High-Current Power Distribution Alarm Panel
Contents
1. NOTE If required by the operating company s installation procedures use anti oxidant compound between the cable compression lugs and the input BATT and RTN terminals Lo D OS 4 Secure the BATT and RTN cables to the input power terminal blocks with the 5 16 18 KEPS nuts as shown Torque the nuts to 40 in lb 4 52 Nem with a 1 2 inch 13 mm socket Compression lug gu A INPUT J MAX INPUT LOAD 200 AMP JZ Torque 5 16 to 40 in lb 4 52 N m 18 KEPS nuts 5 Reinstall the terminal block covers 4 6 Connecting to the Power Bays Figure 6 Input Power Hookup Use extreme caution The DC power circuits surrounding the cable termination points are live Refer to the operating company s installation procedures for connections to power bays You may be required to have power personnel on site when making these connections The power bays come in two basic configurations The fuse breaker battery BATT terminations and the return RTN bus are contained within the same bay The fuse breaker battery BATT terminations are contained within the bay but the return RTN bus is located outside the bay NOTE The 48 VDC BDFB must be electrically isolated from the AC power source and must be reliably connected to earth ground 1 Before making cable connections remove the BDFB fuse breaker for this circuit and remove any signal indicator fuses when present Us2. 24 48 24 200A 200A Output return Output battery Earth ground st Input powerterminal er i RTN terminal BATT terminals Figure 1 Attributes and Dimensions Telect Inc All Rights Reserved 117926 5 AO 1 509 926 6000 telect com d Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 1 5 Schematic diagram fo Qi BATT A INPUT RTN 8 s apa 2 3 5 RTN gt 1 amp aw A g amp TN g gt BATT em Ea 55 e a AN g 4 x 9 O CGND NO POWER C ALARM Note Relays shown in alarm condition INPUT POWER A Y GREEN S ALARM BREAKER ALARM CIRCUIT e d INPUT POWER B eu NEL NC BREAKER FAIL Hd O CGND 9 amp E BATT e e ee Eee RTN OSC O G9 0050N2a O LT RIN B INPUT O BATT Figure 2 Schematic Telect Inc All Rights Reserved 117926 5 AO 4 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 2 Before You Begin 2 1 Document Authority Your operating company s approved installation procedures take priority over this manual Modify these instructions accordingly This manual describes a best practice method of DC distribution breaker panel installat
3. 4 7 Supplying and Testing Input Power A WARNING m DO NOT SUPPLY POWER to the HCPDAP until it is securely mounted and grounded Before supplying input power verify that the HCPDAP has no circuit breakers installed This measure prevents power from reaching any output path 1 At the BDFB fuse breaker board insert the properly rated fuse or breaker for the circuit that feeds the HCPDAP NOTE The maximum allowable fuse or breaker rating is 250 amps BATT E RTN 2 Carefully remove the plastic terminal block covers from the input power terminals 3 Verify your voltmeter s lead designations and DC Q range setting so that they correspond to the plant operating voltage 4 With the voltmeter measure the HCPDAP Input A and Input B voltages for proper polarity as shown A INPUT MAX INPUT LOAD 200 AMP 5 Carefully reinstall the terminal block covers Figure 8 Test Input Polarity 48V 52V to 54V typical or plant operating voltage 24V 26V to 27 5V typical or plant operating voltage Telect Inc All Rights Reserved 117926 5 AO 14 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 4 8 Testing the Input Power Alarms Relays It is recommended that you test the Power Alarm relay with an ohmmeter before installing any further cabling The alarm relays are located on the HCPDAP backp
4. B for a total of 400 amps Do not exceed a rating of 100 amps for any breaker position in the panel The sum of the circuit breaker ratings on either side A or B of the HCPDAP must not exceed that side s maxi mum rated input current Example If A and B input current is rated at 200 amps then the sum of the panel s circuit breaker ratings must be less than or equal to 200 amps A 1 A 2 A 6 lt 200 amps B 1 B 2 B 6 200 amps Telect Inc All Rights Reserved 117926 5 AO 19 1 509 926 6000 telect com Elect High Current Power Distribution Alarm Panel Power 009 6212 2100 5 3 Calculating Circuit Breaker Ratings Refer to your job specifications for equipment maximum output load ratings and corresponding circuit breaker ratings Use the following procedure to calculate the equipment s recommended minimum and maximum circuit breaker rating 1 Determine the maximum output load rating of the equipment in the circuit 2 Multiply the maximum output load rating by a factor of 1 25 to determine a minimum breaker rating 3 Multiply the maximum output load rating by a factor of 1 5 to determine a maximum breaker rating Example If the equipment s maximum output load rating is 20 amps determine the minimum and maximum breaker ratings for the circuit 20 amps x 1 25 25 amps lower limit 20 amps x 1 5 2 30 amps upper limit NOTES Do not exceed a rating of 100 amps for any breaker position in the
5. Breaker Designation Card 5 9 Powering the Load Equipment If you are required to test the functionality of the rack system power up each circuit according to the following procedure NOTE Begin with the first circuit of the High Current Power Distribution Panel s output side A Test only one circuit at a time 1 Activate the circuit s equipment or equipment shelf cards At the High Current Power Distribution Panel switch this circuit s breaker to the ON position Verify that power indicators light up on the cards and equipment If they do not troubleshoot the voltage and polarity with a voltmeter and correct the problem 4 Watch for abnormalities such as arcing or smoking Should this occur shut down the equipment immediately by switching the circuit breaker to the OFF posi tion Then troubleshoot the voltage and polarity with a voltmeter and correct the problem 5 Repeat Steps 1 through 4 for each circuit one circuit at a time for the remaining circuits of output Side A and then for output Side B Upon completion of this process the system is live and ready for operation Telect Inc All Rights Reserved 117926 5 AO 24 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 6 Operation 6 1 Alarm Conditions and Reponses 009 6212 2100 S POWER A ON GREEN Side A is receiving input Nothing normal operating condition POWER power Q
