ADC PowerWorx Circuit Breaker Panel With Reset Switch User Manual

®

PowerWorx

Power Distribution Products

Circuit Breaker Panel With Reset Switch
User Manual

ADCP-80-570

Issue 2

March 2006

20629-A

1361499 Rev A

ADCP-80-570 • Issue 2 • 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 8/2005 Original.

2 3/2006 Wire colors corrected on Page 28.

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 [e-mail].

Page ii

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: [phone]
Fax: [phone]

TABLE OF CONTENTS

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 Panel Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Packaged Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.4 Power Buses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.5 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6 Input Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.7 Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.8 Output Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.9 Chassis Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.10 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.11 Power-on Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.12 Breaker Alarm Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.13 Alarm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.14 Alarm Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.15 Reset Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.16 Circuit Breaker Designation Card and Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.17 Voltage Designation Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.18 Material and Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.19 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.20 Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.21 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.22 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.23 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 Installation Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 Materials Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3 Pre-Installation Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.4 Cable Management Bar (Optional Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5 Mounting Panel on Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.6 Installing Designation Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.7 Installing Voltage Designation Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.8 Installing Ground Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.9 Connecting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

ADCP-80-570 • Issue 2 • March 2006 • Preface

© 2006, ADC Telecommunications, Inc.

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ADCP-80-570 • Issue 2 • March 2006 • Preface

TABLE OF CONTENTS

TABLE OF CONTENTS

Content Page

4.10 Connecting Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.11 Connecting Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.12 Installing Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.1 Testing Power Indicators and Connection Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.2 Testing Alarm Contacts Normal State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.1 Connecting New Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.2 Using the Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.1 Performing a Routine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.2 Replacing a Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8 CUSTOMER INFORMATION AND ASSISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A ALLOWABLE AMPACITIES OF INSULATED CONDUCTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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© 2006, ADC Telecommunications, Inc.

ABOUT THIS MANUAL

This manual describes the PowerWorx Circuit Breaker Panel With Reset Switch, and provides
all information required to install, test, and operate this product.

STANDARD CERTIFICATION

The panel conforms to the applicable requirements of the following: UL/CSA/EN 60950, FCC
Part 15, CISPR 22, and CISPR 24.

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-80-570 • Issue 2 • 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 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.

Warn ing: Disconnect or turn off the power before connecting the input or output wires on the
circuit breaker panel. This may require turning off the system office battery input at the battery
distribution fuse bay or turning off the circuit breakers at the panel.

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.

© 2006, ADC Telecommunications, Inc.

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ADCP-80-570 • Issue 2 • March 2006 • Preface

Warn ing:

exceeds the maximum recommended ambient temperature of 55º C.

Warn ing:

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.

Warn ing:

Warn ing:

overloaded.

LIST OF ACRONYMS

LED -- Light-Emitting Diode

To prevent the system from overheating, do not operate it in an area that

Stability hazard. The rack stabilizing mechanism must be in place, or the

Suitable for mounting on concrete or other non-combustible surface only.

Take care when connecting units to the supply circuit so that wiring is not

Page vi

© 2006, ADC Telecommunications, Inc.

1 PRODUCT DESCRIPTION

This section describes the PowerWorx Circuit Breaker Panel With Reset Switch. Topics include
product functions and features, panel components, packaged hardware, power buses, input
voltage, input connectors, output voltage, output connectors, chassis ground connections, circuit
breakers, power on indicators, breaker alarm indicators, alarm operation, alarm connections,
reset switch, circuit breaker designation card and holder, voltage designation label, material and
finish, cooling, protective covers, mounting, specifications, and dimensions.

1.1 Product Functions and Features

The Circuit Breaker Panel With Reset Switch supplies low-voltage, protected dc power to –24
Vdc or –48 Vdc powered equipment installed in a central office, multimedia headend, remote
site, or other restricted access location. The panel provides the following functions and features:

• Two side-by-side power buses, designated A and B, each with seven power outputs.

• Fourteen circuit breakers (seven per bus). Each bus has two 10 Amp circuit breakers and
five 5 Amp circuit breakers.

ADCP-80-570 • Issue 2 • March 2006

• Maximum input rating of 45 Amps per bus. This corresponds to a maximum input rating
of 90 Amps for the total panel.

• One Power On LED (green) and one Breaker Alarm LED (red) for each bus.

• One Reset switch for the total panel. The Reset switch allows the operator to reset the
panel to a non-alarming state if a breaker has been turned off or tripped due to an
overcurrent condition.

• Alarm contacts (screw-down barrier terminal strips) for remote reporting of an alarm
condition. The alarm contacts can be used to open or close a loop connected to an external
alarm system.

• Mounting brackets providing the ability to mount the panel in a 19-inch (482.6 mm) or 23­inch (584.2 mm) WECO or EIA equipment rack. The panel occupies one rack space (1.75
inches, 44.4 mm).

Note: The panel requires one open rack space above the chassis and one open rack space
below the chassis for heat dissipation.

• Two-hole compression-lug style terminals for input power connections.

• Screw-down barrier terminal strips for output power connections.

• Two chassis ground studs.

• Easy to remove rear protective covers. These covers mount over the input and output
power connections to prevent inadvertent contact.

1.2 Panel Components

Figure 1 shows the components of the circuit breaker panel.

© 2006, ADC Telecommunications, Inc.

Page 1

ADCP-80-570 • Issue 2 • March 2006

1 TO 7 CIRCUIT BREAKERS

BUS A

BUS A
POWER-ON
INDICATOR

(GREEN LED)

BUS B INPUT

POWER TERMINALS

BUS B OUTPUT

POWER TERMINALS

RESET

SWITCH

INDICATOR (RED LED)

FRONT VIEW

ALARM

TERMINALS

CHASSIS

GROUNDING

STUDS

BUS A ALARM

BUS B ALARM

INDICATOR (RED LED)

BUS A OUTPUT

POWER TERMINALS

BUS B
POWER-ON
INDICATOR

(GREEN LED)

BUS B

1 TO 7 CIRCUIT BREAKERS

DESIGNATION CARD

AND CARD HOLDER

BUS A INPUT

POWER TERMINALS

COVER FOR

INPUT POWER

TERMINALS

REAR VIEW

Page 2

© 2006, ADC Telecommunications, Inc.

