Amphenol Telect nrgSMART nrgBDFB-XLW User manual

nrgBDFB-XLW
Installation Guide

2
Amphenol Telect
All rights reserved. 149379-1 A0 07.09.18
1-509-926-6000 — www.telect.com
BDFB-XLW
Installation Guide, Part Number 149379-1 A0
Copyright 2018, Amphenol Telect. All rights reserved.
Telect and Connecting the Future are registered trademarks of Telect, Inc.
22425 East Appleway Ave. # 11
Liberty Lake, WA 99019
Amphenol Telect assumes no liability from the application or use of these products. Neither does Amphenol
Telect convey any license under its patent rights nor the patent rights of others. This document and the products
described herein are subject to change without notice.
Connecting the future for over 30 years
Amphenol Telect looks beyond what's possible in network connectivity and power management. We design and
manufacture products that link fiber optic networks together and protect our customers' investments. We are
driven by the principles of innovation and customer service.
Based in Liberty Lake, WA, Amphenol Telect supports a global network of customers with a comprehensive
product portfolio and values-driven corporate culture. Our products and solutions are found across
communications service networks, data centers, and enterprise and utility networks.
We belong to Amphenol Corporation, one of the world’s largest manufacturers of interconnect products.
Technical Support
Email: [e-mail]
Phone: [phone]

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BDFB-XLW
Table of Contents
Section One: Overview........................................................................................................................................5
1.1 nrgSMART™ ........................................................................................................................................5
1.2 BDFB-XLW Overview...........................................................................................................................5
1.3 Terminology..........................................................................................................................................6
1.4 Specification .........................................................................................................................................7
1.5 Controller Specifications.......................................................................................................................9
1.6 Configuration Options...........................................................................................................................9
1.7 Order Configurations............................................................................................................................9
Section Two: Installation....................................................................................................................................10
2.1 Important Installation Guidelines........................................................................................................11
2.2 Top or Bottom Feeds..........................................................................................................................12
2.2.1 Recommended Feed Cable Routing (750 kcmil cables shown).................................................13
2.3 Number of Panels...............................................................................................................................14
2.3.1 Bottom Feed ...............................................................................................................................14
2.3.2 Top Feed.....................................................................................................................................15
2.4 Panel Bus Bar Options.......................................................................................................................16
Section Three: Frame Installation......................................................................................................................18
3.1 Installation Consideration...................................................................................................................18
3.1.1 Location & Space........................................................................................................................18
3.2 Concrete Floor (DR-ANCS Anchor Kit)..............................................................................................18
3.2.1 Concrete Floor Mounting............................................................................................................19
3.3 Raised Floor (DR-ANCRF Anchor Kit) ...............................................................................................20
3.4 Grounding...........................................................................................................................................21
3.4.1 Grounding Locations...................................................................................................................21
3.4.2 Internal or External Return Bus ..................................................................................................21
3.5 Installation Steps................................................................................................................................22
3.5.1 nrgBDFB-RTNX Option ..............................................................................................................22
3.6 Installing the nrgBT Sensors ..............................................................................................................24
3.7 nrgBDP Power Connections...............................................................................................................25
3.8 nrgBDP Bridging Options ...................................................................................................................28
3.8.1 Without Bridge Feed...................................................................................................................28
3.8.2 With Bridge Feed........................................................................................................................28
3.9 Built-in Controller................................................................................................................................29
3.10 Example of Connections to LAN Port and Daisy Chain Configurations...........................................30
3.11 nrgCONTROL nrgNET Connectivity.................................................................................................31
3.11.1 nrgCONTROL Connectivity ......................................................................................................31
Section Four: Related nrgBDFB-XLW Products................................................................................................33
4.1 Related Products................................................................................................................................33
4.2 Circuit Breakers and Fuses................................................................................................................34
4.3 Compression Lugs..............................................................................................................................35
4.4 Maintenance.......................................................................................................................................36
4.5 Service................................................................................................................................................36