6. er tina Se beta 9 4 2 Cable Conventions saias 9 LM eric 9 5 Installing Breakers iiec cedit rene reed eer rend reu ania pub d vr ed ERE ped ai 10 5 1 General Guidelines for Installing Breakers 10 5 2 HCPDAP Circuit Breaker Capapcity aerea 10 4 2 2 Color Conventions issus 11 4 3 Power System Diagramme 11 4 4 Connecting Ground Cables iii 12 4 5 Connecting Input Power Cables ins 12 4 6 Connecting to the Power BayS iiceene conteste ete Une etre o erkannt Ex adia neu dux aa 13 4 7 Supplying and Testing Input Power iii 14 4 8 Testing the Input Power Alarms Relays sseeeenneeneeenn 15 4 9 Connecting Outpt GCabl65 eorpore du re e is sue e eM RRO ade EU Duas debe 16 5 Installing Breakers tton rti tenu nent neu nu te au nnd ec Luv hase cda dv nsu dau na 19 5 1 General Guidlines for Installing Breakers seseeene 19 5 2 HCPDAP Circuit Breaker Capacity 19 5 3 Calculating Circuit Breaker Ratings 20 5 4 Installing Circuit Breakers reiissi eerie drea cruore sanete nce c canina da sand din nada 20 5 5 Testing HCPDAP Output Circuit Polarity ss 21 5 6 Testing the Breaker Alarm Relays aaneaaaaranna 21 5 6 1 Breaker Alarm Relay TeSti z sn esci eerte retired agua try EE bei Ee s 22 5 6 2 Breaker Alarm Visual Indicator Test 22 5 7 Connecting and Testing External Alarms irreai
7. the circuit breaker to the ON position The circuit is now live 3 With a voltmeter test the equipment polarity by probing the equipment s input power terminal as shown 4 Shutdown power to the circuit by returning the breaker to the OFF position If the cable polarities are reversed correct the circuit cabling at this time 5 Oneata time repeat Steps 1 3 for each HCPDAP output circuit 6 Confirm that all of the circuit breakers are in the OFF position then replace the plastic terminal block covers 5 6 Testing the Breaker Alarm Relays The following tests verify that the HCPDAP Breaker Alarm relay is functioning properly The alarm relays are located on the HCPDAP backplane They are labeled according to their unpowered state The Breaker Alarm relay is unpowered during normal operation Use the table and diagram below as a test guide CAUTION Never use fault current to test circuit breakers or the breaker alarm system Doing so can cause hazardous conditions equipment damage or equipment service interruptions Telect Inc All Rights Reserved 117926 5 A0 1 509 926 6000 telect com Tel amp ENS d Figure 12 Securing the circuit breaker 3 MAx BREAKER EN BATT and RTN cables from HCPDAPoutput terminals RTN Black Red a Equipment BATT and RTN input power terminals Figure 13 Test Equipm
8. Current Power Distribution Alarm Panel Power 009 6212 2100 8 Accessories Alarm card Standard 400223 Face plate Circuit breaker face plate 090 0001 0002 Face plate blank Replacement face plate blank 090 0001 0003 Circuit breakers 10 amp long delay 090 0052 0010 20 amp long delay 090 0052 0020 30 amp long delay 090 0052 0030 40 amp long delay 090 0052 0040 50 amp long delay 090 0052 0050 60 amp long delay 090 0052 0060 70 amp long delay 090 0052 0070 80 amp long delay 090 0052 0080 90 amp long delay 090 0052 0090 100 amp long delay 090 0052 0100 Ground and input terminal 1 0 AWG or 1 Weld Wire 116108 compression lugs 2 0 AWG or 1 0 Weld Wire 116109 3 0 AWG or 2 0 Weld Wire 116110 Output terminal compression lugs 2 AWG 114552 4 AWG 110516 6 AWG 101686 Telect assumes no liability from the application or use of these products Neither does Telect convey any license under its patent rights or the patent rights of others This document and theproducts described herein are subject to change without notice Telect Inc All Rights Reserved 117926 5 AO 1 509 926 6000 telect com 30 Telect
9. Failure to do so can result in hazardous conditions Connect and test each circuit one at time according to the following procedure 1 Construct BATT and RTN cables for both A and B output power circuits Use properly rated cables and two hole compression lugs Insulate the lug barrels with UL 94V 0 rated heat shrink tubing For assistance refer to the operating company s installation procedures or see Telect 117995 Wire Sizing and Labels Locate the output power terminals on the HCPDAP backplane Loosen and remove the plastic terminal covers Clean the contact areas of the compression lugs and the BATT and RTN output terminals Use a coarse non metallic cleaning pad NOTES Remove all power cards and equipment fuses from equipment to be connected to and powered by the HCPDAP Install only one cable per termination point Do not connect more than one load cable to the same breaker BATT terminal position If required by the operating company s installation procedures use anti oxidant compound between the compression lugs and the BATT and RTN terminals 6 4 Secure a BATT cable to the output BATT terminal Torque 10 32 KEPS nuts Note Clean all with the 10 32 KEPS nuts as shown Torque to 20 in lb 2 27 N m contact surfaces the nuts to 20 in Ib 2 27 Nem with a 3 8 inch 10 mm socket Figure 10 Output Cable Hookup Telect Inc All Rights Reserved 117926 5 AO 16 1 509 926 6000 t
10. High Current Power Distribution Alarm Panel Power 009 6212 2100 User Manual Telect Inc All Rights Reserved 117926 5 AO 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 Table of Contents 1 System Description siennes 1 1 1 GeneraliDGSCriptlON m LEE 1 1 2 Electrical Specifications is 1 1 3 Mechanical Specifications 2 5 oerte Ro srs edicao fufas teen en base dn cos ates A aE ens dns 2 1 4 Physical AttrIDUtes coerente er conde era Foster E er eee nea fodeer toutes NOTERER br tite 3 SCIEN AUG HAG FANN 2er dass E R EE anses ares asser eme en 4 2 Before fos M 5 21 Beet M 5 22 1001S T tar 5 2 3 Cables and Cabling Hardware sis 5 2 4 Safety Corm EE 6 2 4 1 Clothing and Work Environment sssssssssssseseeeeeeeeeenen enne nnne 6 2 4 2 Electrical Safety issus hi accedit et alan Co co ate conto alias a ime vean duca dO RR ren 6 2 4 3 In Case of Accident issues 6 3 Euge i 7 3 1 Planning Rack Location and Space 7 3 2 Rack Mounting and Labeling Procedure eseseeeseeeeeneeeeene entren nnns 7 4 Connecting Cables AR neret torte tote re nero NE as haie dofus 9 4 1 Cabling Guideline Snir iicet rated cat vex ren en idee gat tute epu esse
