16 total) or Four 2-pole per bus (8 total 50 Amps Or any combination of 1- and 2- pole breakers Maximum breaker size Input terminal type 2-hole compression lug inch between centers Output terminal type Screw down terminal (8-32) Max lug width inches Alarm terminal type Screw down terminal (3-48) Max lug width 0.20 inches Alarm contact voltage 110 Vac, 125 Vdc maximum Alarm contact current 1 Amp maximum Grounding connections Two #10 studs #10 ring terminals Page 8

15 Table 2. Circuit Breaker Panel Specifications, continued PARAMETER SPECIFICATION REMARKS Environmental Operating temperature 5º C to +55º C Storage temperature 45º C to +85º C Humidity range 0% to 95% humidity No condensation Altitude range Up to 13,000 ft. (3.96 km) Fire rating All components UL94-V1 or better Acoustic noise 0 dba above ambient Heat dissipation (fully loaded) 160 watts max. at 200 Amps 80 watts per bus Torque Mounting bracket chassis screws 15 pound force-inches 1.7 Newton meters Mounting bracket rack screws 27 pound force-inches 3.1 Newton meters Input power terminal nuts 32 pound force-inches 3.6 Newton meters Output power terminal screws 15 pound force-inches 1.7 Newton meters Alarm terminal screws 8 pound force-inches 0.9 Newton meters Grounding stud nuts 23 pound force-inches 2.6 Newton meters Page 9

16 11.11 INCHES (282 MM) INCHES (254 MM) INCHES (584.2 MM) INCHES (435 MM) 22.3 INCHES (567.7 MM) INCHES (28.6 MM) 1.73 INCHES (43.9 MM) A Figure 3. Dimensions of Select Series Circuit Breaker Panel 2 BEFORE STARTING INSTALLATION This section provides general installation recommendations, unpacking and inspection procedures, and lists the tools and material required for panel installation. 2.1 General Installation Recommendations The Select Series circuit breaker panel must be installed in a central office, equipment room, CEV or other restricted access location. Mount the panel in the uppermost area of the rack to reduce the exposure of the power wiring. Route ground, power, and alarm cables to the panel according to local practice and procedures. After routing the cables, secure them to the equipment rack or to any cable management devices that are in use. Follow the instructions provided in this manual when connecting the cables to the panel. Install the protective covers on the rear side of the panel after all the wiring Page 10

17 connections are made and all tests are completed. Do not apply power to the panel until all wiring and tests are completed. Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. Warning: Wet conditions increase the potential for receiving an electrical shock when installing or using electrically-powered equipment. To prevent electrical shock, never install or use electrical equipment in a wet location or during a lightning storm. 2.2 Unpacking and Inspection Before starting the installation, always open the shipping boxes and verify that all parts have been received and that no shipping damage has occurred. Use the following procedure to unpack and inspect the circuit breaker panel: 1. Open the shipping carton and carefully unpack the circuit breaker panel from the protective packing material. 2. Check the panel for broken or missing parts. If there are any damages, contact ADC (see Section 7, Customer Information and Assistance, at the end of this manual) for an RMA (Return Material Authorization) and to reorder if replacement is required. 2.3 Installation Tools Required The following tools are required to install the circuit breaker panel: Phillips screwdrivers (#1 and #2) Flat-blade screwdrivers (medium and large Torque screwdriver calibrated in pound-force inches or Newton meters Torque wrench calibrated in pound-force inches or Newton meters 3/8-inch and 7/16-inch sockets (for torque wrench) Wire cutter Wire stripper Compression lug crimper Multimeter Heat gun 2.4 Materials Required The following materials are required to install the circuit breaker panel: #2 AWG insulated copper wire for input power wires #10 AWG copper wire for ground connections Page 11

