Installing the DC Rectifier Shelf

The DC Rectifier shelf can be installed in a standard 19-in or 23-in telecommunications rack.

Note 1:  It is recommended that two people be available to install the shelf. One to hold the shelf in position while the other secures the shelf to the rack.

Note 2: If installing the DC Rectifier Shelf in a 23-in rack, a pair of mounting ear extensions are required, available separately, to the mounting brackets on either side of the shelf.

Danger: While performing the following steps, ensure that proper safety precautions are taken while working in the facility AC Power breaker panel.

Use the following procedure to install the DC Rectifier Shelf:

1. Before installing the shelf, loosen the retaining screws in the rear covers and remove the rear covers.
   
   
    

2. Remove knockouts, as required, for chassis ground and AC power cables. 
   
   
    

3. Place conduit or cord grips into the holes.
4. Route the AC input cords and a chassis ground lead through the conduit or cord grips into the AC input section.
5. Connect the chassis ground lead to one of the chassis grounding terminals in the AC power connection area.

   Note: The ground lead should have sufficient length to reach to the nearest rail mounting area.]

6. Before mounting the shelf, grind or otherwise remove the powder coating from one of the mounting screw holes on the rack rail, to accept the chassis ground cable.
7. Position the shelf in the rack leaving a gap of at least 0.75-inches above and below the shelf for proper airflow.
8. Insert four #12-24 screws in the mounting ears of the shelf and secure the mounting screws. Place the ground cable(s) under the screw prepared inStep 6. Torque the mounting screws to 25 in-lbs (2.5 n-m).
9. Route the AC power input cable(s) through the conduit or cable grip(s) installed inStep 2.

110VAC Connections

1. Make the ground connections by loosening the grounding terminal sufficiently to allow insertion of the ground lead. Then tighten the terminal.
   
   
    
2. Connect each line/hot to Line 1 (L1), rectifier 1 (R1), labeled on the AC terminal block.
3. Connect the neutral to the slot labeled Line 2/N (L2), rectifier 1 (R1).
3. Repeat for each remaining rectifier.

220VAC Connections

1. Make the ground connections by loosening the grounding terminal sufficiently to allow insertion of the ground lead. Then tighten the terminal.
   
   
    
2. Connect the line/hot to Line 1 (L1), rectifier 1 (R1), labeled on the AC terminal block.
3. Connect the second line/hot to the slot labeled Line 2/N (L2), rectifier 1 (R1).
4. Repeat the procedure for each remaining rectifier.

DC Connections

Warning: It is very important to verify polarity of all shelf connections before connecting equipment to the shelf. A wrong connection can cause the system to not work properly, can damage the shelf, and may cause bodily harm. For continued protection against fire, replace fuses with another of the same type and rating. Indicating fuses have exposed live parts. Use caution when replacing or servicing indicator fuses.

Note: Use the distribution label card, located on the door of the distribution section, to check fuse and breaker locations.

1. Assemble a DC reference ground lead using #14 AWG wire and 2-hole lugs.
2. Connect the DC Reference ground lead to the DC Reference Ground terminals in the DC connection area.

   Note: The ground lead should have sufficient length to reach to the nearest rail mounting area.

3. Grind or otherwise remove the powder coating from two mounting holes on the rack rail, to accept the DC Reference Ground cable.
4. Route circuit breaker cables through the cable openings located on the left, as viewed from the rear, of the shelf.

   Note: Routing the cables in any other manner may harm personnel or the system.

5. For load circuit breakers and return connections, connect lugs to the double 1/4"-20 studs with 5/8" centers, accessible from the rear. The circuit breakers can be found behind the distribution door on the right side of the shelf when viewing it from the front. Torque the nuts to 65 in-lbs (7.5 n-m).

   Total Installed Output Capacity (Amps)	Wire Size (AWG) Using 90ºC Wire (per NEC Table 310.16)
   	AWG	mm2
   20	14	2.5
   30	12	4.0
   40	10	6.0
   50	8	10.0
   75	6	16.0
   90	4	25.0
   125	2	35.0

6. For GMT output and return connections, connect ring terminals onto the #6-32 screws on the GMT terminal strips accessible from the rear. Select the wire and ring terminal size according to the following table. Torque the terminal screws to 22 in-lbs (3 n-m). GMT cables should be routed straight down through the cable holes just below the GMT terminal block. Install fuses into appropriate slots in the GMT fuse block. 
    

   GMT Fuse Rating	Wire and Lug Gauge (AWG) Using 90ºC Wire (per NEC Table 310.16)
   Amps	AWG	mm2
   1	24	0.25
   2	24	0.25
   5	24	0.25
   7.5	22	0.5
   10	20	0.75
   15	18	1.0

7. Install bullet-nose style circuit breakers into the breaker connection points in the distribution panel. Install breakers with the "Line" bullet connector on the left and the "Load" bullet connector on the right (refer to the labeling on the breaker for Line and Load bullets). Alarm contacts, on the circuit breakers, should short-circuit between NC (normally closed) and C (common) connections in a tripped state.