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Alpha Sidecar PDF Installation guide

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PRIMARY DISTRIBUTION SYSTEM
Sidecar PDF
™
SETUP AND OPERATION MANUAL
Comm/net Systems, Inc.
4237 – 24th Avenue West
Seattle, WA 98199
TEL: 206.282.8670
FAX: 206.282.8684
www.commnetsystems.com
24/7 Sales & Service
To purchase Comm/net Systems solutions, contact your
Comm/net Systems representative at: (800) 274-0544
or e-mail: [email protected]
About Comm/net Systems
Comm/net Systems, Inc. (CSI) is the leader in high power density communications power
systems. Comm/net oers comprehensive power and communications site systems integration
and deployment services via a national footprint of regional branch oces. Additional
information can be found at www.commnetsystems.com.
© 2017 Comm/net Systems, Inc. All rights reserved. Comm/net Systems, and the Comm/
net Systems logo are registered trademarks of Comm/net Systems, Inc. in the United States
and other countries. All other trademarks, service marks, registered marks, or registered
service marks are the property of their respective owners. Comm/net Systems assumes no
responsibility for any inaccuracies in this document. Comm/net Systems reserves the right to
change, modify, transfer, or otherwise revise this publication without notice.
Document Number: 048-734-30
Revision Level: r01
Published: January 2017
SETUP AND OPERATION MANUAL
PRIMARY DISTRIBUTION SYSTEM
Sidecar PDF
™
SIDECAR PDF
SETUP AND OPERATION MANUAL
ABOUT THIS MANUAL
About This Manual
To reduce the risk of damage to equipment, injury, or death; and to ensure proper
installation and operation of Comm/net Systems products, please be sure to read and
understand the entirety of this manual and any other supplied documentation. Keep
this document in a safe and accessible place for future reference.
Safety and Alert Symbols
The following symbols may appear in this manual, other supplied documentation, or on Comm/net Systems product labeling. The meaning of
this indication is explained below.
NOTICE
INDICATES IMPORTANT INFORMATION REGARDING THE COMPLETE AND PROPER FUNCTION OF A PRODUCT.
TYPICALLY REFERS TO MONITORING CONFIGURATION OR OTHER NON-DANGEROUS SITUATIONS.
CAUTION
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD DAMAGE
EQUIPMENT/PROPERTY OR COULD RESULT IN MINOR OR MODERATE INJURY.
WARNING
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN INJURY OR DEATH.
DANGER
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH.
Product support
If you have any questions concerning Comm/net Systems products and services, contact our support sta. Our knowledgeable support team
can provide product technical support and answer other questions regarding Comm/net products and services.
In addition to contacting Comm/net Support directly via phone or e-mail, our online help desk is available 24 hours a day, 7 days a week. The
help desk includes answers to commonly asked questions and self-help articles as well as an online ticket submission system if you need to
contact Comm/net after normal business hours.
y Comm/net support is available by phone or e-mail Monday – Friday from 8am – 4:30pm Pacic Standard Time.
y The online web portal is available 24/7 to submit support requests and general questions, or view the FAQ and self-help articles.
NOTE: All questions submitted to the web portal will be answered during normal business hours.