COVER FOR

OUTPUT POWER

TERMINALS

COVER FOR

INPUT POWER

TERMINALS

Figure 1. Circuit Breaker Panel Components

20631-A

1.3 Packaged Hardware

The shipped product includes hardware components that are packaged separately and shipped in
the carton with the basic panel. Figure 2 shows the shipped items:

• 5/16-inch long, Phillips drive, 8-32 flat-head screws (8)—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.

• #10 ring terminals (2) for #12–#10 AWG wire—Can be used to connect the grounding
cables to the grounding studs.

• 2-Hole Lugs for #6 AWG wire (4)—Used to connect input power cable to input power
terminal blocks.

ADCP-80-570 • Issue 2 • March 2006

REAR COVER FOR OUTPUT

POWER/ALARM TERMINAL BLOCK

2-HOLE LUGS FOR

6 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

AND SCREWS

20633-A

Figure 2. Packaged Hardware

Page 3

© 2006, ADC Telecommunications, Inc.

ADCP-80-570 • Issue 2 • March 2006

• Rear protective input terminal covers (2) and output/alarm terminal cover (1)—Used to

prevent accidental contact with the alarm and power terminals.

•#6-32 Screws (4)—Used to fasten output/alarm terminal cover to rear of panel chassis.

• Designation card and card holder (1)—Used to record information about the protected

equipment. Cards and clear cover insert into the card holder.

• Voltage label (1)—Used to indicate whether the input voltage is –48 or –24 Vdc.

1.4 Power Buses

Each circuit breaker panel has two isolated power buses. Each bus distributes the input power to
the output power circuits. In each bus circuit, current flows from the input power bus, through
the circuit breaker, to the output power circuit. The current capacity of each bus is 45 Amps
maximum. Figure 3 is a block diagram of the power buses.

–24V/–48V

BATTERY A

RETURN A

–24V/–48V

BATTERY B

RETURN B

BATTERY RETURN

1
2
3
4
5
6
7

BUS A

FA

RETURN A

BUS B

FB

RETURN B

BATTERY RETURN

1
2
3
4
5
6
7

POWER A LED

BREAKER
ALARM A LED

POWER B LED

BREAKER ALARM B LED

ALARM RESET PUSHBUTTON

20691-A

C
NO

NC

SYSTEM ALARM

C
NO

NC

CONNECTIONS

Page 4

© 2006, ADC Telecommunications, Inc.

Figure 3. Circuit Breaker Panel Block Diagram

Each of the power buses supports seven circuit breaker positions including two 10 Amp circuit
breaker positions and five 5 Amp circuit breaker positions giving a total capacity per bus of 45
Amps.

When a circuit breaker trips, the input power bus is disconnected from the corresponding output
circuit.

1.5 Input Voltage

The dual bus circuit breaker panel can accommodate either –24 Vdc on both buses or –48 Vdc on
both buses.

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 voltage level is sensed by the circuit breaker panel circuitry. The input voltages used with
the circuit breaker panel can fall within the following ranges:

• –24 Vdc nominal, within range of –21 Vdc to –30 Vdc

ADCP-80-570 • Issue 2 • March 2006

• –48 Vdc nominal, within range of –42 Vdc to –56 Vdc

1.6 Input Connectors

Each power bus has two input connectors on the rear of the circuit breaker panel through which
input power is provided. The two input power connectors are labeled “BATT” (battery) and “RTN”
(return). Each input connector consists of a pair of 0.25-inch (0.635 cm) studs (with nuts) mounted
on a plastic terminal block. Each pair of studs can accept different size 2-hole compression lugs used
with a range of wire sizes up to #6 AWG copper wire. Two 2-hole lugs per bus for use with #6 AWG
wire (four total) are provided with the circuit breaker panel. Additional lugs are available as
accessory items. Maximum lug width is 0.62 inches (1.6 cm). 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).

1.7 Output Voltage

The output voltage will be the same as the applied input voltage.

1.8 Output Connectors

Each bus has two screw-down terminal strips with seven 8-32 screws each on the back of the
panel. The upper terminal strip contains the BATT (power feed) connectors. The lower terminal
strip contains the RTN (return) connectors. When a piece of equipment is connected to the
circuit breaker panel, it is connected to one BATT connector and one RTN connector located
vertically above and below one another.

© 2006, ADC Telecommunications, Inc.

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ADCP-80-570 • Issue 2 • March 2006

The individual terminals are on 0.375 inch (9.525 mm) centers with a distance between barriers
of 0.32 inch (81.3 mm). The terminals can accept a variety of wire sizes up to #12 AWG with
crimp-on spade lug connectors or wires in sizes from #12 AWG to #22 AWG with the insulation
stripped back. The connectors or wires are inserted under the screws in the terminal strip, and
the screws are tightened down.

In selecting the copper 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).

1.9 Chassis Ground Connections

Two #10 studs (with nuts) are provided for grounding the circuit breaker panel chassis. The
studs are mounted on 0.625 inch (15.875 mm) centers, and can accommodate a 2-hole
compression lug. Two crimp ring lug terminals for use with two #10 AWG wires are provided
with the circuit breaker panel.

1.10 Circuit Breakers

The circuit breakers are magnetic actuation, manual reset, single pole, replaceable, 60 Vdc rated
circuit breakers, with finger guard and amperage markings. Each power bus has two 10 Amp
breakers and five 5 Amp breakers. The maximum capacity per bus is 45 Amps.

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 Tab l e 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).

Circuit breakers are field-replaceable. Please contact ADC Technical Support if replacement is
required (refer to Section 8, Customer Information and Assistance, on page 29).