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BDFB-XLW
4.6 Warranty Information..........................................................................................................................36
4.6.1 In-Warranty Service....................................................................................................................36
4.6.2 Out-of-Warranty Service.............................................................................................................36
4.7 Repacking for Shipment.....................................................................................................................36
4.8 Notices................................................................................................................................................37
List of Figures
Fig. 2-1: nrgBDFB-XL top and bottom feeds.....................................................................................................12
Fig. 2-2: Feed cable routing...............................................................................................................................13
Fig. 2-3: Bottom feeds .......................................................................................................................................14
Fig. 2-4: Top feeds.............................................................................................................................................15
Fig. 2-5: Bridging examples...............................................................................................................................16
Fig. 2-6: Bridging examples...............................................................................................................................17
Fig. 3-1: DR-ANCS anchor kit ...........................................................................................................................18
Fig. 3-2: Isolation pad (nrgBDFB-XL-ISO).........................................................................................................19
Fig. 3-3: DR-ANCRF anchor kit.........................................................................................................................20
Fig. 3-4: Grounding and daisy chain locations ..................................................................................................21
Fig. 3-5: nrgBDFB-RTNX position on frame......................................................................................................22
Fig. 3-6: Attaching the nrgBDFB-RTNX.............................................................................................................22
Fig. 3-7: nrgBDFB-RTNX installed ....................................................................................................................23
Fig. 3-8: nrgBDP Panel input feed connections ................................................................................................24
Fig. 3-9: Inserting and extracting the nrgBT sensor ..........................................................................................24
Fig. 3-10: Output GMT fuse...............................................................................................................................25
Fig. 3-11: Rear view of BDP panel....................................................................................................................25
Fig. 3-12: Connecting nrgBDP panels...............................................................................................................26
Fig. 3-13: nrgSMART alarm card.......................................................................................................................26
Fig. 3-14: Equipment output connections..........................................................................................................27
Fig. 3-15: Bridging options without a bridge feed..............................................................................................28
Fig. 3-16: Bridging options with a bridge feed...................................................................................................28
Fig. 3-17: nrgSMART controller.........................................................................................................................29
Fig. 3-18: Configuration diagram.......................................................................................................................30
Fig. 3-19: LAN connection.................................................................................................................................32

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BDFB-XLW
Section One: Overview
1.1 nrgSMART™
nrgSMART describes the family of distributed network monitoring and management products, from BDFBs to
high-current and low-current secondary panels. nrgSMART allows you to collect performance data on distributed
assets and tools to help you efficiently access business critical and actionable information.
Amphenol Telect recognizes the industry need to manage distributed assets more efficiently, get better power
performance out of deployed assets, as well as pursue realistic and achievable alternative energy goals. Through
nrgSMART, access to data at the equipment level provides the foundation for managing performance of a
distributed DC power distribution system.
•Individual circuit monitoring: Measure power at the circuit level. This enables powerful trend analysis
and insights into equipment performance and enables preventative maintenance processes.
−High accuracy, 100% passive monitoring, modular sensor modules with no calibration required
•Collect feed voltage, circuit current and temperature
•Network data collection: Intelligent interpretation of the collected data, based on equipment data
signature (smart alarms), drives relevant business decisions. The built-in controller uses an SNMP or
Modbus TCP/IP interface to send data to a customer’s network management system. An additional 22
rack mounted nrgSMART panels, for a total of 30 panels per controller, can be connected to this
controller for monitoring.
1.2 BDFB-XLW Overview
The Amphenol Telect nrgBDFB-XLW 1000A Battery Distribution Fuse Bay includes up to eight panels per bay
with each panel supporting a single feed with a maximum input rating of 1000A. Each panel contains 20 circuit
positions for either bullet-style breakers or TFD fuse holders and features -48V operating voltage to fit in legacy
and next-generation network applications with advanced circuit-level monitoring.
The nrgBDFB-XLW provides total front access to fuses and LED status.
All terminals for outputs, ground and alarms are on the rear of the panel. Input terminals are located on the front
interior side of the panel, accessible via the front door.
•Inputs are studs for dual-hole lugs
•Ground terminals are studs for dual-hole lugs
•Output studs are for dual-hole lugs
•Power/fuse alarm terminals are wire wrap pins.
The bullet terminals can accept either TFD fuse holders or bullet-style circuit breakers. Single pole, double pole
and triple pole breakers are also supported.

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1.3 Terminology
The following is a list of acronyms and abbreviations used throughout this manual.
Acronym/Abbreviation
Term
A
Amperage
AWG
American wire gauge
BATT
Battery
BDFB
Battery distribution fuse bay
DC
Direct current
GND
Ground
IP
Internet protocol
KCmil
Thousand circular mil
Kg
Kilogram
LAN
Local area network
Lbs
Pounds
LCD
Liquid crystal display
LED
Light-emitting diode
mA
Milliampere
mm
Millimeters
MCM
Million cubic metre
OSP
Outside plant
PC
Personal computer
RMA
Return material authorization
RTN
Return
SNMP
Simple network management protocol
TFD
Telecom fuse disconnect
TUV
Technical Inspection Association
UL
Underwriters Laboratories
V
Voltage
VAC
Voltage alternating current
VDC
Voltage direct current
W
Watt