11. NC Do not connect C Common terminal or alarm C Common terminal or alarm RTN ground bus RTN ground bus NO Alarm activation terminal NO Alarm activation terminal 4 Switch an HCPDAP circuit breaker to the OFF position to test the external Breaker Alarm connection See 5 6 Testing the Breaker Alarm Relays on page 3 NOTE If the external alarm boards are equipped with a reset function reset the boards after each test 5 TURN OFF input power to the HCPDAP to test the external Power Alarm connection See 4 8 Testing the Input Power Alarm Relays on Page 4 6 6 Restore input power to the HCPDAP Telect Inc All Rights Reserved 117926 5 AO 23 1 509 926 6000 telect com ec 1 High Current Power Distribution Alarm Panel Power 009 6212 2100 5 8 Labeling the Distribution Panel If required use cable tags to label output cables At each end of the cable indicate the opposite end s termination point and the cable polarity To assist service personnel fill in the breaker designation card shown here Include Rack location Breaker position and RACK BAY ESCENA corresponding equipment location FUSE TYPE FUSE TYPE FUSE LOAD FUSE LOAD POS AMP AMP LOCATION POS amp AMP LOCATION Breaker rating Equipment output load rating Post the breaker designation card near the distribution panel Figure 16
12. OFF Input power to the panels A Examine all cable connections fuses A side has been interrupted breakers and switches at this panel and at the original DC power supply Correct ALARM O any problems and restore power POWER B ON GREEN Side B is receiving input Nothing normal operating condition power POWER A OFF Input power to the panel s B Examine all cable connections fuses side has been interrupted breakers and switches at this panel and B at the original DC power supply Correct amp any problems and restore power ALARM ON RED A output circuit breaker has Before resetting the breaker examine tripped or turned OFF on the equipment being powered and all either side of the panel cabling to the equipment Correct as needed and reset the breaker OFF All panel breakers are closed Nothing normal operating condition or ON 6 2 Replacing the Alarm Card 1 Use a No 1 Phillips screwdriver to loosen the alarm card s two captive screws Pull the alarm card straight out of the panel Align the replacement alarm card to the opening on the face of the panel 4 Slide the alarm card straight into the opening so that the card s edges are positioned in the PCB guides 5 Push until the card s connector is firmly seated The alarm card s front panel should sit against the face of the distribution panel 6 Use a No 1 Phillips screwdriver to secure the card s captive screw
13. ays select a properly rated breaker for the circuit Refer to your job specifications for maximum output load ratings and corresponding circuit breaker ratings or see 5 3 Calculating Circuit Breaker Ratings on page 20 Read the installation guide provided with the circuit breaker When using high current breakers try to leave at least one empty breaker position between breakers Keep cover plates over all vacant circuit breaker positions at all times during installation Replace circuit breakers with the exact same breaker size type and rating In cases of nuisance tripping it may be necessary to install a breaker with an increased time delay during the powering of some equipment If you increase a circuit breaker rating verify that the corresponding output cables are of the proper gauge 6 5 Replacing Breakers N CAUTION This procedure is performed when this equipment is powered Failure to follow this procedure may damage equipment or cause equipment service interruptions 1 Follow the operating company s standard procedures for notifying the alarm center 2 Place a warning tag on the equipment that says in effect Warning Service Personnel Working on Equipment Telect Inc All Rights Reserved 117926 5 AO 26 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 3 Verify that the breaker to be removed is in the OFF position Remove the breaker s mo
14. e 400 amps total The distribution panel holds six bullet terminal front access circuit breakers per side 12 total Each breaker position is capable of breakers rated up to 100 amps Acceptable voltages are 20 to 30 VDC or 20 to 60 VDC Features include Dual feed power inputs Input A and Input B Accepts circuit breakers rated up to 100 amps see Accessories on Page 8 1 Breaker alarm with single visual and single remote dry contact indicator Visual A and B input power alarms with single remote dry contact indicator Replaceable alarm card Total rear access TRA for input and output power 009 6212 2100 is Listed by UL for USA and Canada 009 6212 2100 is NEBS and CE certified 1 2 Electrical Specifications Operating voltages 20 to 60 VDC 20 to 30 VDC Maximum input interruption device rating 250A Maximum continuous input load rating 200A Maximum output interruption device rating 100A per circuit breaker Maximum continuous output load rating 100A per circuit breaker Alarm contact ratings continuous 2A at 30 VDC 0 6A at 60 VDC 1A at 120 VAC Alarm board power ratings maximum power draw 20V 32 mA 0 64 W 24V 40 mA 0 96 W 27V 44 mA 1 19 W 30V 46 mA 1 38 W 42V 54 mA 2 27 W 48V 58 mA 2 78 W 56V 63 mA 3 58 W 960V 66 mA 3 96 W Max operating temperature at max load ratings 55 C 131 F Min operating temperatu
