High Current Power Distribution Unit Installation Guide

High Current Power Distribution Unit Installation Guide
High Current Power Distribution Unit
Installation Guide
This manual covers the following part numbersTrimm 767xxxxxxx Family
Table of Contents
Section 1- General Information ..................................................................................................................... 2
1.1 - Product Description ........................................................................................................................... 3
1.2 - Inspection .......................................................................................................................................... 3
1.3 - What’s Included ................................................................................................................................. 3
Section 2 – Before You Begin ....................................................................................................................... 3
2.1 - Tools Required For Installation ......................................................................................................... 3
2.2 - Input Bus Amperage Rating .............................................................................................................. 4
2.3 - Fuse Sizing Information .................................................................................................................... 4
2.4 – Fuse/Circuit Breaker Replacement Information ............................................................................... 4
2.5 - Wiring Temperature Information ....................................................................................................... 4
2.6 - General Notes on Terminal Connections .......................................................................................... 4
2.7 - Terminal Information ......................................................................................................................... 4
Section 3 – Rack Mounting ........................................................................................................................... 5
3.1 - Rack Mounting .................................................................................................................................. 5
3.2 - Additional Rack Mounting Instructions .............................................................................................. 5
Section 4 – Input and Grounding Cabling ..................................................................................................... 5
4.1 - Chassis Grounding (Earthing) ........................................................................................................... 5
4.2 - Input Wiring (Battery Connection) ..................................................................................................... 5
4.3 - Input Wiring (Return Connection)...................................................................................................... 5
4.4 - Power Verification Test ..................................................................................................................... 5
4.5 - Smart Meter Module .......................................................................................................................... 6
Section 5 – Output and Alarm Cabling.......................................................................................................... 6
5.1 - Output Wiring .................................................................................................................................... 6
5.2 - Output Wiring (GMT Modules Barrier Strip Type) ............................................................................. 6
5.3 - Output Wiring (GMT Modules Set Screw Type) ................................................................................ 6
5.4 - Alarm Wiring ...................................................................................................................................... 6
5.5 - Plastic Rear Safety Cover Installation ............................................................................................... 6
Section 6 – Final Installation ......................................................................................................................... 6
6.1 - Fuse Installation ................................................................................................................................ 7
6.2 - Energizing the Panel ......................................................................................................................... 7
Section 7 – Accessories ................................................................................................................................ 7
Section 1- General Information
Copyright © Trimm, Inc. All rights reserved.
INS-767xxxxxxx Rev C. 03/31/09 High Current Power Distribution Installation Instructions
2
1.1 - Product Description
Trimm, Inc.’s High Current DC power distribution unit offers a modular design for those needing fused
protection from .18 Amps to 250 Amps per position (600 Amps maximum per bus). This unique flexible
design accepts many standard telecommunication fuse types as well as single and dual pole circuit
breakers. With its modular design it’s easy to add more modules in the field as the need arises. This unit
is available in a compact 2U or 4U rack space configuration. Power and alarm status are displayed locally
with relay contacts for remote fuse fail and power failure indication. An optional meter module allows
voltage, current and remote temperature readings to be displayed locally as well as acting as an SNMP
agent to send failure traps and respond to manager request strings. Voltage, current and temperature
readings are also viewable via an integrated web server as a web page. This product is suitable for use in
central office locations, network telecommunication facilities and data centers.
1.2 - Inspection
Inspect the panel for any noticeable defects, missing parts (See “What’s Included” below), or shipping
damage. Please notify Trimm, Inc. if any problems are found at 1-800-298-7466. No products may be
returned to Trimm, Inc. without the proper Return Material Authorization (RMA) number.
1.3 - What’s Included
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•
•
•
•
•
This unit should be packaged with the following items. Please notify Trimm, Inc. if any of these
items are not included so a replacement can be sent out right away.
High current panel (verify part number from sticker on right side of unit.)