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BDFB-XLW
1.4 Specification
Panels
Number of panels per BDFB
1 – 8
Number of circuit positions per panel
20
Feeds
Each panel is a single feed
Panel Inputs
Voltage range, nominal voltage
-40V to -60V (nominal -48 VDC)
Max. input load rating per panel
1,000A (continuous)
Short circuit withstand rating
5,000A
Nominal power loss at full load
Less than 140W per panel @ 54,000W full load per panel (1000A x 54V)
nrgNET bus rating
7A
Percentage of full power dissipation at
nominal voltage
Less than 1%
Input terminal studs (with nuts, flat washers
and spring washers) for dual-hole
compression lugs
•Two pair of 3/
8
-16 studs on 1-inch centers per terminal [max. lug width of
1.79" (49.2 mm)] per pair
•Torque nut (using 9/16-inch or 15 mm wrench) to 150 in/lb.
(~17 N•m), max.
Input wire size
#1 AWG to 750 MCM
Listed upstream protection required
1,250A max.
Dual-Hole Outputs
Max. output single-pole, long-delay circuit
breaker (ea.)
100A (80A continuous load)
Max. output TPS or TLS
125A (100A continuous load)
Minimum short circuit interrupt rating
5,000A
Output terminal studs (with KEPS, nuts and
washers) for dual-hole compression lugs
•1/
4
-20 studs on 5/
8
-inch centers [max. lug width of 0.625" (15.8 mm)] for
a BATT terminal and 0.70" (17.7 mm) for a RTN terminal
•Torque bolts (using 7/16-inch or 12 mm wrench) to 50 in/lb.
(~5.5 N•m), max.
Output wire size
#14 AWG minimum
Dry Contact Alarms
Alarm wire size
#22 to #18 AWG
Alarm terminals
Wire wrap
Relay contact ratings
Dry Form-C contacts
(1A @ 30 VDC, 0.5A @ 60 VDC, 0.3A @ 125 VAC)
Max. alarm power rating
@ 24V: 72 mA (1.73W)
@ 48V: 174 mA (7.06W)
Voltage Sensor
Sensor accuracy
0 to -19.99V: ±0.3V
-20V to -60V: ±0.1V
Voltage measurement range
0 to -60 VDC
Feed voltage detection
0 to -19.99V: Alarm
-20V to -60V: Normal
NOTE:
•Voltage measurement may be slightly different than at input terminal blocks due to the voltage drop within the panel.
•
Sensors are factory calibrated and do not require user adjustment.

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Frame Grounding
Earth GND terminal bolts (with washers) for
dual-hole compression lugs
•Two pairs of 1/
4
-20 threaded holes on 5/
8
-inch centers
•Torque nut (using 7/16-inch or 12 mm wrench) to 50 in/lb.
(~5.5 N•m), max.
•Two pair of 3/8-16 threaded holes on 1-inch centers
•Torque nut (using 9/16-inch or 15 mm wrench) to 150 in/lb.
(~17 N•m), max.
Ground wire size
•#2 AWG recommended (for 1/
4
-20 threaded holes on 5/
8
-inch centers)
•4/0 AWG @ 1,250A over-current protection (for 3/8-16 threaded holes on
1-inch centers)
Communication
nrgNET connector from BDFB to
external panels
Removable 5-pin connector with screw down terminals
nrgNET connector functions
Two fused nrgNET outputs
Supported protocols
Proprietary nrgNET used to communicate between panels and controller
via SNMP or Modbus TCP/IP
Supported browsers
Chrome (recommended)
Firefox
Fit and Finish
Material
Cold rolled-steel (weldment frame)
Aluminum rear door and side panels
Color
White powder coat (-XLW)
Mechanical
Dimensions (W x D x H)
30" W x 32" D x 84" H
Weight
Installed: 670 lbs.
Shipping: 855 lbs.
Environmental
Operating temperature
-5° to 40°C
At 30°C, 1,000A per panel (eight panels total)
At 40°C, 800A per panel (eight panels total)
Humidity
0 to 90%, non-condensing

