Whirlwind MASS Punch Operating instructions

Brand: Whirlwind

Model: MASS Punch

Type: Operating instructions

ADCP-75-003 • Issue 11 • October 2003

1271503 Rev A Page 1

Broadcast and Entertainment Products

QCP

™

Mark II

Installation Instructions

Content Page

INTRODUCTION............................................................................ 1

Revision History..................................................................... 1

Trademark Information ................................................................ 1

Admonishments..................................................................... 2

General Safety Precautions ............................................................. 2

1 GENERAL INFORMATION ................................................................ 2

1.1 Rules of Use ................................................................... 3

1.2 Different Wire Sizes or Types........................................................ 3

1.3 Fanning Strips and Cable Routing..................................................... 3

1.4 Installing Bare Wires ............................................................. 3

1.5 Insertion Tools ................................................................. 3

PROCEDURE 1: FRONT SIDE WIRE TERMINATION INSTRUCTIONS ..................................... 5

PROCEDURE 2: REAR SIDE WIRE TERMINATION INSTRUCTIONS ...................................... 8

PROCEDURE 3: REPLACING A BROKEN WIRE MODULE ............................................ 10

2 CUSTOMER INFORMATION AND ASSISTANCE .................................................. 13

INTRODUCTION

These instructions provide installation and maintenance procedures for the QCP Mark II wire

termination system for QCP Mark II patch bays and broadcast jackfields.

Revision History

ISSUE DATE REASON FOR CHANGE

Issue 9 02/1999 Updated to QCP Mark II, and to add replacement tips and Q115 manual insertion tool description.

Issue 10 02/2001 Non-technical update.

Issue 11 10/2003 Updated to provide additional information on how to distinguish the wire retention side from the wire

cut-off side on wire modules and to clarify various technical details in Procedures 1,2, and 3.

Trademark Information

ProPatch and QCP are trademarks of ADC Telecommunications, Inc.;

ADC and ICON are registered trademarks of ADC Telecommunications, Inc.

ADCP-75-003 • Issue 11 • October 2003

Page 2

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

Listed here are all general admonishments which apply throughout procedures within these

instructions.

Warning: Never install electrical equipment in a wet location or during a lightning storm.

When installing or modifying equipment lines, disconnect lines at the network interface before

working with uninsulated lines or terminals to prevent electrical shock.

1 GENERAL INFORMATION

These instructions provide installation and maintenance procedures for the QCP Mark II wire

termination system. QCP wire termination contacts were developed for Belden 8451, 9451 or

equivalent twisted pair cables and are featured on the following ADC products:

• ProPatch Mark II patchbays,

• Ultra Patch cable termination panels,

• VAMP (Video Audio Modular Patchbays),

• ICON (Integrated Cable Organizations Network).

The QCP Mark II wire module consists of a split cylinder insulation displacement contact

mounted in an individual color-coded plastic insulator. Wires may be terminated on both the

front and rear side of the contact. Split cylinder contacts and insulators that become worn

with use may be removed and replaced. New split cylinder contacts and insulators are

available as accessory items.

ADCP-75-003 • Issue 11 • October 2003

Page 3

1.1 Rules of Use

Each side (front and rear) of a split cylinder contact, shown in Figure 1, may be used to

terminate either one or two, solid or stranded, copper wires. The following size wires may be

terminated:

• 22 AWG

• 24 AWG

• 26 AWG

• 0.4 mm to 0.79 mm.

18984-A

THE U-SHAPED NOTCH IS ON

THE WIRE RETENSION SIDE OF

THE SPLIT CYLINDER CONTACT

PLASTIC

INSULATOR

SPLIT CYLINDER CONTACT

(FRONT SIDE)

SPLIT CYLINDER CONTACT

(REAR SIDE)

Figure 1. QCP Mark II Split Cylinder Contact

1.2 Different Wire Sizes or Types

When terminating two wires on the same side of a split cylinder contact, both wires must be of

the same type (solid or stranded) and of the same wire gauge. Wires terminated on opposite

sides (front vs. rear) of the contact do not have to be the same wire gauge. If terminating a

wire on a contact that was used previously, each wire must always be as large as or larger than

any previously terminated wire.

