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ADCP-75-003 • Issue 11 • October 2003
1271503 Rev A Page 1
© 2003, ADC Telecommunications, Inc.
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
© 2003, ADC Telecommunications, Inc.
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
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© 2003, ADC Telecommunications, Inc.
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
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© 2003, ADC Telecommunications, Inc.
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
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© 2003, ADC Telecommunications, Inc.
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
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© 2003, ADC Telecommunications, Inc.
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
T
R
S
T
R
S
Figure 4. Position Wire Over Split Cylinder Contact (Front Side of Typical Panel)
ADCP-75-003 • Issue 11 • October 2003
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© 2003, ADC Telecommunications, Inc.
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
T
R
S
T
R
S
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
T
R
S
T
R
S
6893-A
Figure 6. Wire Installed and Seated in Contact (Front Side of Typical Panel)
ADCP-75-003 • Issue 11 • October 2003
Page 8
© 2003, ADC Telecommunications, Inc.
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
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© 2003, ADC Telecommunications, Inc.
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
© 2003, ADC Telecommunications, Inc.
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
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© 2003, ADC Telecommunications, Inc.
6896-A
Figure 9. Placement of Insertion Tool for Module Removal (Rear Side of Typical Panel)
6897-A
1 49 2 50 3
T
R
S
T
R
S
Figure 10. Split Cylinder Contact Insulator Mounting Position (Front Side of Typical Panel)
ADCP-75-003 • Issue 11 • October 2003
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© 2003, ADC Telecommunications, Inc.
6898-B
1 49 2 50 3
T
R
S
T
R
S
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
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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.
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BELGICASTRAAT 2,
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PHONE:
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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.
© 2003, ADC Telecommunications, Inc.
All Rights Reserved
Printed in U.S.A.
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