18 #8 16 AWG insulated copper wire for the output power wires (use black for the RTN wire and red for the BATT wire) #22 26 AWG insulated copper wire for the wire-wrap pin terminal alarm wires or #16 30 AWG insulated copper wire for the screw-down terminal alarm wires. Heat-shrink tubing 3 INSTALLATION This section provides the installation procedures for the Select Series circuit breaker panel. 3.1 Test Continuity Each Select Series panel is thoroughly tested at the ADC factory before being shipped. However, before the panel is installed, a continuity test 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 - Connect one test probe to the A input power BATT ( ) terminal and the other test probe to the A input power RTN (+) terminal (see Figure 4). Verify that no continuity exists between the input power BATT and RTN terminals. Repeat test procedure for the B input power terminals. Test 2: Input Battery to Output Battery - Place each of the A power bus circuit breakers in the ON position. Connect one test probe to the A input power BATT ( ) terminal and the other test probe to the #1 output power BATT ( ) terminal on the A output terminal block (see Figure 5). Verify that continuity exists between the specified terminals. Verify that continuity exists between the A input power BATT ( ) terminal and each of the remaining A output power BATT terminals. Repeat the same test procedure for the B power bus circuits. Place all circuit breakers in the OFF position following completion of this test. TEST 1- POWER BUS B: VERIFY NO CONTINUITY EXISTS BETWEEN BATT AND RTN TERMINALS TEST 1- POWER BUS A: VERIFY NO CONTINUITY EXISTS BETWEEN BATT AND RTN TERMINALS A Figure 4. Test 1: Input Battery to Input Return Page 12

19 TEST 2- POWER BUS B: VERIFY CONTINUITY EXISTS BETWEEN INPUT AND OUTPUT BATT TERMINALS TEST 2- POWER BUS A: VERIFY CONTINUITY EXISTS BETWEEN INPUT AND OUTPUT BATT TERMINALS A Figure 5. Test 2: Input Battery to Output Battery Test 3: Input Return to Output Return - Connect one test probe to the A input power RTN (+) terminal and the other test probe to the #1 output power RTN (+) terminal on the A output terminal block (see Figure 6). Verify that continuity exists between the specified terminals. Repeat the test procedure for each of the remaining output power RTN terminals. Repeat the same test procedure for the B input power terminal block circuits. Test 4: Alarm Terminals - Connect the test probes alternately between the C and NC terminals and the C and NO terminals on each set of alarm terminals. Verify that no continuity exists between the C and NC terminals and that continuity does exist between the C and NO terminals. If the circuit breaker panel fails any of the specified tests, it is defective and must not be installed. Contact ADC (see Section 7, Customer Information and Assistance) for an RMA (Return Material Authorization) and to reorder if replacement is required. TEST 3- POWER BUS B: VERIFY CONTINUITY EXISTS BETWEEN INPUT AND OUTPUT RTN TERMINALS TEST 3- POWER BUS A: VERIFY CONTINUITY EXISTS BETWEEN INPUT AND OUTPUT RTN TERMINALS A Figure 6. Test 3: Input Return to Output Return Page 13

20 3.2 Mounting Procedure The circuit breaker panel can be mounted in either a 19- or 23-inch wide rack. Two sets of mounting brackets are provided with the panel. Eight 5/16-inch (7.94 mm) long, threadforming, Phillips-drive, 8-32 flat-head screws are provided for attaching the mounting brackets to the panel. Four 3/8-inch (9.53 mm) long, Phillips-drive, pan-head screws and four #12 flat washers are provided for attaching the mounting brackets to the equipment rack. Caution: When attaching the mounting brackets to the circuit breaker panel, use only the 5/16- inch (7.94 mm) long, thread forming, flathead screws provided with the panel. Use of any other hardware could cause contact with internal parts of the panel. If parts are missing, contact ADC to order replacement parts. Use the following procedure to install the circuit breaker panel in the equipment rack: 1. Select the 19- or 23-inch mounting brackets (whichever set is required) and orient for installation as shown in Figure Attach the brackets to the sides of the circuit breaker panel chassis using the eight 5/16- inch (7.94 mm) 8-32 flathead thread-forming screws provided. Tighten screws to 15 pound force-inches (1.7 Newton meters) of torque to insure grounding. 3. Place the panel in the specified mounting space within the rack as shown in Figure 8. Note: Provide one rack unit of space above and below the panel for air circulation. 4. Secure the panel to the rack using the four 3/8-inch (9.525 mm) long pan-head screws and #12 flat washers provided (use star washers when required by local practice). Tighten the screws to 27 pound-force inches (3.1 Newton meters) of torque to insure grounding. Page 14