4 x #12-24 x ½” self-tapping mounting screws (8 for the 4U configuration)
Fasteners for input (battery and return) and output connections (equipment return bus hardware
not included)
1/4” bolt and washer kit (For chassis ground connection.)
Installation instruction packet
Other items in shipping box may include
• Installed fuses/circuit breakers
• Meter module w/current sensors
• Temperature sensors
Section 2 – Before You Begin
This panel should be installed in a restricted access area by qualified service personnel only.
All connections/methods should meet all national/local electrical codes as well as company specific
methods or procedures. Failure to do so may result in damage to the equipment, and or personal injury.
A readily accessible disconnect device must be incorporated into the supply wiring for this product. This
disconnect device must be capable of interrupting the maximum available fault current determined by
analysis for your system.
2.1 - Tools Required For Installation
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•
•
•
•
•
•
•
Depending on the part number ordered the following tools are needed to install this product.
Multimeter
No. 2 Phillips head torque screw driver
Torque wrench with 9/16 socket
Suitable crimp tooling for the terminals
Cable ties or lacing cord
Writing utensil or label maker for circuit designation
Wire wrap tools (for remote alarm wiring)
Copyright © Trimm, Inc. All rights reserved.
INS-767xxxxxxx Rev C. 03/31/09 High Current Power Distribution Installation Instructions
3
2.2 - Input Bus Amperage Rating
This product was designed to be used at its input bus amperage rating of 600 Amps, fed by a 2 x 750
MCM wire and protected by a 750 Amp maximum overcurrent device. If your required circuit rating is
below that, you may size the input wire and interrupt/overcurrent device according to your needs per the
National Electrical Code NFPA 70 ampacity tables or your local/company methods and procedures. In the
event that this product and its associated wiring/overcurrent device are under the minimum rating, you
should re-label over the panel’s input bus rating to prevent accidental circuit overloading in the future.
2.3 - Fuse Sizing Information
The fuse manufacturer recommends that GMT fuses rated 8 to 15 Amps be continuously operated at no
more than 70% of their nominal current rating. All fuse types/amperages may be continuously operated
at 80% of their nominal current rating.
2.4 – Fuse/Circuit Breaker Replacement Information
The correct fuses or circuit breakers may be ordered from the table at the end of this document. See
section 7
2.5 - Wiring Temperature Information
The wiring for this product should be rated 90° C or better.
Wiring protected by GMT fuses shall be at least one size larger than the minimum required wire based on
the National Electric Code, NFPA 70 ampacity tables.
2.6 - General Notes on Terminal Connections
•
•
•
•
•
Bare conductors should be coated with appropriate antioxidant compound before crimp
connections are made.
Use appropriate shrink tubing over un-insulated terminal barrels.
Ensure that the mating surface of both the terminals and their connection point are clean and free
of paint.
Appropriate antioxidant should be applied to the mating surfaces of all connections.
Use only listed terminals and crimp tooling when making connections.
2.7 - Terminal Information
The following terminals or suitable equivalents may be used for connection to this product. Only listed
terminals and their recommended crimping tooling should be used. These recommendations are based
on the panel’s bus amperage rating.
767xxxxxxx Fam ily Suggested Field Wiring Term inals (Code w ire)
Connection
Manufacturer†
Manf. Part Number
Wire Gauge
Input
Panduit
LCDN750-38D
Output
Panduit
LCD2-14A
750 MCM
2 AWG
10/12 AWG
2 AWG
Output (GMT modules)
Panduit
PV10-6RX
Chassis Ground
Panduit
LCD2-14A
Remote Alarm
Stud Size Hole Spacing
3/8"
1/4"
#6
1/4"
1"
5/8"
Single Hole
5/8"
Max. Width
2"
.625"
.312"
1"
Wire Wrap (Non required)
† The abo ve list is o nly a suggestio n. Equivalent terminals may be used pro vided they are listed and crimped with the appro priately listed crimp to o ling.