15. e a DC voltmeter to verify that no voltage is present at the BDFB output terminals Clean the contact areas of the cable compression lugs and the power bay output terminals Use a coarse non metallic cleaning pad 4 Carefully secure the BATT cables to the BDFB output terminals in a neat uniform manner according to the operating company s installation procedures Provide only one BATT cable termination per fuse breaker position Do not combine separate loads on the same fuse breaker NOTES If required by the operating company s installation procedures use anti oxidant compound between the cable compression lugs and the BDFB output BATT and RTN terminals Do not connect the returns to any bus bars marked for CO grounds Telect Inc All Rights Reserved 117926 5 AO 13 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 5 Carefully secure the RTN cables to the BDFB return bus in a neat uniform manner according to the operating company s installation procedures For two cable arrangements it is normally acceptable to connect the A and B return RTN cable lugs to the return bus bar in a back to back arrangement so that they sandwich the bus bar as shown ACCEPTABLE SO RETURN BUS BAR LB oY Hu TU UNACCEPTABLE A B RETURN BUS BAR A Figure 7 Bus Bar Diagram
16. eded Read the installation guide provided with the circuit breaker When using high current breakers try to leave at least one empty breaker position between breakers 5 2 HCPDAP Circuit Breaker Capapcity The HCPDAP maximum circuit breaker capacity is 200 amps per side A and B for a total of 400 amps Do not exceed a rating of 100 amps for any breaker position in the panel The sum of the circuit breaker ratings on either side A or B of the HCPDAP must not exceed that side s maximum rated input current Example If A and B input current is rated at 200 amps then the sum of the panel s circuit breaker ratings must be less than or equal to 200 amps A 1 A 2 A 6 lt 200 amps B 1 B 2 B 6 lt 200 amps Telect Inc All Rights Reserved 117926 5 AO 10 1 509 926 6000 telect com lelect High Current Power Distribution Alarm Panel Power 009 6212 2100 4 2 2 Color Conventions When using colored cables use the following color conventions RED Battery BATT polarity A BLUE Battery BATT polarity B BLACK Return RTN GREEN Earth ground 4 3 Power System Diagram AC MAINS RECTIFIERS BATTERIES BATTERY DISTRIBUTION FUSE BREAKER BOARDS BDFB Primary DC power distribution sources HIGH CURRENT POWER DISTRIBUTION PANEL EQUIPMENT HIGH CURRENT POWER DISTRIBUTION PANEL INPUTA INPUTA INPUT B EQUIPMENT Figu
17. elect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 NOTE To easily cable this device connect to the output BATT terminal before you connect to the RTN terminal 5 Secure a RTN cable to the output RTN terminal with the 10 32 KEPS nuts as shown Torque the nuts to 20 in Ib 2 27 Nem with a 3 8 inch 10 mm socket 6 Attach the other ends of these cables to the corresponding BATT and RTN terminals of the equipment to be powered by the HCPDAP Secure the cables according to the equipment manuals or to the operating com pany s standard installation procedures Repeat Steps 3 through 6 for each circuit for both Side A and for Side B Reinstall the plastic terminal block covers Use designation labels to record output equipment connections A 1 through A 6 and B 1 through B 6 ac cording to the operating company s standard installation procedures Telect Inc All Rights Reserved 117926 5 AO 17 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 This page was intentionally left blank Telect Inc All Rights Reserved 117926 5 AO 18 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 5 Installing Breakers 5 1 General Guidlines for Installing Breakers Operating companies have guidelines to determine proper circuit breaker ratings Telect recommends you follow those guidelines whe
18. ent Polarity Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 5 6 1 Breaker Alarm Relay Test 1 Verify that one input power source is ON 2 Onthe same input side of the HCPDAP manually BREAKER turn a circuit breaker to the OFF position to ALARM establish an alarm condition Use an ohmmeter to test the Breaker Alarm relay as POWER shown in the diagram and the table FAIL Figure 14 Test Breaker Alarm Relays When the circuit breaker is OFF alarm state When the circuit breaker is ON normal state Place the ohmmeter Ohmmeter reads Place the ohmmeter Ohmmeter reads probes here probes here Black probe C CLOSED Black probe C OPEN or OL open load Red probe NO Red probe NO Black probe C OPEN or OL open load Black probe C CLOSED Red probe NC Red probe NC 5 6 2 Breaker Alarm Visual Indicator Test Observe the HCPDAP s alarm card while performing the following test for breaker alarm visual indicators S 1 Switch the circuit breaker to the ON position The alarm card s Alarm LED is off POWER 2 Switch the circuit breaker to the OFF position The alarm card s Alarm LED is on RED Q 3 Return the breaker to the OFF position A If the Alarm LED does not illuminate ALARM O a Verify that the breaker is in the OFF position b Replace the alarm card See 6 2 Replacing the Alarm Card on Page 6 1 POWER When the c
19. er Distribution Alarm Panel Power 009 6212 2100 7T Service 7 1 Owner Maintenance Telect s High Current Fuse Panel does not require preventive maintenance 7 2 In Warranty Service For assistance with installation component identification or missing parts call Telect 509 926 6000 An application engineer will help you Telect will repair or replace defective products See Repacking for Shipping in this section NOTE Call Telect for a Return Material Authorization RMA before returning any equipment 7 3 Out of Warranty Service The procedure for out of warranty service is the same as for in warranty service except that Telect charges a processing fee and you must submit a purchase order along with a Return Material Authorization RMA before returning equipment Call Telect at 1 509 926 6000 for help getting these forms The processing fee guarantees a repair estimate and is credited against actual material and labor costs 7 4 Repacking for Shipment 1 Tag the equipment showing owner s name address and telephone number together with a detailed description of the problem 2 Use the original shipping container if possible If you do not have it package the equipment in a way to prevent shipping damage Include the RMA inside the container 3 Insure the package NOTE Telect is not liable for shipping damage Telect Inc All Rights Reserved 117926 5 AO 29 1 509 926 6000 telect com Telect High