y Phone: 1-800-274-0544
y E-mail: [email protected]
y Online Web Portal: https://commnetsystems.freshdesk.com
SIDECAR PDF
SETUP AND OPERATION MANUAL
TABLE OF CONTENTS
Table of Contents
Section 1: Purpose and Applicability . . . . . . . . . . . . . . . . . . . . . .1
1.1 Applicable PDFs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Termination Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Applicable Return Busses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Section 2: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Section 3: Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . .2
Section 4: Site Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Section 5: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.1 Installation Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.1.1 Elevated Operating Ambient . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.1.2 Reduced Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.1.3 Mechanical Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.1.4 Circuit Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.1.5 Reliable Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.1.6 Disconnect Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.2 Mechanical Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
5.3 Floor Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
5.4 Mounting External Return Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
5.5 Frame Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
5.6 Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
5.6.1 Return Connections for Alarm Wiring . . . . . . . . . . . . . . . . . .5
5.6.2 Alarm Wiring for DC Plants with Alarm Termination Panel . . . . . . . . 5
5.6. 3 Alarm Wiring for CXCM4 without Alarm Termination Panel . . . . . . 5
5.7 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5.7.1 Input Connections with Bus Tie Kits . . . . . . . . . . . . . . . . . . .6
5.7.2 Input Connections Standalone Version . . . . . . . . . . . . . . . .6
5.7.3 Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5.8 Fuse Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Section 6: Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6.1 BCM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6.1.1 Fuse Fail/Breaker Trip LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6.1.2 Setting the Load Size Display . . . . . . . . . . . . . . . . . . . . . . . . .8
Section 7: Product Specications . . . . . . . . . . . . . . . . . . . . . . . . .9
Appendix A: Mechanical Specications . . . . . . . . . . . . . . . . . . .11
Appendix B: Footprint Drawing . . . . . . . . . . . . . . . . . . . . . . . . .13
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SETUP AND OPERATION MANUAL
PAGE vI -
THIS PAGE INTENTIONALLY LEFT BLANK
SIDECAR PDF
SETUP AND OPERATION MANUAL
PURPOSE AND APPLICABILITy - PAGE 1
Section 1: Purpose and Applicability
1.1 Applicable PDFs
This document applies to all models of the Sidecar PDF including the following part numbers:
TABLE 1. MODEL CONFIGURATIONS
PART NUMBER DESCRIPTION
016-1771-10 Sidecar PDF; Left Mount; 4000A; (8) 1200A TPL Fuse Sockets
016-1772-10 Sidecar PDF; Right Mount; 4000A; (8) 1200A TPL Fuse Sockets
016-1773-10 Sidecar PDF; Left Mount; 4000A; (8) 800A TPL Fuse Sockets
016-1774-10 Sidecar PDF; Right Mount; 4000A; (8) 800A TPL Fuse Sockets
016-1775-10 Sidecar PDF; Left Mount; 4000A; (4) 1200A TPL Fuse Sockets; (4) 800A Fuse Sockets
016-1776-10 Sidecar PDF; Right Mount; 4000A; (4) 1200A TPL Fuse Sockets; (4) 800A Fuse Sockets
016-1777-10 Sidecar PDF; Left Mount; 4000A; (12) 300A GJ Breakers
016-1778-10 Sidecar PDF; Right Mount; 4000A; (12) 300A GJ Breakers
016-1779-10 Sidecar PDF; Left Mount; 4000A; (6) 600A GJ Breakers
016-1780-10 Sidecar PDF; Right Mount; 4000A; (6) 600A GJ Breakers
016-1781-10 Sidecar PDF; Standalone; 4000A; (4) 1200A TPL Fuse Sockets; (4) 800A Fuse Sockets; Sockets Right
016-1782-10 Sidecar PDF; Standalone; 4000A; (4) 1200A TPL Fuse Sockets; (4) 800A Fuse Sockets; Sockets Left
016-1783-10 Sidecar PDF; Left Mount; 4000A; (24) 250A GJ Breakers
016-1784-10 Sidecar PDF; Right Mount; 4000A; (24) 250A GJ Breakers