100% 135% 150% 200% 400% 600% 800% 1000% 1200%

NO

TRIP

1.11 Power-on Indicators

A green LED Power On indicator for each power bus is mounted on the front panel of the circuit
breaker panel. If the LED indicator is on, power is being applied to the bus input connectors. If
the green LED indicator is off, power is not being applied to the bus input connectors.

.300-

7.00

Table 1. Short Delay Trip Times in Seconds

PERCENT OF RATED CURRENT

.200-

5.00

.100-

2.00

.030-

.500

.008-

.300

.006-

.150

.005-

.100

.005-

.100

Page 6

© 2006, ADC Telecommunications, Inc.

1.12 Breaker Alarm Indicators

For each bus, the circuit breaker panel has one visual Breaker Alarm indicator (red LED)
mounted on the front of the panel. The breaker alarm indicator lights if any circuit breaker on
the corresponding bus trips off. Loss of power to either bus will cause the circuit breaker alarm
indicator for the corresponding bus to be off.

1.13 Alarm Operation

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.

Each bus contains circuitry that operates a set of Form C alarm relay contacts when any circuit
breaker on the bus trips off or when input power to the bus is lost. The alarm contacts may be
used to open or close a loop connected to an external alarm system.

Alarm connections are provided though a screw-down barrier terminal strip located on the rear
side of the panel. During normal operation, the normally open (NO) contacts remain open and
the normally closed (NC) contacts remain closed. When a circuit breaker trips or power is lost,
the NO contacts close creating a connection from NO to common (C), and the NC contacts open
creating an open circuit between the NC and C contacts. When the Reset button is tripped, these
contacts return to a normal operational state.

ADCP-80-570 • Issue 2 • March 2006

The maximum current rating for each set of alarm relay contacts is 1.0 Amp.

1.14 Alarm Connections

The panel has a screw-down barrier terminal strip for the alarm relay contact connections. The
screw-down terminal strip consists of two single row terminal blocks, each with three 3-48
screw terminals. The screw terminals are mounted on 0.250 inch (6.350 mm) centers with a
maximum distance between barriers (maximum connecting terminal width) of 0.200 inch
(5.080 mm). The three terminals in each row are labeled NO, C, and NC. The terminals will
accept #16 to #30 AWG copper wire with insulation stripped back.

1.15 Reset Switch

The Reset switch, when tripped, stops the reporting of any current alarms due to circuit breakers
being in the off position. In this state, only new alarms are reported.

1.16 Circuit Breaker Designation Card and Holder

A circuit breaker designation card as shown in Figure 4 and a card holder are provided with the
circuit breaker panel. The card holder is intended to be attached either to one of the panel
mounting brackets, to a part of the rack in which the panel is installed, at a location close to the
panel, or to the underside of the panel, as desired.

© 2006, ADC Telecommunications, Inc.

Page 7

ADCP-80-570 • Issue 2 • March 2006

The card should be filled out with circuit information for each of the circuit breakers installed in
the panel and inserted in the card holder. The card holder has a pressure sensitive adhesive
backing for attachment.

1.60 IN.

(4.06 CM)

2.36 IN.

(5.99 CM)

16753-A

10 POSITION A AND B CARD

Figure 4. Circuit Breaker Designation Card

1.17 Voltage Designation Label

A voltage designation label such as shown in Figure 5 is provided with the circuit breaker panel.
The label is intended to be filled out with the actual voltage present on the buses and placed on
the panel. The voltage designation label has a pressure sensitive adhesive backing for
attachment.

1.18 Material and Finish

The panel chassis and brackets are made of 16-gauge cold rolled steel. The panel and brackets
are finished with a putty-color powder coat.

0.38 IN.

(0.96 CM)

14228-A

1.00 IN.

(2.54 CM)

Figure 5. Voltage Designation Label

1.19 Cooling

The circuit breaker panel is ventilated to allow efficient convection cooling of all components
without the use of fans or blowers. Holes are provided in the top and bottom of the panel to allow
heated air to escape from the panel and cool air to enter.

Page 8

© 2006, ADC Telecommunications, Inc.

Note: The panel requires one open rack space above the chassis and one open rack space
below the chassis for heat dissipation.

1.20 Protective Covers

The panel has three protective covers mounted on the rear side of the panel. Two of these are
snap-on covers that mount over the input power connectors. A third, larger cover mounts over
the output power connectors and the external alarm connections. This cover is secured with four
6-32 screws provided with the panel. Access to these connectors and terminals is obtained by
removing the appropriate cover. The covers over the input power terminals are removed by
unsnapping them from their position. The larger cover is removed by loosening (but not
removing) the four screws. The holes in the large cover are keyed to allow it to be pulled to the
side and lifted clear of the screws.

1.21 Mounting

The circuit breaker panel can be mounted in a 19- or 23-inch rack (48.26 or 58.42 cm) using the
mounting brackets shown in Figure 2 on page 3. The panel can be flush mounted or recessed 1,
2, 3, or 4 inches (25.4, 50.8, 76.2, or 101.6 mm) from the front of the rack. The mounting holes
are slotted to permit installation in racks with WECO 1.00-inch (2.54 cm) hole spacing or EIA

1.25-inch (3.18 cm) hole spacing.

ADCP-80-570 • Issue 2 • March 2006

The following mounting brackets and screws are enclosed with the circuit breaker panel:

• Two brackets for 19-inch rack installations;

• Two brackets for 23-inch rack installations;

• Eight 5/16-inch (7.936 mm) long, 8-32 chromate finish, thread-forming, flathead screws
for attaching the brackets to the circuit breaker panel;

• Four 3/8-inch (9.525 mm) long, 12-24 thread-forming screws and washers for attaching
the brackets to the rack.

Caution: Use only the 5/16-inch (7.936 mm) long, chromate finish, flathead, thread forming
screws for attaching the mounting brackets to the circuit breaker panel. Use of any other
hardware could cause contact with internal parts of the panel. If parts are missing, please
contact ADC.

