ADC PowerWorx Select Series User manual

ADCP-80-531 • Issue 4 • July 2004

1262204 Rev B Page 1

PowerWorx

Power Distribution Products

Select Series Circuit Breaker

Power Distribution Panel User Manual

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Important Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Trademark Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Admonishments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 GENERAL CHARACTERISTICS AND FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Power Buses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 Input Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.4 Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.5 Output Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.6 Chassis Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.7 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.8 Power-On Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.9 Circuit Breaker Alarm Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1.10 Alarm Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

(continued)

Content Page

16755-B

ADCP-80-531 • Issue 4 • July 2004

Page 2

1.11 Alarm Contact Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.12 Circuit Breaker Designation Card and Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.13 Voltage Designation Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.14 Material and Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.15 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.16 Protective Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.17 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.18 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.19 Color. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.20 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.21 Environmental Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1 Recommended Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Use of Screws in Accessories Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.3 Protective Cover Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4 Cable Management Bar (Optional Accessory for Circuit Breaker Panels). . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.5 Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.6 General Wiring Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.7 Chassis Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.8 External Alarm Contact Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.9 Output Power Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.10 Input Power Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.11 Circuit Breaker Designation Card Holder and Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.12 Voltage Designation Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.1 Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.2 Wiring Connection Torque Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.3 Connection Polarity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.4 Alarm Contact Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.5 Circuit Breaker Alarm Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.4 Power-On LED Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.5 Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8 CUSTOMER INFORMATION AND ASSISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

_________________________________________________________________________________________________________

Content Page

ADCP-80-531 • Issue 4 •July 2004

Page 3

INTRODUCTION

This manual describes the PowerWorx

Select Series Circuit Breaker Power Distribution Panel,

hereinafter called “circuit breaker panel” or “panel.” A complete description of the circuit

breaker panel and its available options and accessories is provided plus the information required

to install, test, and operate the circuit breaker panel.

Application: The circuit breaker panel is a high current (100 Amps per bus) circuit breaker type

power distribution platform. The circuit breaker panel may be used to supply protected dc

power to the type of telecommunications products typically installed in central offices,

multimedia headends, remote sites, and other locations.

Input Power: The circuit breaker panel contains two buses (feeds) that accept either –24 Vdc or

–48 Vdc input power (both buses must have the same voltage) of up to 100 Amps per bus for a

total of 200 Amps per panel.

Output Power: The circuit breaker panel provides circuit breaker protected output power with

up to 8 circuit breaker positions per bus. The current rating for each circuit breaker may be 1, 3,

5, 10, 15, or 20 Amps (see Subsection 1.7, Circuit Breakers).

Standards

The circuit breaker panel meets UL, Telcordia (formerly Bellcore), NEC 1999, CSA, NEBS

Level 3, IEC, and CE standards.

Important Features

The circuit breaker panel incorporates the following important features:

• Self-configuring voltage (–24 Vdc or –48 Vdc) capability and up to 100 Amps per bus to

simplify installation and allow one panel to fit most dc voltage applications

• ON/OFF lettering on each circuit breaker for quick identification of tripped circuit

breakers as well as ampere ratings

• Eight circuit breaker positions per bus (field-replaceable)

• Alarm contact connections built into the circuit breaker panel for external connection to

visual, audio, and remote alarms

• Two field-replaceable high-brilliance Power-On green LED indicators and two Alarm red

LED indicators (not field-replaceable)

• Easily-removable (turn four screws) plastic protective cover over connectors to enhance

safety and panel accessibility

• Two-post grounding to ensure robust and reliable ground connectivity

Standard Configuration

The standard configuration circuit breaker panel has two power buses (feeds), with each power

bus having multiple circuit breaker positions. The two buses are duplicates of each other in the

number and type of circuit breakers. The capacity of each bus is one to eight circuit breakers.

Each bus has Power-On and Alarm indicators on the front of the chassis and input, output,

ground, and alarm contact connections on the rear of the chassis.

ADCP-80-531 • Issue 4 • July 2004

Page 4

The current capacity of each bus is 100 Amps maximum. The total current of the circuit breaker

panel (both buses) is 200 Amps maximum.

