ADC PowerWorx User Manual
ADCP-80-545
March 2006
PowerWorx® Power Distribution Products
Select Series Circuit Breaker
Power Distribution Panel User Manual
Issue 3
17943-A
1361498 Rev A
ADCP-80-545 • Issue 3 • March 2006 • Preface
COPYRIGHT
© 2006, ADC Telecommunications, Inc.
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.
LIST OF CHANGES
The technical changes incorporated into this issue are listed below.
PAGE IDENTIFIER DESCRIPTION OF CHANGE
26 Step 9 Changed wire color from black to white and vice versa.
27 Figure 20 Changed wire color from black to white and vice versa.
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 1-800-366-3891, extension 73475
(in U.S.A. or Canada) or 952-917-3475 (outside U.S.A. and Canada), or by e-mail to connectivity_tac@adc.com.
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ADC Telecommunications, Inc.
P.O. Box 1101, Minneapolis, Minnesota 55440-1101
In U.S.A. and Canada: 1-800-366-3891
Outside U.S.A. and Canada: (952) 938-8080
Fax: (952) 917-1717
TABLE OF CONTENTS
Content Page
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
STANDARDS CERTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
ADMONISHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
1 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Product Functions and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Circuit Breaker Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Packaged Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Power Buses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.9 Input/Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.10 Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.11 Output Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.12 Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.13 Alarm Operation and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.14 LED Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.15 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.16 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 BEFORE STARTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 General Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Unpacking and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Installation Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Materials Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Test Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Mounting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Chassis Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 External Alarm System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Output Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.6 Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7 Protective Cover Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.8 Cable Management Bar Installation (Accessory Item) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.9 Circuit Designation Card and Voltage Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Power and Alarm Indication Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Connection Polarity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Alarm Contacts Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ADCP-80-545 • Issue 3 • March 2006 • Preface
© 2006, ADC Telecommunications, Inc.
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ADCP-80-545 • Issue 3 • March 2006 • Preface
TABLE OF CONTENTS
Content Page
5.1 Circuit Breaker Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Connecting New Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Power LED Indicator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 CUSTOMER INFORMATION AND ASSISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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© 2006, ADC Telecommunications, Inc.
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.
ADCP-80-545 • Issue 3 • March 2006 • Preface
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.
Warn ing: 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
-
Warn ing: The circuit breaker panel uses electrical voltage and current levels that may be
considered an electrical hazard per GR-1089. 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.
Warn ing: 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.
© 2006, ADC Telecommunications, Inc.
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ADCP-80-545 • Issue 3 • March 2006 • 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.
Warn ing: 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.
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© 2006, ADC Telecommunications, Inc.
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.
ADCP-80-545 • Issue 3 • March 2006
• Mounts within 1 rack space (1.75 inches).
• Dual-bus power feeds with a maximum input rating of 100 Amps per bus.
Warn ing: 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.
© 2006, ADC Telecommunications, Inc.
Page 1
ADCP-80-545 • Issue 3 • March 2006
1 TO 8 CIRCUIT BREAKERS
(BLANK PANEL IF NO
CIRCUIT BREAKER)
BUS B INPUT
POWER TERMINALS
BUS B OUTPUT
POWER TERMINALS
BUS A
POWER-ON
INDICATOR
(GREEN LED)
BUS A
CIRCUIT BREAKER
ALARM INDICATOR (RED LED)
FRONT VIEW
ALARM INDICATOR (RED LED)
ALARM
TERMINALS
BUS A OUTPUT
POWER TERMINALS
CHASSIS
GROUNDING
STUDS
BUS B
POWER-ON
INDICATOR
(GREEN LED)
BUS B
CIRCUIT BREAKER
BUS A INPUT
POWER TERMINALS
1 TO 8 CIRCUIT BREAKERS
(BLANK PANEL IF NO
CIRCUIT BREAKER)
DESIGNATION CARD
AND CARD HOLDER
COVER FOR
INPUT POWER
TERMINALS
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© 2006, ADC Telecommunications, Inc.
COVERS FOR
OUTPUT POWER
TERMINALS
COVER FOR
REAR VIEW
INPUT POWER
TERMINALS
Figure 1. Select Series Circuit Breaker Panel (Typical)
17939-A
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:
ADCP-80-545 • Issue 3 • March 2006
REAR COVERS FOR OUTPUT
POWER/ALARM TERMINAL BLOCK
2-HOLE LUGS FOR
2 AWG WIRE
VO LTAGE
LABEL
REAR COVERS FOR INPUT
POWER TERMINAL BLOCK
#10 RING TERMINALS FOR
12-10 AWG WIRE
5/16-INCH (7.936 MM) 8-32
FLAT-HEAD SCREWS
ORIENTATION FOR
19-INCH RACK INSTALLATION
3/8-INCH (9.525 MM) 12-24
SCREWS AND #12 WASHERS
ORIENTATION FOR
23-INCH RACK INSTALLATION
DESIGNATION CARD
AND CARD HOLDER
UNIVERSAL MOUNTING BRACKETS
Figure 2. Packaged Hardware Components
• One set of 19-inch mounting brackets
AND SCREWS
17942-A
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© 2006, ADC Telecommunications, Inc.
ADCP-80-545 • Issue 3 • March 2006
• 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, 12-24 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 12–10 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
• Circuit breaker ratings - Both 1-pole and 2-pole circuit breakers are used with the panel.
• Alarm contact connections - Either screw-down terminals or wire-wrap pin terminals may
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
• 2-hole compression lugs - Used to attach the BATT and RTN cables to the power input
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.
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.
be specified for the alarm contact connections.
breakers with a rating of 26, 30, 36, 40, and 50 Amps are available.
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
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© 2006, ADC Telecommunications, Inc.
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
584.2 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 1.75- 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.
ADCP-80-545 • Issue 3 • March 2006
Warn ing: 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.
© 2006, ADC Telecommunications, Inc.
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