Copyright © Trimm, Inc. All rights reserved.
INS-767xxxxxxx Rev C. 03/31/09 High Current Power Distribution Installation Instructions
4
Section 3 – Rack Mounting
3.1 - Rack Mounting
Secure the panel to the rack using the self tapping screws provided.
3.2 - Additional Rack Mounting Instructions
If installed in a closed or multi-unit rack assembly, the operating ambient
temperature of the rack environment may be greater than room ambient.
Therefore, consideration should be given to installing the equipment in an environment compatible with
the unit’s maximum operating temperature. Mounting of the equipment in the rack should be such that a
hazardous condition is not achieved due to uneven mechanical loading.
Section 4 – Input and Grounding Cabling
Before installation, verify that the input power disconnect device is turned “OFF”.
4.1 - Chassis Grounding (Earthing)
This product is suitable for use in either a Common or Isolated (CBN or IBN) Bonding Network. Crimp the
ground wire to the terminals provided. Attach the wires to the panel using the supplied bolts and lock
washers. Torque fasteners to 50 in-lbs. Attach other end of ground pigtail to the rack or other suitable
grounding location. Reliable Earthing of rack-mounted equipment should be maintained.
4.2 - Input Wiring (Battery Connection)
Crimp the battery wires to the proper terminals. Attach the battery input wires to the panel using the
supplied flat washers and bolts. Torque the fasteners to 150 in-lbs. This product is suitable for use with
either common or isolated (DC-C or DC-I) treatment of the battery return connection.
4.3 - Input Wiring (Return Connection)
This unit includes a rotating bus bar assembly which may be tilted up to 45
degrees forward or backwards to facilitate easier wire routing. Decide which
position is right for your application and adjust the bus bar if necessary by simply
loosening (but not removing) the screws securing both sides of the assembly on
the side of the panel. After the position has been set re-torque the fasteners to 3 inlbs.
Fasteners are not included for any of the return connections to this panel. The
return bus bar has teardrop shaped holes which allow #3/8 stud x 1” center-center
distance or #1/4 stud x 5/8” center-center distance lugs. Crimp the return wire to
the proper compression lug. Attach the wire to the return input bus bar. Wires may
be attached on both sides of the return bus bar unless specifications require a
dedicated connection. (Example: CO ground connection)
4.4 - Power Verification Test
This test is to verify proper function of the panel prior to the connection of loads.
Turn on the overcurrent protection/disconnect device supplying power to the A side bus. Use a multimeter
to verify that voltage and polarity are correct at the input connection. Verify that the PWR LED is
illuminated “green”. Verify that continuity is present between C and NC alarm contacts. Install a failed
Copyright © Trimm, Inc. All rights reserved.
INS-767xxxxxxx Rev C. 03/31/09 High Current Power Distribution Installation Instructions
5
fuse if possible and verify that the LED changes to “red”. With the failed fuse in place verify that continuity
is present between C and NO alarm contacts. Repeat these steps for the B side bus if applicable.
4.5 - Smart Meter Module
If the unit you are installing includes the optional Smart Meter Module, proceed to the “Smart Meter
Module Installation/Calibration Procedure” document (INS-7600210001) prior to installing the output
cabling.
Section 5 – Output and Alarm Cabling
Before continuing installation, verify that the overcurrent protection/disconnect device is turned “OFF”.
5.1 - Output Wiring
Remove the orange input cover for the position(s) you are wiring by pulling up.
Locate and remove the supplied #1/4-20 locking nuts included with this panel.
Crimp the wire to the proper compression lug. Attach the wire to the output
connection using the supplied nuts and washers. Torque the fasteners to 24 in-lbs.
Reattach the output cover for each position by pushing it down over the studs.
Label each position on the supplied circuit designation card.