The power dissipation of the circuit breaker panel is 100 watts maximum at 200 Amps.

The dimensions of the circuit breaker panel are 1.75 inches (4.45 centimeters) high, 17.13 inches

(43.5 centimeters) wide, and 10 inches (25.41 centimeters) deep. This does not include depth of

protective cover and connectors, circuit breakers, and visual indicators that extend beyond the

chassis.

The circuit breaker panel can be mounted in 19- or 23-inch racks (48.26 or 58.42 cm) with

WECO or EIA hole spacing using the mounting brackets provided.

Options

The circuit breaker panel is available with the following options:

• One to eight replaceable circuit breakers can be installed for each bus

• Selection of circuit breaker values (1, 3, 5, 10, 15, or 20 Amps).

• Panel can be equipped with any combination of circuit breakers (with specified values) as

long as total current draw on each bus does not exceed 100 Amps

• Selection of circuit breakers that trip instantly or trip after a short delay

• Two types of alarm contact connectors, either a screw-down terminal strip connector or a

wire wrap pin block connector

• Color of the circuit breaker panel is putty white.

Accessories

Several accessories for the circuit breaker panels are available (see Section 2, Accessories):

• Circuit breakers with capacity values of 1, 3, 5, 10, 15, and 20 Amperes

• Cable management bar kit

• Compression lugs for connection to the input connectors

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

• Spare circuit breaker designation card kit

Revision History

ISSUE DATE REASON FOR CHANGE

Issue 1 09/2001 Original

Issue 2 03/2002 Updated to cover replaceable circuit breaker feature

Issue 3 07/2004 Updated to add warning saying use of one bus only on dual bus panel will result in false alarms

ADCP-80-531 • Issue 4 •July 2004

Page 5

Trademark Information

ADC and PowerWorx are registered trademarks of 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.

General Safety Precautions

1 GENERAL CHARACTERISTICS AND FEATURES

This section defines the general characteristics and features of the Select Series Circuit Breaker

Panel. A typical circuit breaker panel with protective covers in place is shown in Figure 1. A

typical circuit breaker panel with the protective cover removed is shown in Figure 2.

Configurations and features other than those described may be available by special order. The

accessories available for the circuit breaker panel are listed in Section 2, Accessories.

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.

Caution: The circuit breaker panel uses electrical voltage and amperage levels which, per

GR-1089, 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 panel is energized. Only insulated tools should be used on energized

elements of the panel.

Caution: All circuit breaker panel wiring and cabling should be connected with the system

office battery input off or disconnected at the office distribution panel.

Caution: A replacement circuit breaker must have exactly the same current rating as the circuit

breaker being replaced.

ADCP-80-531 • Issue 4 • July 2004

Page 6

Figure 1. Front and Rear View of ADC PowerWorx Select Series Circuit Breaker Panel

with Protective Cover Attached (8/8-Position Panel Shown)

16756-B

UL/CSA/CE

LABEL

VENTS

PROTECTIVE COVER

PLACED OVER INPUT

AND OUTPUT POWER,

GROUND, AND ALARM

CONNECTIONS

MOUNTING

BRACKETS

FOR 23-IN. (58.42 CM)

RACK MOUNTING

BUS A

POWER-ON

INDICATOR

(GREEN LED)

BUS B

POWER-ON

INDICATOR

(GREEN LED)

BUS A

CIRCUIT BREAKER

INDICATOR (RED LED)

BUS B

CIRCUIT BREAKER

INDICATOR (RED LED)

1 TO 8 CIRCUIT BREAKERS

(BLANK PANEL IF NO

CIRCUIT BREAKER)

1 TO 8 CIRCUIT BREAKERS

(BLANK PANEL IF NO

CIRCUIT BREAKER)

FRONT VIEW

REAR VIEW

ADCP-80-531 • Issue 4 •July 2004

Page 7

Figure 2. Rear View of Select Series Circuit Breaker Panel with Protective Cover Removed

to Show Connections (Panel with Wire Wrap Alarm Connection Shown)

1.1 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 100 Amps

maximum. A typical circuit breaker panel block diagram is shown in Figure 3.