016-1785-10 Sidecar PDF; Left Mount; 2900A; (4) 600A GJ Breakers
016-1786-10 Sidecar PDF; Left Mount; 4000A; (2) 1200A TPL Fuse Sockets
016-1833-10 Sidecar PDF; Left Mount; 4000A; (6) 300A GJ Breakers
016-1834-10 Sidecar PDF; Right Mount; 4000A; (6) 300A GJ Breakers
016-1861-10 Sidecar PDF; Hybrid; Left Mount; 4000A; (4) 1200A TPL Fuse Sockets; (6) 300A GJ Breakers
016-1862-10 Sidecar PDF; Hybrid; Right Mount; 4000A; (4) 1200A TPL Fuse Sockets; (6) 300 GJ Breakers
016-1863-10 Sidecar PDF; Hybrid; Left Mount; 4000A; (4) 800A TPL Fuse Sockets; (6) 300A GJ Breakers
016-1864-10 Sidecar PDF; Hybrid; Right Mount; 4000A; (4) 800A TPL Fuse Sockets; (6) 300A GJ Breakers
016-1865-10 Sidecar PDF; Hybrid; Standalone; 4000A; (4) 1200A TPL Fuse Sockets; (6) 300A GJ Breakers; Sockets/Breakers Left
016-1866-10 Sidecar PDF; Hybrid; Standalone; 4000A; (4) 1200A TPL Fuse Sockets; (6) 300A GJ Breakers; Sockets/Breakers Right
016-1867-10 Sidecar PDF; Hybrid; Standalone; 4000A; (4) 800A TPL Fuse Sockets; (6) 300A GJ Breakers; Sockets/Breakers Left
016-1868-10 Sidecar PDF; Hybrid; Standalone; 4000A; (4) 800A TPL Fuse Sockets; (6) 300A GJ Breakers; Sockets/Breakers Right
1.2 Termination Kits
This document covers the installation of the following termination kits:
TABLE 2. TERMINATION KITS
PART NUMBER DESCRIPTION
016-1770-10 Bus Kit; Top Feed; Sidecar PDF
016-1792-10 Interbay Bus Kit; Right Sidecar PDF to 19" Rectier Bay; 2900A
016-1793-10 Interbay Bus Kit; Left Sidecar PDF to 19" Rectier Bay; 2900A
016-1796-10 Interbay Bus Kit; Right Sidecar PDF to 23" Rectier Bay; 2900A
016-1797-10 Interbay Bus Kit; Left Sidecar PDF to 23" Rectier Bay; 2900A
016-1798-10 Interbay Bus Kit; Right Sidecar PDF to 23" Rectier Bay; 4000A
016-1799-10 Interbay Bus Kit; Left Sidecar PDF to 23" Rectier Bay; 4000A
016-1810-10 Interbay Bus Kit; Right Sidecar PDF to (2) 19" Rectier Bays; Return Kit Included; 4000A
016-1811-10 Interbay Bus Kit; Left Sidecar PDF to (2) 19" Rectier Bays; Return Kit Included; 4000A
016-1812-10 Interbay Bus Kit; Right Sidecar PDF to (3) 19" Rectier Bays w/Bus Duct; 4000A
016-1813-10 Interbay Bus Kit; Left Sidecar PDF to (3) 19" Rectier Bays w/Bus Duct; 4000A
016-1814-10 Interbay Bus Kit; Right Sidecar PDF to (2) 23" Rectier Bays; Return Kit Included; 4000A
016-1815-10 Interbay Bus Kit; Left Sidecar PDF to (2) 23" Rectier Bays; Return Kit Included; 4000A
016-1816-10 Interbay Bus Kit; Right Sidecar PDF to (2) 19" Rectier Bays; 4000A
016-1817-10 Interbay Bus Kit; Left Sidecar PDF to (2) 19" Rectier Bays; 4000A
016-1818-10 Interbay Bus Kit; Left Sidecar PDF to existing Argus 23" Rectier Bay
016-1819-10 Interbay Bus Kit; Right Sidecar PDF to existing Argus 23" Rectier Bay
016-1835-10 Interbay Bus Kit; Left Sidecar PDF to existing Argus 23" PDF
016-1836-10 Interbay Bus Kit; Right Sidecar PDF to existing Argus 23" PDF
016-1837-10 Interbay Bus Kit; Left Sidecar PDF (mounted on the right) to 19" Rectier Bay; 4000A
016-1838-10 Interbay Bus Kit; Right Sidecar PDF (mounted on the left) to 19" Rectier Bay; 4000A
016-1839-10 Interbay Bus Kit; Left Sidecar PDF (mounted on the right) to 23" Rectier Bay; 4000A
016-1857-10 Interbay Bus Kit; Right Sidecar PDF to (2) 23" Rectier Bays; 4000A
016-1858-10 Interbay Bus Kit; Left Sidecar PDF to (2) 23" Rectier Bays; 4000A
016-1869-10 Interbay Bus Kit; Right Sidecar PDF (mounted on the left) to 23" Rectier Bay; 4000A
1.3 Applicable Return Busses
This manual applies to the following return busses:
TABLE 3. EXTERNAL RETURN BUS
PART NUMBER DESCRIPTION
016-1890-10 External Return Bus; Sidecar PDF; 2900A
016-1891-10 External Return Bus; Sidecar PDF; 4000A
SIDECAR PDF
SETUP AND OPERATION MANUAL
PAGE 2 - THEORy OF OPERATION
Section 2: Theory of Operation
The Side car PDF is a low prole side-mounted PDF system for adding additional
primary distribution to Comm/net power plants. Bus connections allow for easy
connection to existing Comm/net power plants without any additional cabling. Tiered
internal terminations allow for easy landing and lacing of cables inside the cabinet. The
system is available in left and right mount congurations, with GJ Breaker and TPL fuses
for over current protection.
