ABB 4CKT COMBINER 1600312215A User manual

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Power Express 2 Circuit and 4 Circuit Combiner
Quick Start Guide: 8600430826P
1600312215A 4CKT COMBINER
1600389997A 2CKT COMBINER

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Contents
Safety statement······················································································································ 3
Precautions ······························································································································· 4
Equipment Identification········································································································· 5
Information - Tools Required ·································································································· 6
Step 1 – Mount Shelf ················································································································· 6
Step 2 – Connect chassis Ground ···························································································· 6
Step 3 – Connect DC Input ······································································································· 7
Step 4– Connect DC Output ···································································································· 7
Step 5 - Connect DC Output to Ground··················································································· 8
Step 6 – Connect Alarm Cable·································································································· 8
Information: LEDs and Alarms ································································································ 9
Specifications and Applications ····························································································· 9
Change History (excludes grammar & clarifications)···························································· 10
Disclaimer ································································································································· 11
List of Figures
Figure 1 Mounting Shelf ··········································································································· 6
Figure 2 Chassis Ground Connection ····················································································· 6
Figure 3 DC Input Connection ································································································· 7
Figure 4 DC Output connection······························································································· 7
Figure 5 Alarm Connection······································································································· 8

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Safety Statements
• Do not install this equipment over combustible surfaces.
• Rules and Regulations - Follow all national and local rules and regulations when making field connections.
• Compression Connectors:
• U. S. or Canada installations - use Listed/Certified compression connectors to terminate Listed/Certified field-
wire conductors where required.
• All installations - apply the appropriate connector to the correct size conductor as specified by the connector
manufacturer, using only the connector manufacturer’s recommended or approved tooling for that connector.
• Electrical Connection Securing - Torque to the values specified on labels or in the product documentation.
• Cable Dress - dress to avoid damage to the conductors and undue stress on the connectors.
• Fuses and Circuit Breakers - Size as required by the National Electric Code (NEC) and/or local codes.
• Refer to the equipment ratings to assure current does not exceed:
• Continuous Load (List 1) - 60% of protector rating
• Maximum Load (List 2 - typically end of discharge) - 80% of protector rating.
• Field-wired Conductors - Follow all National Electric Code (NEC) and local rules and regulations .
• Insulation rating: 90°C minimum; 105°C (minimum) if internal to enclosed equipment cabinets.
• Size AC field-wired conductors with 75°C ampacity (NEC) equal to or greater than their panel board circuit breaker
rating.
• Size DC field-wired conductors with 90°C ampacity (NEC) equal to or greater than circuit breaker/fuse rating.
• AC and DC input disconnect/protection - Provide accessible devices to remove input power in an emergency.
• Alarm Signals - Provide external current limiting protection. Rating 60V, 0.5A unless otherwise noted.
• Grounding - Connect the equipment chassis directly to ground. In enclosed equipment cabinets connect to the cabinet ac
service ground bus. In huts, vaults, and central offices connect to the system bonding network.
• Circuit Breakers and Fuses - Use only those specified in the equipment ordering guide.
• GMT Style Fuses - Use only fuses provided with safety caps.

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Precautions
• Install, service, and operate equipment only by professional, skilled and qualified personnel who have the necessary
knowledge and practical experience with electrical equipment and who understand the hazards that can arise when
working on this type of equipment.
• Disconnect batteries from outputs and/or follow safety procedures while working on equipment. Batteries may be
connected in parallel with the output of the rectifiers. Turning off the rectifiers will not necessarily remove power from the
bus.
• Do not disconnect permanent bonding connections unless all power inputs are disconnected.
• Verify that equipment is properly safety earth grounded before connecting power. High leakage currents may be possible.
• Exercise care and follow all safety warnings and practices when servicing this equipment. Hazardous energy and voltages
are present in the unit and on the interface cables that can shock or cause serious injury. When equipped with ringer
modules, hazardous voltages will be present on the ringer output connectors.
• Use the following precautions in addition to proper job training and safety procedures:
• Use only properly insulated tools.
• Remove all metallic objects (key chains, glasses, rings, watches, or other jewelry).
• Follow Lock Out Tag Out (LOTO) procedures: customer specified, site specific, or general as appropriate.
Disconnect all power input before servicing the equipment. Check for multiple power inputs.
• Wear safety glasses.
• Follow Personal Protective Equipment requirements: customer specified, site specific, or general as appropriate.
• Test circuits before touching.
• Be aware of potential hazards before servicing equipment.
• Identify exposed hazardous electrical potentials on connectors, wiring, etc.
• Avoid contacting circuits when removing or replacing covers;.
• Use a personal ESD strap when accessing or removing electronic components.
• Personnel with electronic medical devices need to be aware that proximity to DC power and distribution systems,
including batteries and cables, typically found in telecommunications utility rooms, can affect medical electronic
devices, such as pacemakers. Effects decrease with distance.