20. hazards in your work area such as wet floors ungrounded power cables cluttered aisles etc Keep tools away from walkways aisles or places where people could trip over them Provide safety cones when saying equipment or cables on the floor Always secure loose cables to the cable racks 2 4 2 Electrical Safety Only trained and qualified personnel should install service or replace this device Read all installation instructions before you connect this device to a power source Disconnect all power before you install or remove this device or before you work near a power supply Never assume that circuit power is off always verify This equipment must be grounded Verify that it is connected to earth ground before applying power Never operate this equipment in the absence of an earth ground Contact an authorized electrical inspection authority or an electrician if you are uncertain that suitable grounding is available A readily accessible interruption device breaker or fuse must be incorporated in the fixed input wiring Do not work on the system or handle cables during periods of lightning activity Locate the emergency power OFF switch in the room in which you are working in order to quickly shut down power if an electrical accident occurs 2 4 3 In Case of Accident Should you witness an electrical accident do the following Turn OFF power to the system 2 When possible stay with the victim and send another person to get
21. inch 25 in Ib 2 83 N m 4 2 BATT 2 RTN 5 16 inch 5 16 18 KEPS 1 2 inch 13 mm 6 to 4 0 AWG depending on size of input interruption device 2 hole compression lug Same as cable up to 4 0 AWG 1 width MAX 1 inch 40 in Ib 4 52 N m 24 12 BATT 12 RTN 10 10 32 KEPS 3 8 inch 10 mm 6 to 2 AWG depending on size of output breaker 2 hole compression lug Same as cable up to 6 AWG 0 6 width 5 8 inch 20 in Ib 2 27 N m 6 3 48 18 22 AWG Telect Inc All Rights Reserved 117926 5 A0 2 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 1 4 Physical Attributes Cover plate Alarm card Power alarm E indicator Input A e e e e 6 5 4 3 2 1 1 4 5 MAX 100A BREAKER Telect MAX 100A BREAKER MAX 200A CONFIGURATION SPOKANE WA MAX 200A CONFIGURATION 800 551 4567 Breaker alarm indicator Captive screw Power alarm Mounting screw indicator Input B Dimensions L x W x D 17 25 x 5 x 8 inches 43 82 x 12 7 x 20 32 cm 5 8 5 8 Lug width Lug width Breaker alarm and 1 59 1 59 0 60 1 52 0 60 1 52 power alarm relays RTN BATT BATT RTN NO C IBREAKER NC ALARM NG POWER NO FAIL B INPUT 6 A INPUT 48
22. ion and operation It does not attempt to specify a standard for engineering design and installation 2 2 Tools The following tools and terminals are needed to install this device No 1 and No 2 Phillips head screwdrivers No 2 flathead screwdriver 7 16 inch 12 mm 1 2 inch 12 mm and 3 8 inch 10 mm torque wrenches or sockets Cable cutter and insulation stripping tool Approved wire terminal crimping tools Lacing cord or nylon cable ties Voltmeter Ohmmeter 2 3 Cables and Cabling Hardware The following cables and terminals are needed to install this device Ground cable s 2two hole compression lugs for ground cable s Two BATT and two RTN input power cables 4two hole compression lugs for input power cables BATT and RTN output cables as needed 2two hole compression lugs per output cables 18 AWG to 26 AWG standard telecom hookup wire to connect remote alarms Telect Inc All Rights Reserved 117926 5 AO 5 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 2 4 Safety Warnings 2 4 1 Clothing and Work Environment Do not work alone under potentially hazardous conditions Wear safety glasses Do not wear loose clothing that may get caught in equipment Roll up your sleeves and remove or fasten neckties and scarves Remove jewelry such as rings necklaces and watches before working on this equipment Eliminate potential
23. ircuit Relay closure status Visual indicator amp B breaker is is Alarm LED is OFF C NO ON RED ON C NC OFF Telect Inc All Rights Reserved 117926 5 AO 22 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 5 7 Connecting and Testing External Alarms This section applies to alarm systems that require a ground for activation Follow this procedure to connect the HCPDAP alarm relays to the central office alarm system To determine which hook up wire size to use refer to the operating company s installation procedures or use 18 22 AWG standard telecom hook up wire 1 Follow the operating company s installation procedures when designating connecting labeling and recording alarm circuits Connect the Power Fail alarm relay leads to the external alarm leads as shown in the diagram and the table below Connect the Breaker Alarm relay leads to the external alarm leads as shown EXTERNAL ALARM HCPDAP RELAY CONNECTIONS CONNECTIONS To external alarm activation terminal To external alarm RTN GND bus BREAKER _ No connection ARM Sofa tenninal POWER FAIL To external alarm mem RTN GND bus No connection Figure 15 Alarm leads Power Fail Alarm Breaker Alarm Connect relay To external alarm Connect relay To external alarm terminal receiver terminal receiver NC Do not connect