The slotted mounting hole pattern in the mounting brackets compensates for vertical rack
differences and allows mounting the circuit breaker panel in either 1.75- or 2-inch (4.45 or 5.08 cm)
rack spaces.

© 2006, ADC Telecommunications, Inc.

Page 9

ADCP-80-570 • Issue 2 • March 2006

1.22 Specifications

Tab le 2 lists specifications for the circuit breaker panel.

PARAMETER SPECIFICATION REMARKS

Physical

Weight 12 pounds (5.45 kilograms)

Table 2. Circuit Breaker Panel Specifications

Dimensions (HxWxD) 1.75 x 17.13 x 11.0 inches

See Figure 6.

(44 x 435 x 280 mm)

Color Putty white

Rack mounting 19- or 23-inch (EIA or

WECO hole spacing)

Flush or with a recess of 1, 2,
3, or 4 inches (25.4, 50.8,

76.2, or 101.6 mm)

Electrical

Operating voltages –24 Vdc nominal Input range: –21 to –30 Vdc

–48 Vdc nominal Input range: –42 to –56 Vdc

Input current 45 Amps max. per bus 90 Amps max. per panel

Circuit breaker rating 5 or 10 Amps Positions are labeled

Circuit breaker positions 7 per bus 14 per panel

Max. circuit breaker size 10 Amps rating 45 Amps per bus

Input terminal type 2-hole compression lug Stud type accepting up to #6

AWG wire

Output terminal type

Alarm contact current

7-position screw-down barrier
terminal strip

1 Amp max.

Accepting a variety of wire
up to 12 AWG wire

Grounding connection

Environmental

Operating temperature

Storage temperature

Humidity range

Altitude range –197 feet (0.06 km) to 13,000

Acoustic noise 0 dBA above ambient

Heat dissipation (no load) 1 Watt per bus

Heat dissipation (fully loaded)

Page 10

© 2006, ADC Telecommunications, Inc.

Two #10 studs and nuts on

0.625 centers

–5º C to +55º C

–45º C to +85º C

0% to 95% humidity

feet (3.96 km) above sea level

30 Watts max. at

25º C ambient

temperature, full load

No condensation

PARAMETER SPECIFICATION REMARKS

Tor que

Mounting bracket chassis screws 15 pound-force inches 1.7 Newton meters

Mounting bracket rack screws 27 pound-force inches 3.1 Newton meters

Alarm contacts 9 pound-force-inches 1 Newton meter

Input power terminal nuts 32 pound-force inches max. 3.5 Newton meters max.

Output power terminal screws 12 pound-force inches max. 1.3 Newton meters max.

Grounding stud nuts 20 pound-force inches max. 2.2 Newton meters max.

1.23 Dimensions

Dimensions

ADCP-80-570 • Issue 2 • March 2006

Table 2. Circuit Breaker Panel Specifications, continued

11.10 IN.

(28.2 CM)

10.00 IN.
(25.4CM)

1.75 IN.

(4.4 CM)

1.12 IN.

(2.9 CM)

23.00 IN.

(58.4 CM)

17.13 IN.

(43.5 CM)

Figure 6. Panel Dimensions

22.31 IN.

(56.7 CM)

20634-A

© 2006, ADC Telecommunications, Inc.

Page 11

ADCP-80-570 • Issue 2 • March 2006

2 ACCESSORIES

The following accessories for the PowerWorx circuit breaker panel are available:

• Cable management bar with mounting screws. Provides cable tie points. Installed at rear
of circuit breaker panel by fastening ends of bar to both sides of the panel;

• Various sizes of two-hole compression lugs for input power connection.

• Lug terminals to connect #10 AWG wire to earth ground.

• Circuit breaker designation card kit.

3 UNPACKING AND INSPECTION

Unpack and inspect the various components as follows:

1. Inspect the exterior of the shipping container for evidence of handling that may have
damaged the components in the container.

2. Unpack each container while carefully checking the contents for damage and verify with
the packing slip.

3. File a claim with the commercial carrier and notify ADC Customer Service if damage is

4. Refer to Section 8, Customer Information and Assistance at the back of this manual, for

Save all shipping containers for use if the equipment requires return shipment at a future date.

4 INSTALLATION

The circuit breaker panel must be installed in a central office, equipment room, or restricted
access location.

The following guidelines should be used when mounting the circuit breaker panel in a rack:

• Mount the circuit breaker panel in the uppermost area of the rack to reduce exposure of the

• Provide a minimum of 1.75 inches (4.45 cm) of air space (one rack space) between the top

Caution: This equipment employs electrical voltage and amperage levels which may be
considered an electrical hazard. Care should be exercised to assure that only qualified
personnel are allowed to install, operate, maintain, or otherwise come in contact with this
equipment when the circuit breaker panel is energized.

detected or if parts are missing. Save damaged cartons for inspection by the carrier.

repair, replacement, and warranty information.

power wiring.

of the circuit breaker panel and the next item in the rack for cooling.

Warn ing: Never install power equipment in a wet location or during a lightning storm. When
installing or modifying power lines, disconnect lines at the source before working with
uninsulated lines or terminals to prevent electrical shock.

Page 12

© 2006, ADC Telecommunications, Inc.

4.1 Installation Tools Required

The following tools are required to install the circuit breaker panel:

• Screwdrivers (both Phillips and flatblade)

• Torque screwdriver calibrated in pound-force inches or Newton meters

• 3/8-inch and 7/16-inch bits (for torque screwdriver)

• Wire cutter

• Wire stripper

• Compression lug crimper

• Multimeter

•Heat gun

4.2 Materials Required

The following materials are required to install the circuit breaker panel:

ADCP-80-570 • Issue 2 • March 2006

• Insulated copper wire for input and output power wires (see Appendix A)

• Heat-shrink tubing

• Multimeter

4.3 Pre-Installation Testing

Each circuit breaker panel is thoroughly tested at the ADC 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.