Each of the power buses supports eight circuit breaker positions. Any combination of circuit

breakers up to 100 Amps total capacity may be installed in the circuit breaker mounting

positions for each power bus. Other circuit breaker capacity configurations may be available by

special order.

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

circuit.

Warning: Use of one bus only on a dual bus panel will result in false alarms for the unused bus.

Power is required on both buses on a dual bus panel for normal operation.

16757-B

BUS B INPUT

CONNECTORS

(TWO-HOLE

COMPRESSION

LUG-STUD TYPE)

BUS A INPUT

CONNECTORS

(TWO-HOLE

COMPRESSION

LUG-STUD TYPE)

BATTERY

RETURN

BATTERY

RETURN

BUS B OUTPUT

CONNECTORS

(SCREW-DOWN

BARRIER TERMINAL

STRIPS)

BUS A AND BUS B

ALARM CONTACT

CONNECTOR (WIRE-

WRAP PIN BLOCK

TYPE SHOWN)

CHASSIS

GROUND

TERMINALS

BUS A OUTPUT

CONNECTORS

(SCREW-DOWN

BARRIER TERMINAL

STRIPS)

ADCP-80-531 • Issue 4 • July 2004

Page 8

Figure 3. PowerWorx Circuit Breaker Panel Block Diagram (8/8-Position Panel Shown)

1.2 Input Voltage

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

both buses.

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

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

BATTERY RETURN

BATTERY A

RETURN A

POWER A LED

BREAKER

ALARM A LED

BATTERY RETURN

BATTERY B

RETURN B

BUS A

RETURN A

POWER B LED

BREAKER

ALARM B LED

BUS B

RETURN B

–24V/–48V

SYSTEM ALARM

CONNECTIONS

16758-B

ADCP-80-531 • Issue 4 •July 2004

Page 9

1.3 Input Connectors

Each power bus has two input connectors on the rear of the fuse panel through which input power is

provided. The two input power connectors are labeled “BATT” (battery) and “RTN” (return). Each

input connector consists of two pairs of studs (with nuts), each mounted on a plated copper bar. Each

set of studs can accept different size 2-hole compression lugs which can be used with a range of wire

sizes up to #2 AWG copper wire. Two 2-hole lugs per bus and one spare lug for use with #2 AWG

wire (five total) are provided with the circuit breaker panel. Additional lugs are available as

accessory items (see Section 2, Accessories).

1.4 Output Voltage

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

1.5 Output Connectors

Each output circuit has two connectors through which the output power is provided for

connection to telecommunications equipment. Each output connector consists of two screw-

down barrier terminal strips. Eight terminals with 6-32 screws are mounted in each terminal

block. Two terminal blocks are provided per bus (one block for output and one block for return).

The terminals are on 0.375 inch (9.525 mm) centers with a distance between barriers of 0.325

inch (8.26 mm). The terminals can accept #12 to #22 AWG copper wire with crimp-on spade

lug or ring connectors, or wires with the insulation stripped back. The connectors or wires are

inserted under the screws in the terminal strip, and the screws are tightened down.

1.6 Chassis Ground Connection

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. The ground connection can be used to

attach a separate grounding conductor when mounting the circuit breaker panel in non-

grounded or non-conducting material or when required by local practice. The studs can

accommodate 2-hole lugs and up to #6 AWG wire. Two crimp ring lug terminals for use with

two #10 AWG wires are provided with the circuit breaker panel. The circuit breaker panel can

be properly grounded using only one stud.

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Page 10

1.7 Circuit Breakers

The circuit breakers are magnetic actuation, manual reset, single pole, replaceable, 60 Vdc rated

circuit breakers, with finger guard and ampere markings. Circuit breaker values of 1, 3, 5, 10,

15, and 20 Amperes capacity are available. Each circuit breaker can be field-replaced by another

breaker with a different current rating or time delay. A breaker with a higher current rating may

be installed as a replacement as long as the total current draw of the affected bus does not

exceed 100 Amps.