24. lane They are labeled according to their unpowered state Use the table and diagram below as a test guide When both A and B input power is ON Place the ohmmeter probes here Ohmmeter reads Black probe C 0 ohm Red probe NC Black probe C OPEN or OL open load Red probe NO BREAKER ALARM POWER FAIL Figure 9 Test Power Alarm Relays Input power for Relay closure Visual indicator Power LED is Input A Input B status is Power A Power B ON ON C NC ON GREEN ON GREEN ON OFF C NO ON GREEN OFF OFF ON C NO OFF ON GREEN OFF OFF C NO OFF OFF To test the Breaker Alarm relay at this time see 5 6 Testing the Breaker Alarm Relays on Page 21 Telect Inc All Rights Reserved 117926 5 AO 15 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 4 9 Connecting Output Cables Output cables connect the HCPDAP to equipment that is to be powered The cables must support 125 of the rated continuous load current of the equipment in the circuit up to 100 amps The HCPDAP is powered during this procedure It is highly recommended that you TURN OFF HCPDAP INPUT POWER at the BDFB for this procedure Remove or lock out the BDFB circuit breakers or verify that the BDFB fuse positions are open Also verify that there are no breakers present in the HCPDAP for the output circuits being cabled
25. medical assistance Otherwise determine the condition of the victim then call for help 3 Determine if the victim needs CPR If qualified take appropriate action Telect Inc All Rights Reserved 117926 5 AO 6 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 3 Rack Mounting 3 1 Planning Rack Location and Space The distribution panel s mounting brackets provide mounting access to the following racks 19 inch 48 26 cm EIA racks 23 inch 58 42 cm WECO racks Telect recommends the following mounting practices Mount the panel to the upper most rack position Allow one rack unit of empty space 1 75 inches or 4 45 cm below the panel to provide adequate ventilation 3 2 Rack Mounting and Labeling Procedure Do not supply power to the equipment rack or the distribution panel until the panel is securely mounted and grounded Note that the distribution panel has three sets of mounting points flush three inch offset and four inch offset The panel ships with brackets positioned for flush mounting to a 19 or 23 rack 1 Decide if the distribution panel is to be mounted flush with the equipment rack or if it is to be offset extended from the rack 2 f needed move the mounting brackets to the desired position on the product s chassis Torque the screws to 25 in Ib 2 83 Nem 3 Align the holes in the mounting brackets to the holes on the equipmen
26. n lugs approved by a nationally recognized test laboratory NRTL for all power cables and ground cables Crimp all terminals with tooling approved by the terminal s manufacturer Cover power cable compression lug barrels with UL94VO rated heat shrink tube Mark each cable end with its opposite termination destination and its polarity Secure cables to the equipment rack to prevent loose falling cables At the BDFB and other equipment attach power cables to the cable management system CMS with lacing cord or nylon cable ties before terminating them When installing power cables do not strain or twist the cables The cables must move smoothly and easily into place nstall cables in a neat uniform manner In most cases your operating company s installation procedures will provide you with the necessary guidelines and wire charts necessary to determine the properly rated wires cables and compression lugs to perform this installation If this information is not provided consult your engineer or see Telect 117995 Wire Sizing and Labels 4 2 Cable Conventions 4 2 1 Polarity Use the following conventions when preparing cables BATT Battery BATT refers to the power distribution source s circuit interrupt fuse breaker polarity RTN Return RTN refers to the plant polarity referenced to earth ground Telect Inc All Rights Reserved 117926 5 AO 9 1 509 926 6000 telect com Telect High Curre
27. ne nane 8 Figure 5 Power System iii 11 Figure Input Power Hookup coe ieec erano perde excu cae eds pet uep Fear nanda ERA 13 Figure 7 Bus Bar Diagramme sr epe dede Ce ecoute E ed dos una rere ewes 14 Figure 8 Test Input Polarity 2 nee aaae RR NEETA ana deno Bude de ase BU e ni 14 Figure 9 Test Power Alarm Relays iii 15 Figure 10 Output Cable MOOK Pesci acces etre ret Paseo sereine can E bey exo peu zu eae 16 Figure 11 Installing the circuit breaker enne 20 Figure 12 Securing the circuit breaker 21 Figure 13 Test Equipment Polarity is 21 Figure 14 Test Breaker Alarm Relays sese 22 Figure 15 Alarm leads uuo ec tet neret e Lene tre tus qute ap eeu ru tent s egi 23 Figure 16 Breaker Designation Card ss 24 Figure 17 Alarm Cal d assiriana aona AE qu net pee eat een tt that 25 Figure 18 Installing the Circuit Breaker recenter reinen ern tenera 27 Telect Inc All Rights Reserved 117926 5 AO 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 1 System Description 1 1 General Description The Telect dual feed High Current Power Distribution Alarm Panel HCPDAP Model 009 6212 2100 accepts two input power circuits of the same polarity up to 200 amps It distributes up to 200 amps load amperage per sid
28. nt Power Distribution Alarm Panel Power 009 6212 2100 5 Installing Breakers 5 1 General Guidelines for Installing Breakers Operating companies have guidelines to determine proper circuit breaker ratings Telect recommends you follow those guidelines where applicable Also follow the guidelines below when installing circuit breakers in the High Current Power Distribution Alarm Panel HCPDAP These practices prevent injury to personnel ensure proper distribution panel operation and prevent damage to the distribution panel and connected equipment Install all output cabling and verify output cable polarities before permanently activating breakers Always select a properly rated breaker for the circuit Refer to your job specifications for maximum output load ratings and corresponding circuit breaker ratings or see 5 3 Calculating Circuit Breaker Ratings on Page 5 2 N CAUTION The maximum rated load current for each circuit breaker position must not exceed 100 amps The combined current for each output branch circuit total A output or total B output must not exceed 200 amps per side Keep cover plates over all vacant breaker positions at all times during installation Review the HCPDAP s power requirements and corresponding cable gauges any time the you add or remove equipment from the panel This practice confirms proper breaker ratings for the modified circuits and it ensures that the panel load capacity is not exce