© 2006, ADC Telecommunications, Inc.

Page 13

ADCP-80-570 • Issue 2 • March 2006

Test 1: Input Battery to Input Return—Use the following procedure:

1. Connect one test probe to the A bus BATT input power terminal and the other test probe to
the A bus RTN input power terminal (Figure 7).

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

20635-A

Figure 7. Test 1: Input Battery to Input Return

2. Verify that no continuity exists between the BATT input and RTN input terminals.

3. Repeat the test procedure for the B bus.

Test 2: Input Battery to Output Battery—Use the following procedure (Figure 8):

1. Starting on the A bus, at the output terminal for circuit 1, connect the negative test probe to
the bus A input BATT power terminal and the positive test probe to bus A output BATT
power terminal for the circuit being tested.

2. Turn on circuit breaker A1.

3. Verify that continuity exists between the specified terminals.

4. Repeat the test procedure for each remaining circuit (A 2-7, B 1-7).

Page 14

© 2006, ADC Telecommunications, Inc.

TEST 2- POWER BUS B:

VERIFY CONTINUITY EXISTS

BETWEEN INPUT AND

OUTPUT BATT TERMINALS

Figure 8. Test 2: Input Battery to Output Battery

TEST 2- POWER BUS A:

VERIFY CONTINUITY EXISTS

BETWEEN INPUT AND

OUTPUT BATT TERMINALS

20636-A

ADCP-80-570 • Issue 2 • March 2006

Test 3: Input Return to Output Return—Use the following procedure:

1. Starting at bus A, connect the negative test probe to the RTN input power terminal and the
positive test probe to the RTN output power terminal for circuit 1 (Figure 9).

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

20637-A

Figure 9. Test 3: Input Return to Output Return

2. Verify that continuity exists between the specified terminals.

3. Repeat the test procedure for each remaining circuit (A 2-7, B 1-7).

Test 4: Alarm Terminals—Use the following procedure:

Note: This procedure tests the alarm indicator contacts as they should be with no

power being supplied to the panel. In this state, the normally open (NO) contacts
should be closed and the Normally Closed (NC) contacts should be open.

1. Starting at the top set of alarm terminals on the right rear side of the panel, verify that no
continuity exists between the C and NC terminals(Figure 10).

CHECK THAT CONTINUITY

EXISTS BETWEEN THE

“NO” AND “C” TERMINALS

CHECK THAT NO CONTINUITY

EXISTS BETWEEN THE

“C” AND “NC” TERMINALS

20702-A

Figure 10. Test 4: Alarm Contacts

2. Connect the test probes between the C and NO terminals on the first set of alarm
terminals. Verify that continuity exists between the C and NO terminals.

3. Repeat the test procedure for the other set of alarm terminals.

© 2006, ADC Telecommunications, Inc.

Page 15

ADCP-80-570 • Issue 2 • March 2006

4.4 Cable Management Bar (Optional Accessory)

Before installing the circuit breaker panel in the rack, determine if the optional cable management
bar was ordered for this panel. If so, install the bar before mounting the panel on the rack.

Use the following procedure:

1. Position the cable management bar at the rear of the panel as shown in Figure 11.

2. Secure the bar to the panel using the 0.25-inch (6.35 mm) long 4-40 screws supplied with

the cable management bar.

Note: The cable management bar can be recess-mounted by using the mounting holes closest
to the front of the panel.

Caution: When attaching the cable management bar to the circuit breaker panel, use only the
hardware supplied with the cable management bar. Use of any other hardware could cause
contact with internal parts of the circuit breaker panel. If parts are missing, please contact ADC.

Note: A circuit breaker panel with the cable management bar attached may exceed the
12-inch (3.05 mm) overall depth objective described in GR-63 CORE, 02-14.

CABLE

MANAGEMENT

BAR

4.5 Mounting Panel on Rack

The circuit breaker panel can be mounted in either a 19- or 23-inch (48.26 or 58.42 cm) wide
rack using the 1.75-inch high (4.45 cm), 19- or 23-inch rack mounting brackets. The brackets,
mounting screws, and washers are provided with the panel.

MOUNTING BRACKET

INSTALLED FOR

23-IN. (58.42 CM)

RACK MOUNTING

ATTA C H TO
EITHER SET
OF 3 HOLES

20645-A

Figure 11. Cable Management Bar Installation

Page 16

© 2006, ADC Telecommunications, Inc.

ADCP-80-570 • Issue 2 • March 2006

Caution: When attaching the mounting brackets to the circuit breaker panel, use only the
5/16-inch (7.935 mm) long, chromate finish, flathead, thread forming screws supplied with the
panel. Use of any other hardware could cause contact with internal parts of the circuit breaker
panel. If parts are missing, please contact ADC.

Use the following procedure to install the circuit breaker panel in the rack:

1. Select either the 19-inch or 23-inch brackets.

2. Attach the mounting brackets to the sides of the chassis using the eight 5/16-inch (7.94
mm) 8-32 flathead thread-forming screws provided. Tighten the screws to 15 pound-force
inches (1.7 Newton meters) of torque to insure grounding. Refer to Figure 12.

ORIENTATION FOR

19-INCH RACK

NSTALLATION

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

ORIENTATION FOR

23-INCH RACK

INSTALLATION

20638-A

Figure 12. Repositioning the Mounting Brackets (Optional)

3. Place the circuit breaker panel in the specified mounting space within the rack as shown in

Figure 13.

Note: Provide one rack unit of space above and below the circuit breaker panel for air
circulation.

4. Secure the panel to the rack using the four 3/8-inch (9.525 mm) long, 12-24 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.

© 2006, ADC Telecommunications, Inc.