The circuit breaker panel will accommodate from one to eight circuit breakers for each bus (up

to eight circuit breakers installed on each side of the panel). Each circuit breaker position that

does not have a circuit breaker installed will be filled with a black-colored blank plastic plate.

Any circuit breaker mounting positions that are left blank when the panel is ordered cannot be

fitted with field-installed circuit breakers.

Two types of circuit breakers are available. One type trips instantly and one type trips after a

short delay. The trip times as a function of the percent of rated current are shown in Table 1. The

circuit breaker will trip (open) and the switch will move to the “OFF” position (bottom pushed

in) when the circuit current exceeds the capacity of the circuit breaker. To reset the circuit

breaker, push the switch to the “ON” position (top pushed in).

1.8 Power-On Indicator

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 applied to the bus input connectors. If the

green LED indicator is off, power is not applied to the bus input connectors. The Power-On

LED is field-replaceable (see Subsection 7.4, Power-On LED Replacement).

Table 1. Circuit Breaker Trip Times

PERCENT OF RATED CURRENT

TRIP TIME

seconds

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

Instant NO

TRIP

MAY

TRIP

.100

MAX

.100

MAX

.100

MAX

.100

MAX

.100

MAX

.100

MAX

.100

MAX

Short NO

TRIP

.300-

7.00

.200-

5.00

.100-

2.00

.030-

.500

.008-

.300

.006-

.150

.005-

.100

.005-

.100

ADCP-80-531 • Issue 4 •July 2004

Page 11

1.9 Circuit Breaker Alarm Indicator

For each bus, the circuit breaker panel has one visual circuit breaker alarm indicator (red LED)

mounted on the front of the panel. The circuit breaker alarm indicator lights if any circuit

breaker on the corresponding bus fails. The circuit breaker alarm indicator stays off if all circuit

breakers on the corresponding bus are operational. Loss of power to either bus will cause the

circuit breaker alarm indicator for the corresponding bus to be off.

1.10 Alarm Relay Contacts

Each bus contains circuitry that operates a set of Form C alarm relay contacts when any circuit

breaker on the bus trips 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 or a wire wrap pin

terminal block located on the rear side of the circuit breaker 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. The maximum current rating for each set of alarm relay

contacts (three sets are provided) is 1.0 Amp.

1.11 Alarm Contact Connection

The fuse panel is available with either a screw-down terminal block or wire wrap pin terminal

block for the alarm contact connections.

The screw-down terminal block consists of six 3-48 screw terminals mounted in a barrier type

terminal block (see Figure 2). 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). Two sets of three terminals (labeled NO, C, and NC) are provided for

connection with external alarm systems. The screw-down terminals will accept #16 to #30

AWG copper wire.

The wire wrap pin terminal block consists of nine wire wrap pins mounted in a terminal block.

Three sets of three wire wrap pins (NO, C, NC) are provided for connection with external alarm

systems. The wire wrap pins will accept #22 to #26 AWG copper wire.

Warning: Use of one bus only on a dual bus panel will result in false alarms for the unused bus.

Power is required on both buses on a dual bus panel for normal operation.

ADCP-80-531 • Issue 4 • July 2004

Page 12

1.12 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 to the underside of the panel,

one of the panel mounting brackets, to a part of the rack in which the panel is installed, or at a

location close to the panel, as desired. 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.

Figure 4. Circuit Breaker Designation Card

1.13 Voltage Designation Label

A voltage designation label 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.

Figure 5. Voltage Designation Label

1.14 Material and Finish

The circuit breaker panel chassis and brackets are made of 16-gauge cold rolled steel. The panel

and brackets are finished with powder paint.

16753-A

1.60 IN.

(4.06 CM)

2.36 IN.

(5.99 CM)

10 POSITION A AND B CARD

0.38 IN.

(0.96 CM)

1.00 IN.

(2.54 CM)

14228-A

ADCP-80-531 • Issue 4 •July 2004

Page 13

1.15 Cooling

The circuit breaker panel is well 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.