21 19-INCH RACK MOUNTING BRACKETS TIGHTEN MOUNTING SCREWS TO 15 POUND-FORCE INCHES (1.7 NEWTON METERS) OF TORQUE 5/16-INCH (7.94 MM) 8-32 FLAT-HEAD THREAD-FORMING SCREWS 23-INCH RACK MOUNTING BRACKETS A Figure 7. Circuit Breaker Panel Mounting Bracket Installation TIGHTEN MOUNTING SCREWS TO 27 POUND-FORCE INCHES (3.1 NEWTON METERS) OF TORQUE DETAIL DRAWING OF MOUNTING SCREWS AND WASHERS USE #12 STAR WASHERS INSTEAD OF FLAT WASHERS IF REQUIRED BY LOCAL PRACTICE A Figure 8. Typical Circuit Breaker Panel Installation in Equipment Rack Page 15

22 3.3 Chassis Ground Connections Mounting the circuit breaker panel on a grounded metal equipment rack using the metal mounting brackets provided generally provides a sufficient return path to meet equipment grounding requirements. However, installation of a separate grounding conductor is strongly recommended and is often required by local practice or local inspectors. A separate grounding conductor is always needed when the panel is mounted to non-grounded or non-conducting material such as a plastic rack or cabinet. Use the following procedure to connect the panel to an approved office ground source: 1. Obtain two lengths of #10 AWG wire for use as the chassis grounding wires. 2. Terminate one end of each wire with the #10 ring terminals provided (requires crimper). 3. Locate the C GND (chassis ground) studs at the rear of the panel as shown in Figure Connect the ring terminal end of each wire to one of the studs and secure using the nuts with captive star washers provided (requires 3/8-inch socket). Tighten each stud nut to 23 pound-force inches (2.6 Newton meters) of torque. DETAIL DRAWING OF GROUNDING WIRE CONNECTION A TIGHTEN STUD NUT TO 23 POUND-FORCE INCHES (2.6 NEWTON METERS) OF TORQUE Figure 9. Chassis Ground Connections 5. Route the free end of each chassis grounding wire to an approved office ground source. 6. Cut each chassis grounding wire to length and connect it to the office ground source as required by local code or practice. Page 16

23 3.4 External Alarm System Connections Normally open (NO) and normally closed (NC) alarm contacts are provided for connecting the circuit breaker panel to an external alarm system. Alarm connections are provided through either screw-down terminals or wire-wrap pins (option) located on the rear side of the panel as shown in Figure 10. One set of terminals, labeled ALARM, is provided for reporting either a power failure or tripped circuit breaker alarm A WIRE-WRAP PIN CONNECTIONS FOR AUDIO, VISUAL, AND REMOTE ALARMS SCREW-DOWN TERMINAL CONNECTIONS FOR REMOTE ALARMS WIRE-WRAP PIN ALARM CONNECTIONS SCREW-DOWN TERMINAL ALARM CONNECTIONS Figure 10. Alarm Contact Connections The screw-down type terminal strip can accept #16 to #30 AWG copper wire. Screw-down terminal alarm wires may be terminated with spade-type compression lugs (maximum width 0.20 inches/5.08 mm) or the wire insulation may be stripped back from the wire end and the bare wire looped under the screw head. Use a torque screw driver to tighten the terminal screws to 8 pound-force inches (0.9 Newton meters). The wire-wrap terminal strip can accept #22 to #26 AWG solid copper wire. Strip back the insulation approximately 1.5 inches (38.1 mm) before inserting the wire into the wire-wrap tool. Page 17