Page 17

ADCP-80-570 • Issue 2 • March 2006

TIGHTEN MOUNTING SCREWS
TO 27 POUND-FORCE INCHES

(3.1 NEWTON METERS) OF TORQUE

USE #12 STAR WASHERS INSTEAD OF FLAT

WASHERS IF REQUIRED BY LOCAL PRACTICE

Figure 13. Mounting Panel on Rack

4.6 Installing Designation Cards

Attach the designation card holder either to the underside of the circuit breaker panel, to one of
the panel mounting brackets, to part of the rack, or at a location close to the panel. Remove the
backing from the back of the card holder and press the card holder against the mounting surface.
Fill out one of the cards (see Figure 4 on page 8) with circuit information as desired and insert it
in the card holder.

4.7 Installing Voltage Designation Label

Write the voltage used in the circuit breaker panel on the voltage designation label (see Figure 5

on page 8) and attach the label to the panel.

4.8 Installing Ground Wires

20639-A

Connect chassis ground (labeled “C. GND”) to the equipment rack ground (Figure 14) using the
following chassis grounding recommendations:

• Chassis grounding conductor connection point: #10 screws and nuts on 0.625 inch
(15.875 mm) centers. Two #10 crimp ring terminals, for use with #10 AWG wires, are
provided.

Page 18

© 2006, ADC Telecommunications, Inc.

ADCP-80-570 • Issue 2 • March 2006

• Chassis ground conductor: Use two #10 AWG wires if using both chassis ground
connectors or one #6 AWG wire if using one chassis ground connector from connector(s)
to equipment rack.

Torque the nuts to 20 pound-force inches (2.2 Newton meters) maximum. Route the free end of
the chassis grounding wire to an approved office ground source. Terminate the wire at the
ground source.

DETAIL DRAWING

OF GROUNDING

WIRE CONNECTION

TIGHTEN STUD NUT TO

20 POUND-FORCE INCHES

(2.2 NEWTON METERS)
OF TORQUE MAXIMUM

4.9 Connecting Alarms

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 two
single row terminal strips, each with three screws, located on the rear side of the panel. The
terminal strips can accept #16 to #30 AWG solid copper, either with crimp-on spade lugs or ring
connectors, or without lugs with insulation stripped back. Use the following procedure to
connect an external alarm system to the alarm terminals on the circuit breaker panel chassis.

Caution: All Vdc input wiring shall be routed away from any sharp edges and properly
secured in place to prevent chaffing and to provide strain relief. This may be achieved by
tie-wrapping the wires to the rack frame, or by equivalent means.

1. Obtain #16 to #30 AWG wire.

2. Run four lengths of wire from the circuit breaker panel to the external alarm system.

20640-A

Figure 14. Installing Ground Wires

3. Strip back the insulation approximately 0.38 inches (9.5 mm) on the ends of the wires by
the circuit breaker.

4. If using spade lug or ring connectors, crimp the connectors onto the wires and then install
the connectors on the alarm contacts (Figure 15).

© 2006, ADC Telecommunications, Inc.

Page 19

ADCP-80-570 • Issue 2 • March 2006

5. If connecting bare wire, wrap the bare wire around the contact in a clockwise direction.

6. Tighten the screws to approximately 9 pound-force inches (1 Newton meter) of torque.

7. Terminate the other ends of the wires at the appropriate terminals in the external alarm
system.

20641-A

SCREW-DOWN TERMINAL

CONNECTIONS FOR

REMOTE ALARMS

4.10 Connecting Output

Output power is supplied to the protected equipment through the output power screw-down
terminal strips located on the rear of the panel. Wire leads should be equipped with crimp-on
spade lugs or ring connectors that have a minimum width of 0.32 inches (81.3 mm). The
terminals also accommodate copper wire without lugs (insulation stripped back). The terminals
can accept a variety of wire sizes up to #12 AWG with crimp-on spade lug or ring connectors or
wires in sizes from #12 AWG to #22 AWG with insulation stripped back. Follow local code. In
selecting wire size, refer to Appendix A.

.

Caution: Connecting the equipment to the wrong circuit may cause damage to the
equipment or the circuit breaker panel.

SCREW-DOWN TERMINAL

ALARM CONNECTIONS

Figure 15. Alarm Terminals

1. Obtain the required lengths of wire for use as the output power cables.

2. Equip wire leads with spade or ring-type compression lugs (maximum width 0.32 inches)
or prepare a bare wire contact.

Page 20

© 2006, ADC Telecommunications, Inc.

ADCP-80-570 • Issue 2 • March 2006

3. Terminate the wires at the screw-down barrier strip as follows (Figure 16):

– Negative wires (Battery –): Connect to the BATT output power terminals.

– Positive wires (Return +): Connect to RTN output power terminals.

POWER

FEED

TERMINALS

POWER

RETURN

TERMINALS

DETAIL DRAWING OF OUTPUT

TERMINAL BLOCK CONNECTIONS

TIGHTEN TERMINAL SCREWS
TO 12 POUND-FORCE INCHES

(1.3 NEWTON METERS)

OF TORQUE MAXIMUM

4. Tighten the output power terminal block nuts to 12 pound-force inches (1.3 Newton­meters) maximum of torque.

5. Route the free end of each output power cable to the equipment for connection.

4.11 Connecting Input

Input power is supplied to the circuit breaker panel through the A and B input power terminal
blocks located on the rear side of the panel. Each block consists of two pairs of 0.25-inch studs
that are used for connecting the negative (BATT) and positive (RTN) input power cables. The
stud pairs are mounted on 0.625 inch centers and accept 2-hole compression lugs. The
maximum lug width is 0.62 inches. Nuts with captive washers are provided to secure the
compression lugs to the terminal block. In selecting wire size, follow local code. Refer to

Appendix A for ampacity guideline.

20642-A

POWER BUS B

OUTPUT TERMINALS

POWER BUS A

OUTPUT TERMINALS

Figure 16. Connecting Power Output

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.

© 2006, ADC Telecommunications, Inc.