Section 3: Unpacking and Inspection
The Comm/net Systems Sidecar PDF was carefully packaged at the factory to
withstand the normal rigors of shipping, however, you should carefully inspect the box
and contents to conrm that no damage has occurred in transit. Most shipping carriers
require notication of shipping damage within twenty-four hours of delivery, and it is
the responsibility of the recipient to inspect the shipment immediately upon receipt.
The shipment includes the following:
y Sidecar PDF
y Termination Kit
y External Return Bus
y Installation Hardware
y 048-734-30 Sidecar PDF Installation and Operation Manual
If any items are missing or not found, please contact Comm/net sales and support.
Section 4: Site Planning
A minimum of 12 inches of installation space is required on one side of the DC plant
when installing the Sidecar PDF. Access to the rear of the PDF is also required (see Figure
1). Space above or near the bay is required for the external return bus; the PDF cannot be
installed without an external return bus.
LEFT
MOUNT
RIGHT
MOUNT
84 inches
12 inches12 inches
FRONT VIEW
Figure 1. Required Space for Installation
SIDECAR PDF
SETUP AND OPERATION MANUAL
INSTALLATION - PAGE 3
Section 5: Installation
5.1 Installation Preparation
5.1.1 Elevated Operating Ambient
If the rack is installed in a closed or multi-unit rack assembly, the operating ambient
temperature of the rack environment may be greater than room ambient. Therefore,
take care to install the equipment in an environment compatible with the maximum
ambient temperature (TMA) specied in Section 7.
5.1.2 Reduced Air Flow
Installation of the equipment should be such that the amount of air ow required for
safe operation of the equipment is not compromised.
5.1.3 Mechanical Loading
Mounting of the equipment should be such that a hazardous condition is not
achieved due to uneven mechanical loading.
5.1.4 Circuit Overloading
Give consideration to the connection of the equipment to the supply circuit and
the eect that overloading of the circuits might have on overcurrent protection and
supply wiring. Use appropriate consideration for equipment nameplate ratings when
addressing this concern.
5.1.5 Reliable Earthing
Maintain reliable earthing of rack-mounted equipment. Pay particular attention to
supply connections other than direct connections to the branch circuit (e.g., use of power
strips).
5.1.6 Disconnect Device
A readily accessible disconnect device must be incorporated in the building
installation wiring.
SIDECAR PDF
SETUP AND OPERATION MANUAL
PAGE 4 - INSTALLATION
5.2 Mechanical Mounting
NOTICE
y THIS PRODUCT MUST BE INSTALLED WITHIN A
RESTRICTED ACCESS LOCATION WHERE ACCESS IS
THROUGH THE USE OF A TOOL, LOCK AND KEY, OR
OTHER MEANS OF SECURITY, AND IS CONTROLLED BY
THE AUTHORITY RESPONSIBLE FOR THE LOCATION.
y THIS PRODUCT MUST BE INSTALLED AND
MAINTAINED ONLY BY QUALIFIED TECHNICIANS.
The Sidecar PDF is intended to be mounted next to a Comm/net power plant.
Depending on the selected conguration, choose a location on the left or right side of
the power plant rack. The Sidecar PDF has a 12 inch wide footprint.
5.3 Floor Anchoring
The 016-515-10 Anchor Kit is recommend for anchoring the cabinet. All hole sizes and
torque specs for oor anchors refer to this kit.
Step 1. Remove the side panel from the power plant.
Step 2. Mark the oor for drilling. See Figure 2 for the footprint of the cabinet and hole
locations.
Step 3. Drill the (4) 18 mm diameter anchoring holes in the oor based on the hole
locations marked in Step 2.
Step 4. Install the rack over the holes and insert the (4) hilti anchors.
Step 5. Torque the oor anchors to 80 N∙m.
Step 6. Attach the Sidecar PDF rack frame to the rack using the securing plates and
included hardware.
5.4 Mounting the External Return Bus
The Sidecar PDF requires an external return bus (see Figure 3).
Step 1. The return bus kit is intended to be hung from ladder rack with 5/8 in all-
thread. It is compatible with 18, 20, and 24 in ladder rack.
Step 2. Hang two pieces of all-thread from the ladder rack using c-clips.
Step 3. Connect the glastics on top of the return bus to the all-thread hung in Step 2.