24 3.5 Output Power Connections Output power is supplied to the protected equipment through the output power terminal blocks. Each terminal block consists of eight pairs of screw down terminals equipped with 8-32 screws. The screw-down terminals are used for connecting the BATT (battery) and RTN (return) output power wiring to the protected equipment. Copper wire in sizes ranging from #8 to #16 AWG may be used for the output power wiring. The output power wires may be terminated with spade-type compression lugs (maximum width inches) or the insulation may be stripped back and the bare wire looped under the screw head. The panel has two output power terminal blocks, one for power bus A and one for power bus B. Each terminal block has terminals numbered 1-8 from left to right. Note: This panel is pre-wired in the factory. Each circuit breaker (whether single-pole or dual-pole) and each blank insert, going from left to right on the front of the panel, maps to just one output position, going from left to right, on the rear of the panel. The next available output position is always used. Thus, for example, in the configuration shown in Figure 11, the dual-pole circuit breaker in positions 3 and 4 on the front of the panel maps to output 3 on the rear of the panel; the dual-pole circuit breaker in positions 5 and 6 on the front of the panel maps to position 4 on the rear of the panel; and so on. In the example shown, output terminals 7 and 8 are not used. FRONT BREAKERS (BUS A) POLE BLANK 2 POLE 2 POLE BLANK 1 POLE REAR OUTPUT TERMINALS (BUS A) A Figure 11. Hard-Wiring Pattern of Output Terminals Page 18

25 Note: When a panel is preconfigured such that some of the output terminals are not used, the extra screw terminals are not connected to the bus and cannot be used. Caution: Connecting the protected equipment to the wrong circuit may cause damage to the equipment or the circuit breaker panel. Make sure the circuit breaker is the correct type and has the correct current rating as specified by the protected equipment manufacturer. Note: The continuous output load of the equipment during normal operation should not exceed 80% of the rated value of the circuit breaker. This allows some room for manufacturing tolerances and voltage fluctuations in the plant power mains. Connect each pair of output wires to the panel as shown in Figure 12. Use a torque screwdriver to tighten the terminal screws to 15 pound-force inches (1.7 Newton meters) of torque. POWER FEED TERMINALS DETAIL DRAWING OF OUTPUT TERMINAL BLOCK CONNECTIONS POWER RETURN TERMINALS TIGHTEN TERMINAL SCREWS TO 15 POUND-FORCE INCHES (1.7 NEWTON METERS) OF TORQUE A POWER BUS B OUTPUT TERMINALS POWER BUS A OUTPUT TERMINALS Figure 12. Output Power Connections Page 19

26 3.6 Input Power Connections Input power is supplied to the circuit breaker panel through the A and B input terminal blocks. Each input terminal block consists of two pairs of studs that are used for connecting the BATT (battery ) and RTN (return +) input power cables. Each set of studs accepts various size 2-hole compression lugs. Nuts (with captive locking washers) are provided to secure the compression lugs to the studs. Caution: Connect only the input voltage wire [the wire labeled BATTERY or BATT, or labeled with the negative ( ) voltage polarity and/or the voltage value] to the connector on the circuit breaker panel labeled BATTERY. Connect only the input return wire [the wire labeled RTN, RETURN, or BATTERY GROUND, or labeled with the positive (+) voltage polarity] to the connector on the circuit breaker panel labeled RETURN. Caution: Caution should be taken to not reverse the input wires to the circuit breaker panel. Within the panel, the internal return wiring is not protected by circuit breakers. If the wires are reversed, current will flow through the unprotected return wiring in the panel to the equipment. This condition can cause damage to the equipment in the frame in which the panel is installed and to equipment in adjacent frames Warning: Use of one bus only on a dual bus panel will result in false alarms for the unused bus. Power is required on both buses on a dual bus panel for normal operation. Use the following procedure to connect the input power cables to the circuit breaker panel: 1. Obtain four lengths of #2 AWG wire for use as the input power cables. 2. Strip back 7/8 inches of insulation from one end of each wire as shown in Figure HOLE LUG TERMINAL HEAT SHRINK TUBING (2-INCH LENGTH) #2 AWG COPPER WIRE STRIP BACK 7/8 INCH OF INSULATION A Figure Hole Lug Terminal Installation 3. Slide a 2-inch length of heat shrink insulation over the end of each wire. 4. Terminate one end of each wire with the 2-hole lug terminals provided (requires crimper). Page 20