Page 21

ADCP-80-570 • Issue 2 • March 2006

Caution: Connect only the input voltage wire (labeled BATTERY, BATT, NEGATIVE, NEG,
or – and/or the voltage value) to the connector on the circuit breaker panel labeled BATT
(battery). Connect only the input return wire (labeled RTN, RETURN, POSITIVE, POS, +, or
BATTERY GROUND) to the connector on the circuit breaker panel labeled RTN (return).

Caution: Caution should be taken to not reverse input wires to the circuit breaker panel. In the
circuit breaker panel, the internal battery (negative voltage) wiring is protected and the internal
return wiring is not protected by circuit breakers.

Use the following procedure to connect input power wires (Figure 17):

1. Obtain four lengths of copper wire for use as the input power cables.

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 lug terminals (provided; requires crimper).

5. Slide the heat shrink insulation down to the lug terminal so the barrel end of the terminal is
covered.

Note: Replace the protective cover on the circuit breaker panel after all the wiring
connections are made and before power is applied to the panel (refer to Section 4.12,

Installing Protective Covers, on page 23)

Page 22

© 2006, ADC Telecommunications, Inc.

20643-A

TIGHTEN INPUT TERMINAL
NUTS TO 32 POUND-FORCE INCHES
(3.6 NEWTON METERS) OF TORQUE

MAXIMUM

DETAIL DRAWING OF

INPUT POWER

CABLE CONNECTIONS

Figure 17. Installing Input Power

ADCP-80-570 • Issue 2 • March 2006

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 washers) provided to secure the input power wires to the
specified terminals.

8. Connect the negative inputs to the negative (BATT) terminals on the A and B input power
terminal blocks.

9. Connect the positive inputs to the positive (RTN) terminals on the A and B input power
terminal blocks.

10. 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) maximum of torque.

11. Route the free ends of the input power cables to the office battery source.

12. Connect the input power cables to the office battery power source in accordance with
applicable local electrical codes and/or National Electrical Codes. Refer to Appendix A.
Do not apply power to the circuit breaker panel until instructed to do so for testing (see

Section 5).

4.12 Installing Protective Covers

1. Snap the two small protective covers on the input and output terminals (Figure 18).

2. Fasten the large cover to the four corners of the output power terminal blocks using the
four #6-32 screws provided.

COVER FOR

INPUT POWER

TERMINALS

COVER FOR

OUTPUT POWER

TERMINALS

20644-A

COVER FOR

INPUT POWER

TERMINALS

Figure 18. Installing Protective Covers

© 2006, ADC Telecommunications, Inc.

Page 23

ADCP-80-570 • Issue 2 • March 2006

5 TESTING

This section describes how to test the circuit breaker panel after installation.

5.1 Testing Power Indicators and Connection Polarity

Use the following procedure to check that the power input wires are connected for correct
polarity,

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. Using a multimeter set to measure DC voltage, measure the voltage between each input
power (RTN) terminal and chassis ground. The voltage level should be less than 2.0 Vdc.

4. If the voltage is much higher, and reads out in the –30 to –60 Vdc range, the input leads are
probably reversed. If this appears to be true, power down the panel. Disconnect the
negative (BATT) and positive (RTN) input lugs and switch them around. Power up the
panel and check again to verify that the higher voltage is on the negative (BATT) lug.

5. If the problem is such that you can’t figure it out with these instructions, consult with ADC
Technical Assistance Center (TAC).

5.2 Testing Alarm Contacts Normal State

Use the following procedure to test the alarm connections for correct functioning of NO and NC
terminals.

1. Verify that the alarm contacts remain in the normal state when power is applied and all
circuit breakers in the “on” position.

2. 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 all sets of alarm terminals.

3. Verify that continuity exists between the C and NC terminals and that no continuity exists
between the C and NO terminals.

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© 2006, ADC Telecommunications, Inc.

6 OPERATION

This section describes how to operate the circuit breaker panel. Operation includes connecting
new equipment and using the Reset Switch.

6.1 Connecting New Equipment

New equipment may be connected to unused output power circuits following installation and
testing of the circuit breaker panel. Use the following procedure for connecting the output
power wires for new equipment to a previously installed panel:

Warn ing: The circuit breaker 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.

1. Remove the large protective cover from the rear side of the panel.

2. Turn off the circuit breaker for the circuit to which equipment will be added.

ADCP-80-570 • Issue 2 • March 2006

3. Connect the output power wiring to the power output terminals. Wire leads should be
equipped with crimp-on spade lugs or ring connectors that have a minimum width of 0.32
inches (81.3 mm). The terminals also accommodate copper wire without lugs (insulation
stripped back). The terminals can accept a variety of wire sizes up to #12 AWG with
crimp-on spade lug or ring connectors or wires in sizes from #12 AWG to #22 AWG with
insulation stripped back. In selecting wire size, follow local code referring to the ampacity
guidelines provided in Appendix A.

Caution: Use care to avoid shorting out adjacent terminals when connecting new output power
wiring to a powered circuit breaker panel. Shorting can cause injury and damage the panel or
the connected equipment.

4. Re-install the protective cover over the output power terminal blocks.

5. Switch the circuit breaker to the on position and verify that the breaker alarm indicator
turns off.

© 2006, ADC Telecommunications, Inc.

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ADCP-80-570 • Issue 2 • March 2006

6.2 Using the Reset Switch

The purpose of the Reset switch is to allow you to clear an alarm when you turn off a circuit
breaker. When you press the Reset switch, any alarms currently existing are cleared but any new
alarm will be reported.

Use the following procedure:

1. If for some reason you need to turn off power to a particular circuit, switch the circuit
breaker to an off position and then immediately press the Reset Switch.

2. When ready, turn the circuit back on.

Note: Switching the circuit breaker back on returns the circuit to the normal alarm
reporting mode. If any other circuit has an active alarm that was cleared by the Reset
switch, that alarm will continue to be cleared until the circuit breaker for that circuit is
turned back on.

7 MAINTENANCE

Maintenance includes performing a routine inspection and replacing a circuit breaker.