29. panel Due to load current demand variances within the plant operating voltage range Telect recommends that equipment continuous output load during normal operation should not exceed 80 of the circuit breaker s rated value 5 4 Installing Circuit Breakers Do not install circuit breakers under equipment load Doing so may damage breakers 1 Unscrew the cover plate from the distribution Bn panel s intended breaker position Cover plate Confirm that the breaker is in the OFF position Inspect the breaker for any abnormalities and for proper alarm contact pin alignment Remove any oxidation and debris from the breaker s contact surfaces 4 Screw the cover plate to the circuit breaker Properly align the breaker to the slot in the Circuit distribution panel and firmly push the breaker breaker into position as shown Mounting EA Breaker cover plate screw Figure 11 Installing the circuit breaker O Telect Inc All Rights Reserved 117926 5 AO 20 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 6 Secure the breaker to the front of the panel with the mounting screw Perform a cable polarity test on the circuit Repeat Steps 1 through 7 for each remaining circuit 5 5 Testing HCPDAP Output Circuit Polarity Test the polarity of each HCPDAP output circuit Test only one circuit at a time 1 Verify that input power is ON 2 Switch
30. re 5 Power System Telect Inc All Rights Reserved 117926 5 AO 11 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 4 4 Connecting Ground Cables NOTE The RTN and BATT terminals are completely isolated from the chassis ground Earth ground reference is determined by plant polarity 1 Determine the proper ground cable configuration by the BDFB output amperage that feeds the HCPDAP input power terminals Then construct the ground cable s Use properly rated cables with two hole compression lugs For assistance refer to your operating company s installation procedures or see Telect 117995 Wire Sizing and Labels Locate the earth ground studs on the HCPDAP backplane see drawing on next page Recommended For improved surface contact remove the paint from the HCPDAP chassis that surrounds the earth ground studs Use appropriate paint removing tools such as a wire brush or a Dremel tool 4 Clean the contact areas of the compression lugs and the mating surface of the HCPDAP chassis Use a coarse non metallic cleaning pad 5 Secure the compression lug to the grounding studs with the 1 4 20 HEX nuts provided Torque the nuts to 25 in Ib 2 84 Nem with a 7 16 inch 12 mm socket NOTE If required by the operating company s installation procedures use anti oxidant compound between the cable compression lugs and the corresponding grounding surfaces such as the cha
31. re applicable Also follow the guidelines below when installing circuit breakers in the High Current Power Distribution Alarm Panel HCPDAP These practices prevent injury to personnel ensure proper distribution panel operation and prevent damage to the distribution panel and connected equipment Install all output cabling and verify output cable polarities before permanently activating breakers Always select a properly rated breaker for the circuit Refer to your job specifications for maximum output load ratings and corresponding circuit breaker ratings or see 5 3 Calculating Circuit Breaker Ratings on Page 20 The maximum rated load current for each circuit breaker position must not exceed 100 amps The combined current for each output branch circuit total A output or total B output must not exceed 200 amps per side Keep cover plates over all vacant breaker positions at all times during installation Review the HCPDAP s power requirements and corresponding cable gauges any time the you add or remove equipment from the panel This practice confirms proper breaker ratings for the modified circuits and it ensures that the panel load capacity is not exceeded Read the installation guide provided with the circuit breaker When using high current breakers try to leave at least one empty breaker position between breakers 5 2 HCPDAP Circuit Breaker Capacity The HCPDAP maximum circuit breaker capacity is 200 amps per side A and
32. re at max load ratings 10 C 14 F Ambient operating temp at half load 60 C 140 F Max surface temperature of breakers at 26 C 79 F ambient 37 C 99 F Max panel heat dissipation at full load 20W per side at 9600W 200A x 48V per side Percentage of full load heat dissipation Less than 0 596 Telect Inc All Rights Reserved 117926 5 AO 1 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 1 3 Mechanical Specifications Dimensions with brackets 19 00 in 48 26 cm 4 97 in 12 63 cm 7 99 in 20 31 cm Weight without breakers 19 065 Ib 8 648 kg Weight shipping 22 lb 10 kg Mounting capability 19 inch 48 26 cm ETSI brackets sold separately 23 inch 58 42 cm Ground terminals Input terminals Output terminals Alarm terminals Quantity Stud size Nut Socket size Cable Lugs Size Center to center Maximum torque Quantity Stud size Nut Socket size Cable Lugs Size Center to center Maximum torque Quantity Stud size Nut Socket size Cable Lugs Size Center to center Maximum torque Quantity Stud size Cable Kits sold separately See Accessories on page 30 2 1 4 inch 1 4 20 HEX 7 16 inch 12 mm Up to 1 AWG depending on size of input interruption device 2 hole compression lug Same as cable up to 1 AWG 5 8