6.00
21.25
12.00
25.25
2.00
19
.750
540
21.250
152
6.000
305
12.000
19
.750
641
25.250
51
2.000
Figure 2. Location of Anchor Point (refer to Appendix B for more
detail)
19.75
24.25
.625 1.125 1.125
.656
FOR 1/2" BOLTS
FOR 3/8" BOLTS
1.00
1.75
1.875
27.00
6.00
8.00
19.00
1.875
FOR 1/2" BOLTS
FOR 3/8" BOLTS
1.00
1.75
Figure 3. External Return Bus
6.00
21.25
12.00
25.25
2.00
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SETUP AND OPERATION MANUAL
INSTALLATION - PAGE 5
5.5 Frame Grounding
CAUTION
DO NOT ENERGIZE THE PANEL BEFORE THE CHASSIS GROUND IS CONNECTED.
The frame ground connection is located on frame bar of the rack on the inside of the rail (see Figure 4). AWG
ground cable is required.
IMPORTANT: Grounding hardware not included. A properly-sized grounding conductor must be
installed per NEC (250.122).
TABLE 4. GROUND SPECIFICATIONS
TWO HOLE
TERMINATION
TYPE HOLE SIZE
CENTERTO
CENTER
MAXIMUM LUG
WIDTH
REQUIRED
TORQUE
Clinch nut 1/4 in 3/4 in 1 in 100 in∙lbs
Step 1. Connect the lug to the chassis with the included 1/4-20 hardware (see Figure 4). Make sure heat shrink
and no-oxide compound are applied appropriately prior to attachment.
Step 2. Torque the fasteners to 100 in∙lbs. Apply torque seal once the fasteners are torqued appropriately.
5.6 Alarm Wiring
5.6.1 Return Connection for Alarm Wiring
A return connection must be completed in order for proper alarm function.
Step 1. Locate the 18 AWG return wire with a ring terminal attached.
Step 2. Connect this ring terminal to the external return bar, or to the plant return bus.
5.6.2 Alarm wiring for DC Plants with Alarm Termination Panel
For connection to a Comm/net power plant with a Cordex CXCM4 controller and a 1RU alarm termination
panel:
Step 1. Locate the back of the top BCM module in the bay. There is an open 8p8c (RJ-45) jack on the rear of
the BCM housing.
Step 2. Connect a Cat-5e or Cat-6 UTP cable with a TIA/EIA T-568B termination to the 8p8c connector.
Step 3. Connect the other end to an open digital input on the alarm termination board in the power plant.
Step 4. Set the digital input jumper to NO.
5.6.3 Alarm wiring for CXCM4 without Alarm Termination Panel
For connection to a Comm/net power plant with a Cordex CXCM4 controller and a standard alarm
termination block:
Step 1. Locate the back of the top BCM module in the bay. There is a open 8p8c (RJ-45) jack on the rear of the
BCM housing.
Step 2. Connect a Cat-5e or Cat-6 UTP cable with a TIA/EIA T-568B termination to the 8p8c connector.
Step 3. Connect to an open digital input on the alarm termination block on the rear of the CXCM4 controller.
Use the NO connection.
TABLE 5. ALARM CONTACT PINOUT
PIN 1 PIN 2 PIN 3 PIN 48
COM NC NO Reserved
Figure 4. Location of Frame Ground
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SETUP AND OPERATION MANUAL
PAGE 6 - INSTALLATION
5.7 Electrical Connections
5.7.1 Input Connections with Bus Tie Kits
DANGER
y THIS PROCEDURE SHOULD ONLY BE PERFORMED BY
QUALIFIED TECHNICIANS WITH INSULATED TOOLS
AND PROPER PERSONAL PROTECTIVE EQUIPMENT.
y COMM/NET RECOMMENDS INSTALLING THE SIDECAR
PDF WITH THE POWER PLANT DE-ENERGIZED. THIS
IS THE BEST GUARANTEE OF SAFE INSTALLATION.
y IF INSTALLATION MUST BE PERFORMED ON A
LIVE POWER PLANT, USE EXTREME CAUTION.
y USE TEMPORARY INSULATING MATERIAL SUCH AS
INSULATION BLANKETS, NOMEX (FISH PAPER), OR
OTHER TEMPORARY INSULATING MATERIAL TO PREVENT
CONNECTION OF HOT BUS INTO THE GROUNDED RACK
FRAME, RETURN BUS, OR OTHER OBJECTS AT EARTH
GROUND POTENTIAL DURING INSTALLATION.