7.1 Performing a Routine Inspection

Caution: Take care to avoid damaging the circuit breakers or wiring.

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 and dirt from the panel
with a soft bristle brush or soft cloth.

3. If any circuit breaker is broken or damaged, replace the circuit breaker.

7.2 Replacing a Circuit Breaker

Any existing circuit breaker may be field-replaced with an identical circuit breaker or with a
breaker that has the same rating. Use the following procedure to replace an existing circuit
breaker with a new breaker:

1. Turn-off or disconnect the power from the power bus (either A or B) that supplies current
to the circuit breaker to be replaced.

2. Press the Reset switch to suppress alarms for the “off” circuits.

Danger: During normal operation, the terminal connections on the circuit breakers are
electrically energized. Failure to disconnect the power from the power bus that supplies current
to the circuit breaker being replaced may cause severe personal injury to the installer and/or
equipment damage.

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© 2006, ADC Telecommunications, Inc.

ADCP-80-570 • Issue 2 • March 2006

3. Insert a flat-bladed screwdriver into the slot above the circuit breaker as shown in

Figure 19.

4. Push down and forward on the upper circuit breaker lock tab until the top of the circuit
breaker is released from the panel.

5. Hold the top edge of the circuit breaker to keep the circuit breaker from snapping back into
the panel when the screwdriver is withdrawn from the slot.

6. Insert a flat-bladed screwdriver into the slot below the circuit breaker.

7. Push down and forward on the lower circuit breaker lock tab until the bottom of the circuit
breaker is released from the panel.

8. Pull the circuit breaker forward and out of the panel to expose the wiring connections on
the rear side of the circuit breaker.

1. INSERT SCREWDRIVER
INTO SLOT AND DEPRESS
TO RELEASE LOCKING TAB.

2. TILT FUSE FORWARD.

20646-A

Figure 19. Releasing the Circuit Breaker Lock Tab

© 2006, ADC Telecommunications, Inc.

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ADCP-80-570 • Issue 2 • March 2006

9. Disconnect the power and load wires (#14 AWG white and black wires) and the alarm
wires (#24 AWG black wires) from the terminals on the rear side of the circuit breaker as
shown in.

10. Connect the power and load wires to the specified terminals on the rear side of the
replacement circuit breaker (see Figure 20). Note that with the circuit breaker oriented as
shown, the black load wire connects to the top terminal and the white power wire connects
to the bottom (LINE) terminal.

11. Connect the two alarm wires to the specified terminals on the rear side of the replacement
circuit breaker (see Figure 20).

Note: Do not connect any wires to the center terminal on the circuit breaker.

12. Insert the replacement circuit breaker into the opening in the panel and push inward until it
locks into place.

13. Reconnect the power to the power bus.

LOCKING

TAB

FRONT VIEW SIDE VIEW

LOCKING

TAB

Figure 20. Circuit Breaker

LINE

NOT USED

LOAD

(BLACK)

BREAKER ALARM

CONNECTIONS

POWER

20647-C

(WHITE)

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© 2006, ADC Telecommunications, Inc.

8 CUSTOMER INFORMATION AND ASSISTANCE

PHONE:

U.S.A. OR CANADA

Sales: 1-800-366-3891 Extension 73000
Technical Assistance: 1-800-366-3891
Connectivity Extension 73475
Wireless Extension 73476

EUROPE

Sales Administration: [phone]
Technical Assistance: [phone]

EUROPEAN TOLL FREE NUMBERS

Germany:
UK:
Spain:
France:

Italy: 0800 782374

ASIA/PACIFIC

Sales Administration: [phone]
Technical Assistance: [phone]

ELSEWHERE

Sales Administration: [phone]
Technical Assistance: [phone]

WRITE:

ADC TELECOMMUNICATIONS, INC
PO BOX 1101,
MINNEAPOLIS, MN 55440-1101, USA

0180 2232923
0800 960236
900 983291
0800 914032

ADCP-80-570 • Issue 2 • March 2006

ADC TELECOMMUNICATIONS (S'PORE) PTE. LTD.
100 BEACH ROAD, #18-01, SHAW TOWERS.
SINGAPORE 189702.

ADC EUROPEAN CUSTOMER SERVICE, INC
BELGICASTRAAT 2,
1930 ZAVENTEM, BELGIUM

PRODUCT INFORMATION AND TECHNICAL ASSISTANCE:

[e-mail]

[e-mail]

[e-mail]

[e-mail]

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.

© 2006, ADC Telecommunications, Inc.

13944-M

All Rights Reserved

Printed in U.S.A.

© 2006, ADC Telecommunications, Inc.

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ADCP-80-570 • Issue 2 • March 2006

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© 2006, ADC Telecommunications, Inc.

ADCP-80-570 • Issue 2 • March 2006

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/NPFA 70 (1978).

Note: Information for aluminum conductors has been omitted from the table here
because copper conductors only are recommended for use with the ADC 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 TEMPERATURE RATING OF CONDUCTOR
AWG

KCMIL

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

60°C

(114°F)

TYPES

TW*,

UF*

60°C

(114°F)

TYPES

FEPW*,

RH*, RHW*,

THHW*,

THW*,
THWN*,
XHHW*,

USE*, ZW*

THHW*, THW-2*,

60°C

(114°F)

TYPES

TBS, SA,

SIS, FEP*,

FEPB*, MI,

RHH*, RHW-2,

THHN*,

THWN-2*,

USE-2,

XHH,

XHHW*

XHHW-2

ZW-2

© 2006, ADC Telecommunications, Inc.

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ADCP-80-570 • Issue 2 • March 2006

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 TEMPERATURE RATING OF CONDUCTOR

AWG

KCMIL

60°C

(114°F)

TYPES

TW*,

UF*

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

500 320 380 430

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 and number of conductors have
been applied.

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© 2006, ADC Telecommunications, Inc.

www.adc.com

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