1.3 Fanning Strips and Cable Routing

Route and dress all terminated wires through the fanning strips provided with the termination

panel. Use the space between the insulators to route wires to each contact. Allow sufficient

slack in each cable for future wiring changes before tying down cable bundle.

1.4 Installing Bare Wires

Bare wires, such as drain wires or ground wires, must be covered with PVC sleeving before

being terminated. A limited quantity of PVC sleeving is supplied with each QCP termination

product. Additional PVC sleeving is available as an accessory item (SLVG-1).

ADCP-75-003 • Issue 11 • October 2003

Page 4

1.5 Insertion Tools

The QB-2 impact tool and Q115 manual tool, shown in Figure 2, are available for inserting

and terminating wires on QCP split cylinder contacts. The QB-2 impact insertion tool is

equipped with a removable square slotted tip assembly (either the QB-2T or the QB-2LT). The

QB-2 impact tool applies force to the wire by means of a spring-loaded mechanism within the

tool. The Q115 manual tool is a screwdriver-type tool with a non-removable tip. The Q115

manual tool is used to manually apply force to the wire.

QB-2T

REPLACEMENT

TIP

QB-2LT

REPLACEMENT

TIP

QB-2 IMPACT TOOL

(CAN BE EQUIPPED WITH

EITHER QB-2T OR QB-2LT TIP)

Q115 MANUAL

INSERTION TOOL

NON-REMOVABLE TIP

12149-C

Figure 2. QB-2 Impact Tool with Replacement Tips and Q115 Manual Tool

ADCP-75-003 • Issue 11 • October 2003

Page 5

PROCEDURE 1

FRONT SIDE WIRE TERMINATION INSTRUCTIONS

Warning: Never install electrical equipment in a wet location or during a lightning storm.

When installing or modifying equipment lines, disconnect lines at the network interface before

working with uninsulated lines or terminals to prevent electrical shock.

This procedure provides instructions for terminating wires on the front side of termination

panels equipped with QCP Mark II wire modules. Because the orientation of the wire modules

will vary depending on the panel type, use these procedures and illustrations as a general

reference when terminating wires. All illustrations show typical examples of routing and

terminating wires for panels equipped with QCP Mark II wire modules.

STEP PROCEDURE

Wire Installation

1 Trim the outer jacket of the cable to a convenient length. Tape or heat-shrink tubing may

be used on the trimmed jacket if desired.

2 Install PVC (see Figure 3) sleeving over any bare wires.

3 Route the wires through the wire fanning strip that is closest to the split cylinder contacts

that will be used to terminate the wires.

Note: Do not cut or strip the wire to be connected. The insertion tool and the split

cylinder contact take care of these functions automatically.

4 Place each wire diagonally across the split cylinder contact (see Figure 4) and in line

with the two corner slots in the color-coded insulator. Leave a convenient length of

excess wire past the cutting edge of the contact.

Note: The wire retention side of the split cylinder contact has a U-shaped notch (see

Figure 1) and the cut-off side of the contact has a square notch. If necessary, terminate a

scrap piece of wire to verify which side of the wire is retained and which side is cut off.

5 Place the wire slot(s) of the tool tip over the wire (see Figure 5) and align the square

sides of the tool tip with the square sides of the color-coded insulator.

6 Press the insertion tool against the wire until the spring-loaded mechanism (impact tool)

releases to seat the wire into the cylinder slot (see Figure 6) or until the force applied to

the manual tool is sufficient to seat the wire into the cylinder slot.

7 Remove the tool and the salvage end of wire from the contact. Keep the tool

perpendicular to the panel during wire termination and withdrawal.

8 After the wires are terminated, secure cable to the cable tray or cable tie bar using plastic

cable ties.