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Equipment Identification
4 Circuit Combiner - ID Label information
2 Circuit Combiner - ID Label information

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Step 1 - Mount the shelf
1. Position the Combiner Shelf System mounting ears with the
mounting frame. If necessary, mounting ears can be reversed to
better align with other equipment in the frame.
2. Attach shelf to the frame using four screws on each side (two
on each side) - 12-24 (provided/Not provided).
3. Torque to 40 in-lb (4.5Nm) - 5/16” socket.
4. Provide 2 inch minimum clearance at back of shelf for converter
airflow.
Information - Tools Required
• Wire cutters and strippers • Philips Screw Driver - #0
• Cable crimpers • Flat Screw Drivers - 1/8” and 1/16”
• Torque wrench (0-40 in-lb) • Sockets - 7/16” & 5/16”
Step 2 - Connect Chassis Ground
1. Minimum 6 AWG wire is recommended.
2. Lug - double-hole 1/4” on 5/8”centers (Lugs not provided).
3. Secure lug with screws - 10-32 (provided)
4. Torque to 10-32 screws to 30 in-lb (3.4Nm) - 5/16” socket.
Some applications may rely on frame mounting screws for shelf ground omitting the need for this
shelf ground cable.
Figure 2 : Chassis Ground Connection
Chassis Ground
Figure 1 : Mounting shelf
NOTE: It is recommended that wire ferrules are used on all power and ground connections.
Slot For
Wire Dressing

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Step 3 - Connect DC Input
• Verify that the DC Input voltage is 48VDC using a meter.
• Match the marked polarity on all inputs.
Note: Incorrect Input Voltage or Polarity will cause the equipment to not operate properly.
1. Size input cables to minimize voltage drop for installation (recommended wire size is 12 AWG (2.5 mm2).
2. Strip 0.35” or 7/20” (9 mm)
3. Tighten the screw -(1/16” flat screw driver). torque to 4.5 in-oz (0.5 Nm)
4. Pull wire to verify connection.
Caution: Ensure cables do not come in contact with sharp or rough surfaces that may damage insulation and cause
a short circuit.
Screw
Wire
Entry
DC Inputs - NEC Class 2
Step 4 - Connect DC Output
• There are 2 DC terminal Outputs
1. Use appropriately sized output cable for the load being served.
2. Strip the output wire 1/2”.
3. Insert wire fully into wire entry.
4.
5. Pull wire to verify insertion.
Wire Entry
10AWG (6mm2) max
DC Output Ground
Screw
Figure 3 : DC Input Connections
Figure 4 : DC Output Connections
Note : For 2 circuit combiner there are two input connections.

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Step 5 - Connect DC Output to Ground
DC output is isolated from ground (floating). It must be connected to
• Connect Ground to an output at a single point.
This connection may be made on the output terminal block .
Note: Either DC Output polarity (Out+ or OUT-) must be externally connected to DC Reference Ground (CO
Ground).
Step 6 - Connect Alarm Cable
• Remove alarm connector from the chassis.
• Connect alarm wires.
1. Strip wire 3/16”
2. Insert wire fully into wire entry
3. Tighten screw
4. Pull wire to verify.
• Insert alarm connector into the chassis.
Warning: Shock Hazard and Equipment Damage - Equipment and subassembly ports
1. are suitable for connection to intra-building or unexposed wiring or cabling;
2. can be connected to shielded intra-building cabling grounded at both ends.
Figure 5: Alarm Connections

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Information: LEDs and Alarms
LEDs: each input and output: Green OK, RED Fault.
Alarms: Major (MAJ) indicates abnormal output.
Minor (MIN) indicates abnormal conditions not immediately affecting output.
Shelf Output Condition LEDs Circuit Condition (each) Shelf Alarm
Out In
Normal Normal None
Normal Never powered None
Normal
Blink Not powered, was previously powered MIN
Normal
Blink Circuit internal failure, powered MIN
Limited - load power exceeds shelf capability Circuit in limit mode. MAJ
Unpowered Unpowered. MAJ
Specifications and Application
• Specifications and ordering information are in the Power Express Class 2 Distribution Brochure available at
abbpowerconversion.com
• External Surge Protective Devices (SPD)
• Evaluated surge withstand - 1000V, 10/1000 µs pulse.
• Primary protection or other surge protection devices are required on each input where the transient over voltage due to
atmospheric discharge and faults in power distribution systems exceeds these levels.
• For example, external SPDs are required when the product is used with outdoor overhead wiring.
• Equipment and subassembly ports:
 are suitable for connection to intra-building or unexposed wiring or cabling;
 can be connected to shielded intra-building cabling grounded at both ends.
• Grounding / Bonding Network – Connect to an Isolated Ground Plane (Isolated Bonding Network) or an Integrated
Ground Plane (Mesh Bonding Network or Common Bonding Network).
• Installation Environment - Install in Network Telecommunication Facilities, OSP, or Restricted Access location.
• Equipment must be permanently connected.
• DC return may be either Isolated DC return (DC-I) or Common DC return (DC-C).
• Either DC Output polarity (Out+ or OUT-) must be externally connected to DC Reference Ground (CO Ground).
Reference Documents
These documents are available at abbpowerconversion.com
Document Title
850047711 Power Express Remote circuit combiner

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Version Date Description of the change
1.0 01/04/2022 Initial Release
Change History (excludes grammar & clarifications)

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We reserve the right to make technical changes or modify the
contents of this document without prior notice. With regard
to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever
for potential errors or possible lack of information in this
document.
We reserve all rights in this document and in the subject matter and
illustrations contained therein. Any reproduction, disclosure to third
parties or utilization of its contents – in whole or in parts – is
forbidden without prior written consent of ABB.
Copyright© 2021 ABB
All rights reserved
ABB
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Plano, TX USA
abbpowerconversion.com