The hot connection to the power plant is connected via the bus bar jumper kit. The
kit is either left or right mounted depending on the location of the PDF relative to the
power plant.
5.7.2 Input Connections Standalone Version
The standalone version of the Sidecar PDF has a is intended to be cabled to the top
bus in the rack. There are 10 back-to-back termination points for landing up to 20 input
cables (see Figure 5).
Step 1. Run input cables from the power plant to the Sidecar PDF. Run the correct
number of cables for the ampacity of the Sidecar PDF being installed.
Step 2. There are (2) types of termination available. 1/2 in holes on 1-3/4 in centers or
3/8 in holes on 1 in centers (see Table 6 below for termination information).
TABLE 6. STANDALONE INPUT TERMINATION SPECIFICATIONS
TWO HOLE
TERMINATION
TYPE HOLE SIZE
CENTERTO
CENTER
MAXIMUM
LUG WIDTH REQUIRED TORQUE
Through Hole 1/2 in 1-3/4 in 1.75 in 875 in∙lbs
Through Hole 3/8 in 1 in 1.75 in 350 in∙lbs
19.75
24.25
.625 1.125 1.125
.656
FOR 1/2" BOLTS
FOR 3/8" BOLTS
1.00
1.75
1.875
27.00
6.00
8.00
19.00
1.875
FOR 1/2" BOLTS
FOR 3/8" BOLTS
1.00
1.75
Figure 5. Standalone Input Bus
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SETUP AND OPERATION MANUAL
INSTALLATION - PAGE 7
5.7.3 Output Connections
WARNING
ENSURE FUSES ARE NOT INSTALLED OR BREAKERS ARE IN
THE OFF POSITION. CHECK THAT NO POWER IS PRESENT
ON OUTPUT CONNECTIONS BEFORE PROCEEDING.
Each output connection supports up to (4) lugs in a back-to-back conguration (see
Table 7 below for termination specications).
TAB LE 7. OUTPUT TERMINATION SPECIFICATIONS
TWO HOLE
TERMINATION
TYPE
HOLE SIZE
CENTERTO
CENTER
MAXIMUM LUG
WIDTH
REQUIRED
TORQUE
Through Hole 1/2 in 1-3/4 in 1.75 in 875 in∙lbs
Through Hole 3/8 in 1 in 1.75 in 350 in∙lbs
Step 1. Bring cables with appropriate lugs crimped onto them into place to attach
them to the desired output positions. Start from the top and work down to
ease future cabling.
Step 2. Insert the required number of bolts to secure the lugs. For back-to-back lugs,
use a bolt long enough to protrude though both lugs and the bus. Use at and
lock washers appropriately.
Step 3. Install nuts and torque the bolts according to the torque values in Table 7.
5.8 Fuse Installation
NOTICE
y USE BUSSMANN TPL TYPE OR LITTELFUSE
L17T TYPE FUSES ONLY.
y THIS SECTION ONLY APPLIES TO TPL FUSE
MODELS. FOR GJ BREAKER MODELS, THE
BREAKERS ARE INSTALLED IN THE FACTORY.
Step 1. Determine which type of fuse holder is installed. Refer to labeling and
purchasing information to determine this. There is a 1200A max fuse holder
that supports 900A-1200A fuses. There is an 800A max fuse holder that
supports up to an 800A fuse.
Step 2. Remove the fuse holder from the Sidecar PDF. Insert the selected TPL fuse into
the fuse holder. Ensure that the fuse is fully inserted into the fuse holder.
Step 3. Insert the fuse holder into the slot in the PDF.
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SETUP AND OPERATION MANUAL
PAGE 8 - OPERATION
Section 6: Operation
6.1 BCM Operation
For Sidecar PDFs with BCM's (basic control modules) installed, the following institutions apply to
its operation.
Each BCM has two maximum load size displays and two fuse fail/breaker trip indicators.
6.1.1 Fuse Fail /Breaker Trip LED
TABLE 8. FUSE FAIL/BREAKER TRIP LED
LED COLOR STATUS INDICATED
OFF Normal Operation
RED Fuse Failed or Breaker Tripped
6.1.2 Setting the Load Size Display (TPL Fuse Type Racks only)
To set the load size bar graph:
Step 1. Remove the BCM module from the Sidecar PDF by removing the (2) screws on the front
of the BCM.