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BDFB-XLW
1.5 Controller Specifications
Inputs/Outputs
Connection to configuration wizard
10/100 Ethernet, RJ-45 jack
Connection to nrgSMART panels
nrgNET
Voltage range (nominal)
-20V to -57V (nominal -48 VDC)
Max. operating current
3A (80% of 4A fuse rating)
SD card capacity
4 Gigabytes
SD card type
Micro SD
Mounting
Custom BDFB door mount with LCD display
1.6 Configuration Options
1. Top or bottom feed
2. Internal or external return bus
3. Number of panels
4. Panel bus bar options
5. Accessories
1.7 Order Configurations
nrgBDFB-XLWW-pppp-yyy-z-bbb
nrgBDFB-
Description
Bottom Feed
Top Feed
pppp
Panel location
A
AB
ABC
ABCD
D
CD
BCD
ABCD
yyy
Returns
IR (Internal Return)
IRX (Internal Return with Return Extension)
ER (No Internal Return – assumes external return exists)
z
Modules
P (Pass-through – BT)
M (Monitoring – nrgBT)
U (Unpopulated – no module)
bbb
Optional
Internal panel bridging
NOTE: If selected, bridging applies to
both battery and return inputs
ABC
AB
BC
C
AC

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Section Two: Installation
Please read these instructions carefully before installation. If you need assistance, call Amphenol Telect at
1-509-926-6000 or email us at [e-mail]. These instructions presume you have verified the Amphenol
Telect equipment being installed is compatible with the rest of the system, including power, circuit protection,
signal characteristics, equipment from other vendors, and local codes or ordinances.
Inspect equipment after unpacking and compare it to the packaging list. Amphenol Telect is not liable for
shipping damage. Immediately report any shipping damage, defects or missing parts to Amphenol Telect. Keep
all documentation that comes with your shipment. Contact Amphenol Telect Quality at [e-mail].
Amphenol Telect is not responsible for any equipment damage or poor operating performance when these
guidelines are not followed or when non-certified installers are used. Please contact Amphenol Telect Quality at
qualit[email protected]om.
Keep the container until you have checked equipment operation. If you experience any problem, call the
Amphenol Telect Customer Service Department at 1-509-926-6000. Use the original, undamaged container if you
are instructed to return the enclosure to Amphenol Telect.
If a shipping container is damaged, keep it for the carrier’s inspection. Notify the carrier and call the Amphenol
Telect Customer Service Department at 1-509-926-6000.
Other than this installation guide, the nrgBDFB-XLW frame ships with no other components. Optional concrete
and raised floor anchoring kits discussed in this guide are shown on pages 18 and 20.

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BDFB-XLW
2.1 Important Installation Guidelines
•Elevated Operating Ambient Temperature: If you install the rack in a closed or multi-unit rack assembly,
the operating ambient temperature of the rack environment may be greater than room ambient. Take care to
install the equipment in an environment compatible with the maximum operating temperature.
•Reduced Air Flow: Maintain the amount of air flow required for safe operation when installing the equipment
in the rack.
•Mechanical Loading: Ensure mechanical loading is even to prevent hazardous conditions.
•Circuit Overloading: Overloading circuits may affect your overcurrent protection and supply wiring. Use
equipment nameplate ratings.
•Reliable Earthing: Maintain reliable earthing of rack-mounted equipment. Pay attention to supply
connections other than direct connections to the branch circuit (e.g., use of power strips).
NOTE: The nrgBDFB-XLW is DC-I and can be grounded in both CBN and IBN networks. All eight panel feeds
have isolated returns and the chassis grounds are isolated from all returns. The nrgBDFB-XLW is suitable for
installation in network telecommunication facilities and in locations where the NEC applies.
ALERT! It is recommended that this product is 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. This product must be installed and maintained only by qualified technicians.
ALERT! Verify all connections meet requirements specified in local electric codes or operating company
guidelines before supplying power. Unit shall be protected by a listed circuit breaker or branch-rated fuse
sufficient to interrupt power levels specified on the preceding page.
ALERT! Only use components and crimping tools approved by agencies or certifying bodies recognized
in your country or region, such as Underwriter’s Laboratories (UL), TUV, etc.
ALERT! Field modification of this product is not recommended and will void warranty. Due to high current
used in this product, field modifications can result in hazardous conditions. Please contact Amphenol
Telect technical support prior to any field modifications.

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2.2 Top or Bottom Feeds
The nrgBDFB-XLW can be configured for either top or bottom feed installation. For bottom feed, the nrgBDFB-
XLW must be mounted using the raised floor anchor kit (DR-ANCRF). For top installation, either the raised floor
anchor kit (DR-ANCRF) or the concrete floor seismic anchor kit (DR-ANCS) can be used.
Anchor Kit
Top Feed
Bottom Feed
DR-ANCS
Yes
No
DR-ANCRF
Yes
Required
Fig. 2-1: nrgBDFB-XL top and bottom feeds

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2.2.1 Recommended Feed Cable Routing (750 kcmil cables shown)
A
B
BATT
BATT
RTN
RTN
Fig. 2-2: Feed cable routing