1.16 Protective Cover

A thick plastic protective cover is mounted over the input power connectors, the output power

connectors, the chassis ground terminals, and the external alarm contact connections. Access to

these connectors and terminals is obtained by removing the cover. The cover is easily removed

by loosening (but not removing) four screws that attach the cover to the chassis. The holes in the

cover are keyed to allow it to be pulled to the side and then lifted clear of the screws.

1.17 Dimensions

The dimensions of a typical circuit breaker panel are shown in Figure 6.

Figure 6. Dimensions of Circuit Breaker Panel (8/8-Position Panel with

Mounting Brackets Attached for 23-Inch [58.42 cm] Rack Mounting Shown)

22.31 IN.

(56.67 CM)

17.13 IN.

(43.51 CM)

23.00 IN.

(58.42 CM)

1.13 IN.

(2.86 CM)

1.75 IN.

(4.45 CM)

10.00 IN.

(25.41 CM)

10.93 IN.

(27.75 CM)

16762-B

ADCP-80-531 • Issue 4 • July 2004

Page 14

1.18 Weight

The weight of the circuit breaker panel is approximately 10 pounds (4.54 kilograms). The actual

weight is dependent upon the configuration of the panel.

1.19 Color

The color of the circuit breaker panel and mounting brackets is putty white.

1.20 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 7. 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.

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

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.

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.

ADCP-80-531 • Issue 4 •July 2004

Page 15

Figure 7. Mounting Brackets for Mounting Circuit Breaker Panel

in 19- and 23-Inch (48.26 or 58.42 cm) Racks

1.21 Environmental Characteristics

Table 2 lists the environmental characteristics of the PowerWorx Select Series circuit

breaker panel.

Table 2. PowerWorx Select Series Circuit Breaker Panel Environmental Characteristics

PARAMETER DESCRIPTION

Operating temperature –5° C to +55° C

Storage temperature –45° C to +85° C

Humidity range 0% to 95% humidity (non-condensing)

Altitude range –197 ft. (0.06 km) to 13,000 ft. (3.96 km) above sea level

Fire rating All components UL94-V1

Earthquake design NEBS Level 3, Zone 4

Acoustic noise 0 dBA above ambient

Heat dissipation (fully loaded) 50 watts @ 100 Amps per bus, 100 watts @ 200 Amps

total circuit breaker panel load

Heat dissipation (no load) 1 watt per bus

19-INCH RACK MOUNTING

BRACKET INSTALLATION

23-INCH RACK MOUNTING

BRACKET INSTALLATION

USE 3/8-INCH (9.525 MM) 12-24

THREAD-FORMING SCREWS AND

WASHERS TO SECURE MOUNTING

BRACKETS TO RACK

USE 5/16-INCH (7.936 MM) 8-32

THREAD-FORMING FLAT-HEAD

SCREWS TO SECURE MOUNTING

BRACKETS TO PANEL

16965-A

ADCP-80-531 • Issue 4 • July 2004

Page 16

2 ACCESSORIES

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

• Circuit breakers. Current capacity of 1, 3, 5, 10, 15, 20 Amps with choice of two delay

values (instant and short).

• 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

• Three sizes of two-hole compression lugs for #2, #4, and #6 AWG wire for input power

connection

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

• Circuit breaker designation card kit

• Spare circuit breakers for field-replacement

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

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

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

repair, replacement, and warranty information.

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

4 INSTALLATION

Circuit Breaker panels 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

power wiring.

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

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

• Adding a circuit breaker panel to a rack may displace a device which may require

relocation.

ADCP-80-531 • Issue 4 •July 2004

Page 17

4.1 Recommended Installation Tools

Use common hand tools, such as a Phillips screwdriver, a wire wrap gun and bits, a wire

stripper, and a wire lug crimper to install the circuit breaker panel. In addition to these tools, the

following tools are recommended:

• Power screwdriver with bits for Phillips and slotted head screws

• Set of sockets and driver

• Set of open end or box end wrenches

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. Only insulated tools should be used on

energized elements of the circuit breaker panel.