27 5. Slide the heat shrink insulation down to the lug terminal so the barrel end of the terminal is covered. 6. Use a heat gun to apply heat to the heat shrink insulation until it tightens around the wire and barrel end of the terminal. 7. Use the nuts (with captive locking washers) and flat washers provided to secure the input power wires to the specified terminals and as shown in Figure 14: BATT ( ) wires: Connect to BATT ( ) terminals on A and B input power terminal blocks. RTN (+) wires: Connect to RTN (+) terminals on A and B input power terminal blocks. 8. Use a torque wrench (with a 7/16-inch socket) to tighten the input power terminal block nuts to 32 pound-force inches (3.6 Newton meters) of torque. 9. Route the free end of each input power cable to the office battery source. 10. Connect the input power cables to the office battery power source in accordance with applicable local electrical codes and/or National Electrical Codes. Do not apply power to the circuit breaker panel until instructed to do so for testing (see Section 4, Testing) A DETAIL DRAWING OF INPUT POWER CABLE CONNECTIONS TIGHTEN INPUT TERMINAL NUTS TO 32 POUND FORCE INCHES (3.6 NEWTON METERS) OF TORQUE Figure 14. Input Power Connections Page 21

28 3.7 Protective Cover Installation/Removal Install the rear protective covers, shown in Figure 15, when all the wiring and tests are completed. Both the input and output terminal covers snap into place over the terminals. If the protective covers are lost or damaged, contact ADC for replacement (refer to Section 7, Customer Information and Assistance) A COVER FOR INPUT POWER TERMINALS COVERS FOR OUTPUT POWER TERMINALS COVER FOR INPUT POWER TERMINALS Figure 15. Protective Cover Installation/Removal To provide access to the input and output power terminals, it may sometimes be necessary to remove the protective rear covers. To remove a cover, pull outward on the cover until it comes free of the terminal block. 3.8 Cable Management Bar Installation (Accessory Item) The cable management bar is an accessory item that may be attached to the rear side of the circuit breaker panel as shown in Figure 16. Align the cable management bar with the holes on the sides of the chassis. The bar can be recess mounted by using the holes that are closest to the front of the panel. Use the six 1/4-inch (6.35 mm) long 4-40 thread-forming screws provided to secure the cable management bar to the sides of the circuit breaker panel chassis. Caution: When attaching the cable management bar to the circuit breaker panel, use only the 1/ 4-inch (6.35 mm) long, 4-40 thread-forming screws provided with the panel. Use of any other hardware could cause contact with internal parts of the panel. If parts are missing, contact ADC to order replacement parts. Page 22

29 MOUNTING BRACKET INSTALLED FOR 23-IN. (58.42 CM) RACK MOUNTING ATTACH TO EITHER SET OF 3 HOLES CABLE MANAGEMENT BAR A Figure 16. Cable Management Bar Installation 3.9 Circuit Designation Card and Voltage Label A circuit designation card holder and card (2), shown in Figure 17, are provided with the circuit breaker panel. Fill out one of the designation cards with the required circuit information and insert it into the card holder. Attach the card holder to the circuit breaker panel or to any convenient location that is close to the panel. The card holder has a pressure sensitive adhesive back for attachment. A voltage designation label (see Figure 17) is also provided with the circuit breaker panel. Enter the voltage level (measured during testing) for the panel ( 24 or 48 Vdc) in the spaces provided. Attach the voltage label to any convenient mounting point on the panel. The voltage label has a pressure sensitive adhesive back for attachment. DESIGNATION CARD AND CARD HOLDER VOLTAGE LABEL A Figure 17. Circuit Designation Card and Voltage Label Page 23