Step 2. On the rear of the BCM modules, there is a set of potentiometers that set the level of the
load bar graph. Each potentiometer has 10 indications that correspond to about 100A.
Step 3. Set the bar graph potentiometer to about the correct setting for the ampacity of the
fuse being installed.
Step 4. Insert the BCM module back into can to power it on. The fuse size graph should now
display a fuse size. If the size displayed is incorrect, repeat Steps 1-4 again and ne tune
the values until they are correct.
6.1.3 BCM Functionality
Step 1. Remove the BCM module from the Sidecar PDF by removing the (2) screws on the front
of the BCM.
Step 2. On the rear of the BCM module, there is a set of potentiometers that sets the number of
breakers for alarm monitoring.
Step 3. Each potentiometer has 10 indications. Set the potentiometers to the appropriate
settings based on the following table.
TABLE 9. POTENTIOMETER SETTINGS
SW1 POSITION SW2 POSITION NUMBER OF BREAKERS MONITORED
0 0 0
1 0 1 (A Side)
0 1 1 (B Side)
1 1 2
Step 4. Insert the BCM module back into can to power it on.
SIDECAR PDF
SETUP AND OPERATION MANUAL
PRODUCT SPECIFICATIONS - PAGE 9
Section 7: Product Specications
This section describes some basic product specications. Specic congurations will
have their own specications.
TABLE 10. OVERALL RATING INFORMATION SIDECAR PDF BY MAXIMUM RATING INFORMATION
MAXIMUM INPUT CURRENT 1800A 2900A 4000A
Mechanical Dimensions
12 in wide × 25 in deep × 84 in
high
12 in wide × 25 in deep × 84 in
high
12 in wide × 25 in deep × 84 in
high
Input Voltage -48V DC -48V DC -48V DC
Maximum TPL Fuse Circuits 8 8 8
Maximum 1-or-2 Pole GJ Breaker
Circuits 12 12 12
Maximum 4 Pole GJ Breaker
Circuits 6 6 6
Maximum Per Circuit Load Depends on installed distribution Depends on installed distribution Depends on installed distribution
Maximum Ambient Temperature
Maximum Operating Altitude 2000 m 2000 m 2000 m
TABLE 11. TPL FUSE PANEL RATING INFORMATION
TPL 1600 TPL 2400
Maximum Fuse Size 800A 1200A
Maximum Per Circuit Continuous Load 640A 960A
Circuits Per Panel 2 2
TABLE 12. GJ BREAKER PANEL
1OR2 POLE GJ BREAKER 4 POLE GJ BREAKER
GJ Breaker Per Circuit Rating = Installed GJ Breaker Size = Installed GJ Breaker Size
SIDECAR PDF
SETUP AND OPERATION MANUAL
PAGE 10 - PRODUCT SPECIFICATIONS
THIS PAGE INTENTIONALLY LEFT BLANK
SIDECAR PDF
SETUP AND OPERATION MANUAL
PRODUCT SPECIFICATIONS - PAGE 11
12.000
84.000
1.250 TYP
.191 THRU
For use with
Comm/Net Rack Link kit
44.480
25.250
3.000 TYP
5/8" x 16 Weld Nuts
Right Mount Configuration Shown
Figure 6. Overall Mechanical Dimensions for Sidecar PDF. (Overall dimensions
are the same for all models. TPL Version Pictured.)
Appendix A: Mechanical Specications
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SETUP AND OPERATION MANUAL
PAGE 12 - PRODUCT SPECIFICATIONS
Figure 7. Sidecar PDF Configurations (TPL, GJ, Mixed)
TPL Conguration GJ Conguration
Mixed Conguration
SIDECAR PDF
SETUP AND OPERATION MANUAL
PRODUCT SPECIFICATIONS - PAGE 13
Appendix B: Footprint Drawing
6.00
21.25
12.00
25.25
2.00
19
.750
540
21.250
152
6.000
305
12.000
19
.750
641
25.250
51
2.000
Figure 8. Footprint Dimensions for Sidecar PDF
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SETUP AND OPERATION MANUAL
PAGE 14 - PRODUCT SPECIFICATIONS
NOTES:
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