5.2 - Output Wiring (GMT Modules Barrier Strip Type)
This panel accepts up to #10 AWG wire to feed into the equipment and return
connections. In tight spaces the set screw connector can be removed by simply
loosening the 2 screws securing the connector to its header. Crimp the terminals to
the wiring. Remove the screws for each position. Insert the wire onto the
corresponding position for both equipment and return connections. Torque the
screw to 7 in-lbs.
5.3 - Output Wiring (GMT Modules Set Screw Type)
This panel accepts up to #12 AWG wire to feed into the equipment and return connections. In tight
spaces the set screw connector can be removed by simply loosening the 2 screws securing the connector
to its header. Strip the wire to .375”. Loosen the screws for each position. Insert the wire into the
corresponding position for both equipment and return connections. Torque screw to 4.5 in-lbs. Label the
designation card for each circuit you install.
5.4 - Alarm Wiring
The alarm connector is standard wire wrap pins. Continuity is established at
positions C and NC when there is no fuse or power failure. Continuity is
established at positions C and NO when a fuse or power failure has occurred.
5.5 - Plastic Rear Safety Cover Installation
Reattach the rear plastic safety cover by placing it in the correct position and hand tightening the captive
thumb screws. The front cover may be left off until all fuse holders/breakers have been installed.
Section 6 – Final Installation
Circuit breakers should be installed as per the image on the right with the single
alarm terminal towards the top. Fuse holders may be installed with the alarm
terminal at the top or middle position. Failure to do so may result in damage to the
Copyright © Trimm, Inc. All rights reserved.
INS-767xxxxxxx Rev C. 03/31/09 High Current Power Distribution Installation Instructions
6
equipment, and or personal injury. Circuit breakers should always be installed in the “OFF” position. Fuse
holders should always be installed without the fuse in place.
6.1 - Fuse Installation
Orientate and install the correct fuse into its position. Record the protected equipment identification and
location on the supplied designation card.
To install circuit breakers or fuse holders remove the front cover if necessary by loosening the 4 captive
thumb screws. Orientate the fuse/circuit breaker per the above image. Ensure that the alarm terminal is
not bent before installation. Firmly press the fuse holder/circuit breaker’s bullet terminals into the
corresponding position. Ensure that the bullet contacts are fully inserted and seated on the line and load
bus bars. Replace the front cover.
To install Bussmann® TPC, TPW, or GMT fuses, simply push the fuse into the corresponding holder.
GMT fuses require the 5 position GMT module.
To install Bussmann® TPS or Littelfuse® TLS fuses, install the fuse into the
Canadian Shunt® TFD type fuse holder carrier as shown in the image to the
right. These fuses also require a GMT 18/100 A fuse for alarm signaling. Failure
to install the alarming fuse will result in a fuse failure without local or remote fuse
fail indication.
6.2 - Energizing the Panel
Once all steps have been completed above, and a final inspection of the installation has been completed,
you may energize the fuse panel by switching the corresponding interrupt device to its “ON” position.
Section 7 – Accessories
GMT FUSES
PART NUMBER
FUSE AMPERAGE
0300097000
18/100 AMP
0300097001
1/4 AMP
0300097016
3/8 AMP
0300097002
1/2 AMP
0600097065
65/100 AMP
0300097003
3/4 AMP
0300097004
1 AMP
0300097005
1-1/3 AMP
0300097006
1-1/2 AMP
0300097007
2 AMP
0300097008
3 AMP
0300097013
3-1/2 AMP
0300097012
4 AMP
0300097009
5 AMP
0300097011
7-1/2 AMP
0300097010
10 AMP
0300097014
12 AMP
0300097015
15 AMP
0300097100
DUMMY FUSE
0300097209
GMT/X FUSE COVER
Copyright © Trimm, Inc. All rights reserved.