33. s 23 5 8 Labeling the Distribution Panel 35 tices fassent eue E EA EEEN EERENS 24 5 9 Powering the Load Equipment ettet eot ete REP ntu PEE x Ru nda 24 Telect Inc All Rights Reserved 117926 5 AO ii 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 6 Operation E ae 25 6 1 Alarm Conditions and Reponses ssssssssssesseseeeeneeeee neret nnne nnne nns 25 6 2 Replacing the Alarm Card issues 25 6 3 Resetting Breakers siennes 26 6 4 Replacing Circuit Breakers sis iioii neue ote erede duci n pa De cud Re mie 26 6 4 1 Power Considerations re 26 6 4 2 Circuit Breaker Replacement Guidelines 26 6 5 Replacing Breakers orte utere aede nto a ate RR amas ARUM neu Epp RUE one RE Rude 26 T c r ERN 29 721 Owner MAINTENANCE dose tator dents casiers one Dre bee acier en ne cri in inc 29 7 2 In Warranty SEFVICO 22 gados erroe E bu Un na paa s en eur areas Dar aa odd ud asp sn 29 7 3 Out of Warranty Service iii 29 7 4 Repacking for Shipment iii 29 8 ACCEOSS TIOS m M 30 List of Figures Figure 1 Attributes and Dimensions 3 Figure 2 Schematics aiaa aa a a aaa i aia iaia 4 Figure 3 Mounting brackK t ssu ect teccceesssneunectasecenndeiasescoceassesruneedeetacumedianesaceueenesens 8 Figure 4 Rack mounting bracket waie ccccceesecedccces dues dues daneeesnrappens ddaR nada dE ni
34. s just beyond finger tightness v 7 f desired test the alarm card according to the alarm testing procedures in sections 5 6 Testing the Breaker Alarm Relays on Page 21 and Captive screws Asi 62 4 8 Testing the Input Power Alarm Relays on Page 15 Telect alarm cards are factory tested Replacement testing may not be advisable if it effects office system service Telect Inc All Rights Reserved 117926 5 AO 1 509 926 6000 telect com 25 Alarm card connector Alarm card Figure 17 Alarm card Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 6 3 Resetting Breakers Breakers are designed for a long service life If a breaker trips to the OFF position do the following 1 Troubleshoot and correct the problem that caused the breaker to trip If necessary remove and replace any equipment or equipment cards 2 Resetthe breaker by switching it to the ON position 6 4 Replacing Circuit Breakers 6 4 1 Power Considerations Review the following points before installing or replacing circuit breakers into the HCPDAP The panel s input current is limited to 200 amps per side Input A and Input B or 400 amps total The panel s total output current per side Output A or Output B is limited to 200 amps Each of the panel s twelve circuit breaker positions allow a maximum breaker rating of 100 amps 6 4 2 Circuit Breaker Replacement Guidelines Alw
35. ssis equipment rack ground relay rack or ground bus 6 Attach the ground cable s to the ground relay rack or ground bus according to the operating company s installation procedures 4 5 Connecting Input Power Cables Input power cables connect the HCPDAP to the BDFB The cables must support 12596 of the rated continuous load current of the equipment powered by the HCPDAP breakers up to 200 amps per side Before connecting input power cables shut down BDFB Power to the circuits feeding the HCPDAP Remove or lock out the BDFB circuit breakers or verify that the BDFB fuse positions are open 1 Construct BATT and RTN cables for both A and B input power circuits Use properly rated cables and two hole compression lugs Insulate the lug barrels with UL 94V 0 rated heat shrink tubing For assistance refer to the operating company s installation procedures or see Telect 117995 Wire Sizing and Labels Telect Inc All Rights Reserved 117926 5 AO 12 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 2 Locate the two input power terminals Input A and INPUT POWER HOOKUP Input B on the HCDPAP backplane Remove the black plastic terminal covers Input power terminal block 3 Clean the contact areas of the compression lugs and the input power terminal Use a coarse non metallic cleaning pad Heat shrink BATT tubing RTN 1 Note Clean all contact surfaces
36. t rack Then mount the distribution panel to the equipment rack with the four mounting screws and star washers Torque the screws to 35 in lb 4 29 Nem Label the front and the rear of the panel according to the labeling conventions specified in Telect 117995 Wire Sizing and Labels See the illustration on the following page for rack mounting procedure Telect Inc All Rights Reserved 117926 5 AO 7 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 Distribution Panel Flush Position E Mounting Bracket e Offset 7 S Position af i 7 10 screw 116903 25 in lbs 2 83 N m SN SM Figure 3 Mounting bracket Equipment Rack Torque Panhead screws and star washers to 35 in Ibs 4 29 N m j T8 ets Figure 4 Rack mounting bracket Telect Inc All Rights Reserved 117926 5 AO 8 1 509 926 6000 telect com Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 4 Connecting Cables 4 1 Cabling Guidelines NOTE Cables and hook up wires must conform to your operating company s installation guidelines as well as national regional and local electrical codes Follow these guidelines when building cables Account for the worst case situation of your application when selecting materials for cable and hook up wire installations Use properly rated cables and compressio
37. unting screw Pull or gently pry the breaker from the panel Install a cover plate over the vacancy during servicing NOTE If you are permanently removing a breaker always install a cover plate over the vacant breaker position and secure the cover plate with a mounting screw 7T Inspect the replacement breaker Verify that it is of the correct physical type size and rating for the panel position Look for abnormalities and for proper alarm contact pin alignment Remove any oxidation and debris from the contact surfaces Screw the breaker cover plate to the circuit breaker Make sure the breaker is in the OFF position 10 Align the breaker to the slot in the panel and firmly push it into position as shown 11 Secure the breaker to the front of the panel with the mounting screw 12 Switch the breaker to the ON position 13 Verify that power is reaching the output equipment and that the breaker does not trip immediately 14 Record the breaker replacement in the appropriate log Telect Inc All Rights Reserved 117926 5 AO 1 509 926 6000 telect com 27 Circuit breaker Mounting Breaker cover plate screw Figure 18 Installing the Circuit Breaker Telect High Current Power Distribution Alarm Panel Power 009 6212 2100 This page is left blank intentionally Telect Inc All Rights Reserved 117926 5 AO 28 1 509 926 6000 telect com Telect High Current Pow
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