30 4 TESTING Following installation, perform the following tests to verify that the Select Series circuit breaker panel is correctly wired and that the alarm system is functioning properly. Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. 4.1 Power and Alarm Indication Test Place all circuit breakers in the OFF position and then turn on the power (both sources) to the circuit breaker panel. With the power turned on and all circuit breakers turned off, the POWER- A and POWER-B indicators should light and the BREAKER ALARM-A and BREAKER ALARM-B indicators should light. 4.2 Connection Polarity Test Verify that the input power cables are connected to the correct terminals. Using a multimeter that is set to measure DC voltage, measure the voltage between the A and B input power RTN terminals and chassis ground. The voltage level should be less than 2.0 Vdc. If the voltage is more than 2.0 Vdc, disconnect the power from the panel and reverse the input power wires. Reconnect the power and again measure the voltage between the input RTN terminal and the chassis ground. Verify that the voltage level is less than 2.0 Vdc. 4.3 Alarm Contacts Test Verify that the alarm contacts are functioning properly. With power applied and all circuit breakers in the OFF position, the alarm contacts should be in the alarm state. Using a multimeter that is set to test for continuity, connect the probes alternately between the C and NC terminals and the C and NO terminals for both sets of alarm terminals. Verify that no continuity exists between the C and NC terminals and that continuity does exist between the C and NO terminals. 5 OPERATION Operation of the Select Series circuit breaker panel consists of placing circuit breakers in either the ON or OFF position, replacing breakers that fail or that need upgrading, and connecting new equipment to the output power circuits. If a breaker trips, the alarm LED indicator for the corresponding power bus lights and the external alarms are activated (if present). Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. Page 24

31 5.1 Circuit Breaker Operation Each circuit breaker is equipped with a rocker-type ON/OFF switch handle. To turn on the power to the protected equipment, place the circuit breaker handle in the ON position. To turn off the power to the protected equipment, place the circuit breaker handle in the OFF position. The circuit breaker will automatically trip (turn off) when the load current exceeds the current rating of the breaker For the initial power-up of the protected equipment, it is recommended that the voltage level at the equipment be tested. Using a multi-meter that is set to measure DC voltage, verify that the output voltage at the protected equipment is a nominal 24 Vdc or 48 Vdc (whichever applies) and the polarity of the BATT ( ) and RTN (+) lead wires is correct. Perform this test for all output circuits. When all the circuit breaker handles are placed in the ON position, the BREAKER ALARM indicator will go out and the alarm contacts will return to the normal state. Note: All circuit breakers, even those not connected to a load, must be placed in the ON position in order to make the BREAKER ALARM indicators go out and to return the alarm contacts to the normal state. When a circuit breaker trips, the BREAKER ALARM indicator on the corresponding power bus will light and the handle on the tripped breaker will move to the OFF position. To determine which breaker tripped, locate the breaker handle that is in the OFF position. Determine what caused the breaker to trip and take the appropriate corrective action. When the problem has been corrected, place the breaker handle in the ON position. The BREAKER ALARM indicator should go out and the alarm contacts should return to the normal state. 5.2 Connecting New Equipment New equipment may be connected to unused circuit breakers following installation and testing of the circuit breaker panel. Use the following procedure for connecting the output power wires for new equipment to an unused output circuit: Warning: The circuit breaker panel uses electrical voltage and current levels that may be considered an electrical hazard per GR Only qualified personnel should be allowed to install, operate, maintain, or otherwise come into contact with this equipment when energized. Only insulated tools should be used on energized elements of the panel. 1. Remove the plastic protective covers from the rear side of the output power terminal blocks (refer to Section 3.7, Protective Cover Installation/Removal). 2. Locate an unused pair of output power terminals and verify that a circuit breaker of the recommended size and type (as specified by the equipment manufacturer) is installed the corresponding breaker mounting position. 3. Place the circuit breaker handle in the OFF position. Note: Placing the circuit breaker in the OFF position will cause the BREAKER ALARM indicator for the corresponding power bus to light and will cause the alarm contacts to move to the alarm state. Page 25