Warning: 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.

16776-A

PHILLIPS SCREW

HEAD BIT

12504-A

ADCP-80-531 • Issue 4 • July 2004

Page 18

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

bits for Phillips and slotted head screws

4.2 Use of Screws in Accessories Package

The circuit breaker panel accessories kit contains three types of screws. The screws used with

the rack-mounting brackets are thread-forming screws which will provide a solid ground path

between the panel chassis and the rack. Use the power screwdriver to install these screws.

4.2.1 Screws to Attach Brackets to Circuit Breaker Panel

To fasten the mounting brackets (ears) to the circuit breaker panel, use the 5/16-inch

(7.936 mm) long, chromate finish 8-32 screws as shown in Figure 8 (4 for each bracket). Eight

screws are in the package.

Figure 8. Screw for Attaching Bracket to Circuit Breaker Panel

4.2.2 Screws to Attach Brackets to Rack

To fasten the brackets to the rack, use the nickel plated 12-24 screws as shown in Figure 9 (2 for

each bracket). Four screws are in the package.

Caution: When installing the circuit breaker panel, use only the hardware supplied with the

panel. Use of any other hardware could cause damage to the panel. If parts are missing, please

contact ADC.

12506-A

5/16-IN.

(7.936 mm)

THREAD FORMING SCREW,

FLAT HEAD UNDERCUT,

PHILLIPS DRIVE

16977-A

8 - 32

THREAD

ADCP-80-531 • Issue 4 •July 2004

Page 19

Figure 9. Screw for Attaching Bracket to Rack

4.2.3 Screws to Attach Protective Cover to Circuit Breaker Panel

To fasten the plastic protective cover over the power connections, use the four tin plate finish

screws as shown in Figure 10. Four screws are in the package.

Figure 10. Screw for Attaching Protective Cover to Circuit Breaker Panel

4.3 Protective Cover Installation/Removal

To attach the plastic protective cover over the connectors on the rear of the circuit breaker panel,

insert the four screws (defined in Subsection 4.2.3, Screws to Attach Protective Cover to Circuit

Breaker Panel) into the standoffs located next to each output power screw-down barrier strip.

Rotate each screw several turns to get it threaded. Hold the cover so the lettering is oriented

properly and then place the cover over the screw heads. Slide the cover to the left and then

tighten the screws to 9 pound-force inches (1 Newton meter).

To remove the protective cover, loosen but do not remove the four screws that secure the cover

to the panel. Slide the cover to the right and then pull the cover directly outward and away from

the panel. The screws do not need to be completely removed to remove the protective cover.

3/8-IN.

(9.53 mm)

12 - 24

THREAD

PAINT CUTTING, TAPPING SCREW,

PAN HEAD, COMBINATION DRIVE

16592-A

3/8-IN.

(9.53 mm)

6 - 32

THREAD

MACHINE SCREW, PAN HEAD,

PHILLIPS DRIVE

16593-B

ADCP-80-531 • Issue 4 • July 2004

Page 20

4.4 Cable Management Bar (Optional Accessory for Circuit Breaker Panels)

Before installing the circuit breaker panel in the rack, mount the cable management bar (accessory

item, not supplied with panel) on the rear of the panel as shown in Figure 11, using the 0.25-inch

(6.35 mm) long 4-40 screws that are supplied with the cable management bar. The cable

management bar can be recess mounted by using the mounting holes closest to the front of the

panel.

Figure 11. Cable Management Bar Installation

4.5 Rack Mounting

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.

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

1. 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 screws to 15 pound force-

inches (1.7 Newton meters) of torque to insure grounding.

2. Place the fuse panel in the specified mounting space within the rack as shown in Figure 12.

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.

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.

16759-B

CABLE

MANAGEMENT

BAR

ATTACH TO

EITHER SET

OF 3 HOLES

MOUNTING BRACKET

INSTALLED FOR

23-IN. (58.42 CM)

RACK MOUNTING

ADC PowerWorx Select Series User manual

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