INS-767xxxxxxx Rev C. 03/31/09 High Current Power Distribution Installation Instructions
7
767 FAMILY FUSE PANEL ACCEPTED FUSE AND CIRCUIT BREAKER TYPES
Fuses require holders listed at start of each column (order separately)
TPC FUSES
TPS FUSES
TLS FUSES
Uses TPCDS fuse holder
part num ber 0300108180
Uses TFD fuse holder part
num ber 0300108380
Uses TFD fuse holder part num ber
0300108380
PART NUMBER DESCRIPTION PART NUMBER DESCRIPTION PART NUMBER
DESCRIPTION
0300360003
3 AMP
0300350001
1 AMP
0300390001
1 AMP
0300360004
4 AMP
0300350002
2 AMP
0300390003
3 AMP
0300360005
5 AMP
0300350003
3 AMP
0300390005
5 AMP
0300360006
6 AMP
0300350005
5 AMP
0300390006
6 AMP
0300360007
7 AMP
0300350006
6 AMP
0300390010
10 AMP
0300360008
8 AMP
0300350010
10 AMP
0300390015
15 AMP
0300360010
10 AMP
0300350015
15 AMP
0300390020
20 AMP
0300360012
12 AMP
0300350020
20 AMP
0300390025
25 AMP
0300360015
15 AMP
0300350025
25 AMP
0300390030
30 AMP
0300360020
20 AMP
0300350030
30 AMP
0300390035
35 AMP
0300360025
25 AMP
0300350035
35 AMP
0300390040
40 AMP
0300360030
30 AMP
0300350040
40 AMP
0300390050
50 AMP
0300360040
40 AMP
0300350050
50 AMP
0300390060
60 AMP
0300360050
0300360060
50 AMP
60 AMP
0300350060
0300350070
60 AMP
70 AMP
0300390070
0300390080
70 AMP
80 AMP
0300360075
75 AMP
CIRCUIT BREAKERS
0300390090
90 AMP
0300360090
90 AMP
PART NUMBER DESCRIPTION
0300390100
100 AMP
0300360100
100 AMP
030017760A
5 AMP
0300390125
125 AMP
0300360125
125 AMP
030017760B
7.5 AMP
TPW FUSES (2 pole)
030017760C
10 AMP
PART NUMBER
*Uses TPWDS fuse holder
part num ber 7600108280
030017760D
15 AMP
039017770A
110 AMP
030017760E
20 AMP
039017770B
120 AMP
2 POLE CIRCUIT BREAKERS*
DESCRIPTION
030017760F
25 AMP
039017770C
130 AMP
0300380150
150 AMP
030017760G
30 AMP
039017770D
140 AMP
0300380175
175 AMP
030017760H
40 AMP
039017770E
150 AMP
50 AMP
*INCLUDES 2 P OLE A DA P TER KIT A ND 2
P OLE OUTP UT COVER
PART NUMBER DESCRIPTION
0300380200
200 AMP
030017760I
0300380225
225 AMP
030017760J
60 AMP
0300380250
250 AMP
030017760K
70 AMP
BLANK PLUG*
030017760L
80 AMP
7600161501
030017760M
90 AMP
030017760N
100 AMP
*HOLDER INCLUDES 2 P OLE
A DA P TER KIT A ND 2 P OLE
OUTP UT COVER
*BLANK PLUGS PROTECT UNFILLED POSITIONS
Copyright © Trimm, Inc. All rights reserved.
INS-767xxxxxxx Rev C. 03/31/09 High Current Power Distribution Installation Instructions
8
Revision Record
Legend :
Type
R=Revision
T=Typo
A=Addition
N=New
D=Deletion
V=Review
Revision
Date
Type
Section/Comments
A
B
C
02/17/09
02/25/09
03/31/09
N
R
R
New Document
Updated cover
Update format for compliance with GR-454-Core
Copyright © Trimm, Inc. All rights reserved.
INS-767xxxxxxx Rev C. 03/31/09 High Current Power Distribution Installation Instructions
9
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