Wire Removal

1 To change and/or re-terminate a wire, remove wire from the fanning strip and grasp the

wire by hand. Pull the wire straight out from the panel until the wire slides out of the

split cylinder contact. Install the new wire as described in the installation instructions.

ADCP-75-003 • Issue 11 • October 2003

Page 6

6890-B

SLIDE PVC SLEEVE

OVER BARE WIRE

Figure 3. Install PVC Sleeving Over Bare Wire

6891-B

149250351452

25 73 26 74 27 74 28 75

Figure 4. Position Wire Over Split Cylinder Contact (Front Side of Typical Panel)

ADCP-75-003 • Issue 11 • October 2003

Page 7

1 49 2 50 3 51 4 52 5 53 6 54 7 55 8 56 9 57 10 58 11 59 12 60 13 61 14 62

6892-A

Figure 5. Place Tool Over Wire (Front Side of Typical Panel)

1 49 2 50 3 51 4 52 5 53 6 54 7 55 8 56 9 57 10 58 11 59 12 60 13 61 14 62

6893-A

Figure 6. Wire Installed and Seated in Contact (Front Side of Typical Panel)

ADCP-75-003 • Issue 11 • October 2003

Page 8

PROCEDURE 2

REAR SIDE WIRE TERMINATION INSTRUCTIONS

Warning: Never install electrical equipment in a wet location or during a lightning storm.

When installing or modifying equipment lines, disconnect lines at the network interface before

working with uninsulated lines or terminals to prevent electrical shock.

This procedure provides instructions for terminating wires on the rear side of termination

panels equipped with QCP Mark II wire modules. Because the orientation of the wire modules

will vary depending on the panel type, use these procedures and illustrations as a general

reference when terminating wires. All illustrations show typical examples of routing and

terminating wires for panels equipped with QCP Mark II wire modules.

STEP PROCEDURE

Wire Installation

1 Trim the outer jacket of the cable to a convenient length. Tape or heat-shrink tubing may

be used on the trimmed jacket if desired.

2 Install PVC sleeving (see Figure 3) over any bare wires.

3 Route the wires through the wire fanning strip that is closest to the split cylinder contacts

that will be used to terminate the wires.

Note: Do not cut or strip the wire to be connected. The insertion tool and the split

cylinder contact take care of these functions automatically.

4 Place wire diagonally across the end of the contact (see Figure 7) and in line with the

two notches in the end of the split cylinder contact. Leave a convenient length of excess

wire past the cutting edge of the contact.

Note: The wire retention side of the split cylinder contact has a U-shaped notch (see

Figure 1) and the cut-off side of the contact has a square notch. If necessary, terminate a

scrap piece of wire to verify which side of the wire is retained and which side is cut off.

5 Place the wire slot(s) of the tool tip (see Figure 8) over the wire.

6 Hold a wooden block (or similar device) against the front side of the contact to prevent

the split-cylinder from being forced out of the plastic insulator when the wire is

terminated.

7 Press the insertion tool against the wire until the spring-loaded mechanism (impact tool)

releases to seat the wire into the cylinder slot or until the force applied to the manual

tool is sufficient to seat the wire into the cylinder slot.

8 Remove tool and the salvage end of wire from the contact. Keep the tool perpendicular

to the panel during wire termination and withdrawal.

9 After the wires are terminated, secure cable to the cable tray or cable tie bar using plastic

cable ties.

Wire Removal

1 To change and/or re-terminate a wire, remove wire from the fanning strip and grasp the

wire by hand. Pull the wire straight out from the panel until the wire slides out of the

split cylinder contact. Install the new wire as described in the installation instructions.

ADCP-75-003 • Issue 11 • October 2003

Page 9

6894-B

Figure 7. Position Wire Over Split Cylinder Contact (Rear Side of Typical Panel)

6895-B

Figure 8. Tool and Wire Aligned With Split Cylinder Contact (Rear Side of Typical Panel)

ADCP-75-003 • Issue 11 • October 2003

Page 10

PROCEDURE 3

REPLACING A BROKEN WIRE MODULE

Warning: Never install electrical equipment in a wet location or during a lightning storm.

When installing or modifying equipment lines, disconnect lines at the network interface before

working with uninsulated lines or terminals to prevent electrical shock.

This procedure provides instructions for replacing a damaged or worn QCP Mark II wire

module. Replacement split cylinder contacts and color-coded plastic insulators are available

separately as accessory items.

STEP PROCEDURE

1 Remove each wire from both the front and rear sides of the split cylinder contact as

described in Procedures 1 and 2.

2 From the rear side of the panel, place the insertion tool over the split cylinder contact

(see Figure 9) and align the square sides of the tool tip with the square sides of the

insulator.

3 Rap sharply on the end of the tool handle to break the insulator.

Note: The force required to break the insulator with the insertion tool is

approximately twice that required for wire installation.

4 Remove all pieces of the wire module from both sides of the panel.

5 Insert the front-side end of the replacement insulator (not the metal contact) onto the end

of the insertion tool.

6 From the front side of the panel, insert the replacement insulator (see Figure 10) into the

insulator mounting hole.

Note: The two slots in the insulator must be oriented to match the existing insulators.

7 Carefully apply pressure to the insertion tool to force the insulator into the panel

mounting hole.

8 When the insulator is fully seated, carefully withdraw the insertion tool from the

insulator.

9 From the front of the panel, insert the metal split cylinder contact (see Figure 11) into

the insulator as far as possible.

Note: The U-shaped and square notches in the end of the split cylinder contact must

be oriented to match the existing split cylinder contacts.

10 Carefully place the tip of the insertion tool over the split cylinder contact and align the

square sides of the tool tip with the square sides of the insulator.

11 Carefully apply pressure to the insertion tool until the split cylinder contact locks into

position within the insulator.

12 Carefully remove the installation tool from the wire module. Keep the tool perpendicular

to the panel as it is withdrawn.

13 Reinstall the wires (removed in step 1) on the new wire module as described in

Procedures 1 and 2.

ADCP-75-003 • Issue 11 • October 2003

Page 11

6896-A

Figure 9. Placement of Insertion Tool for Module Removal (Rear Side of Typical Panel)

6897-A

1 49 2 50 3

Figure 10. Split Cylinder Contact Insulator Mounting Position (Front Side of Typical Panel)

ADCP-75-003 • Issue 11 • October 2003

Page 12

6898-B

1 49 2 50 3

ORIENT THE SPLIT

CYLINDER CONTACT

TO MATCH THE

ADJACENT CONTACTS

Figure 11. Contact Metal Cylinder in Position For Installation (Front Side of Typical Panel)

ADCP-75-003 • Issue 11 • October 2003

Page 13

2 CUSTOMER INFORMATION AND ASSISTANCE

13944-J

WRITE:

ADC TELECOMMUNICATIONS, INC

PO BOX 1101,

MINNEAPOLIS, MN 55440-1101, USA

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

PHONE:

EUROPE

Sales Administration: +32-2-712-65 00

Technical Assistance: +32-2-712-65 42

EUROPEAN TOLL FREE NUMBERS

UK: 0800 960236

Spain: 900 983291

France: 0800 914032

Germany: 0180 2232923

U.S.A. OR CANADA

Sales: 1-800-366-3891 Extension 73000

Technical Assistance: 1-800-366-3891 Extension 73475

ASIA/PACIFIC

Sales Administration: +65-6294-9948

Technical Assistance: +65-6393-0739

ELSEWHERE

Sales Administration: +1-952-938-8080

Technical Assistance: +1-952-917-3475

PRODUCT INFORMATION AND TECHNICAL ASSISTANCE:

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.

[email protected]

Printed in U.S.A.

Whirlwind MASS Punch Operating instructions

Brand: Whirlwind

Model: MASS Punch

Type: Operating instructions

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Whirlwind MASS Punch Operating instructions

Whirlwind MASS Punch Operating instructions

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