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2.3 Number of Panels
2.3.1 Bottom Feed
Example of panel A
– bottom feed
Example of panels A
and B – bottom feed
Example of panels A,
B, C – bottom feed
Example of panels A,
B, C, D – bottom feed
Fig. 2-3: Bottom feeds

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2.3.2 Top Feed
Example of panel
D – top feed
Example of panels C
and D – top feed
Example of B, C,
D – top feed
Example of A, B, C,
D – top feed
Fig. 2-4: Top feeds

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2.4 Panel Bus Bar Options
The nrgBDFB-XLW bus bridge (nrgBDP-IR) contains bridge bus bars for inputs and returns. Each bus bar
supports up to 1920A.
Example of ABC bridging
Example of AB bridging
Example of BC bridging
Fig. 2-5: Bridging examples

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The nrgBDFB-XLW bus bridge (nrgBDP-IR) contains bridge bus bars for inputs and returns. Each bus bar
supports up to 1920A.
Example of C bridging
Example of AC bridging
Example of A bridging
Fig. 2-6: Bridging examples

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Section Three: Frame Installation
ALERT! Only qualified technicians may install and maintain this product. Verify all connections meet
requirements specified in local electric codes or operating company guidelines.
ALERT! Only use components and crimping tools approved by agencies or certifying bodies recognized
in your country or region, such as Underwriter’s Laboratories (UL), TUV, etc.
3.1 Installation Consideration
3.1.1 Location & Space
The nrgBDFB-XLW frame requires 28" (71 cm) door clearance at the front and rear. Leave as much side
clearance for panel removal and worker access as required by your application or local regulations. If you do not
require side access, you can install the nrgBDFB-XLW frames with zero side clearance and you can leave off any
adjacent panels for side-by-side nrgBDFB-XLW frames needing cross-access.
Choose a location in compliance with your local operating company requirements.
ALERT! The nrgBDFB-XLW frame weighs approximately 650 lbs. (294 kg) when fully loaded including
breakers (160 circuits). Use the appropriate lifting equipment.
3.2 Concrete Floor (DR-ANCS Anchor Kit)
Each Amphenol Telect anchoring kit (sold
separately) contains concrete anchors, threaded
studs and fastening hardware to anchor and secure
the base of one nrgBDFB-XLW frame to a concrete
floor. Isolation pads must be ordered separately
(nrgBDFB-XL-ISO).
1. Using the isolation pad as a template, mark
the hole patterns and move the pad aside.
2. Drill a 3/4" (19 mm) diameter hole to the
appropriate depth. Use a HEPA filter shop
vacuum while drilling to prevent concrete dust
contamination of adjacent equipment.
NOTE: Anchor will be flush with the concrete
surface when installed at each of the four
anchor locations.
3. Using a HEPA filter shop vacuum, clear the
drilled holes of any debris.
4. Install the anchor using the proper setting tool
(P/N 145616). Tool should be driven into the
anchor until the tool shoulder meets the top
of the anchor.
Fig. 3-1: DR-ANCS anchor kit
Bolt
Lock washer
Flat washer
Isolating spacer
Plate
Anchor
Isolation pad
(optional)
Rack

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3.2.1 Concrete Floor Mounting
ALERT! If you drill past a reinforcing bar, you MUST use an isolation pad to isolate the nrgBDFB-XLW
frame from the rebar ground. Amphenol Telect recommends the use of isolation pads on all nrgBDFB-
XLW frame installations to protect against inadvertent rebar grounds.
1. Clear all debris from and around installed anchors.
2. Place the isolation pad over the newly installed anchors.
3. Set nrgBDFB-XLW frame in place on the isolation pad.
4. Place the plate, isolating spacer, flat washers, lock washer and bolt over each anchor location as shown in
Fig. 3-1 (DR-ANCS anchor kit).
5. Torque bolt assembly 22 ft/lbs.
Fig. 3-2: Isolation pad (nrgBDFB-XL-ISO)

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3.3 Raised Floor (DR-ANCRF Anchor Kit)
Each Amphenol Telect anchoring kit (sold separately) contains an isolation pad, concrete anchors, threaded rods
and fastening hardware to anchor and secure the base of one nrgBDFB-XLW frame to a raised floor and the
concrete below it. See “Fig. 3-2 Isolation pad” on page 19 for a view of the isolation pad.
1. Locate the isolation pad over one raised floor panel.
2. Using the isolation pad as a template, mark the hole patterns and move the pad aside.
3. Drill a 5/8" (18 mm) diameter hole at each of the four anchor locations.
4. Remove the floor panel and transfer the panel holes to the concrete.
ALERT! If you drill past a reinforcing bar, you MUST use an isolation pad to isolate the nrgBDFB-XLW
frame from the rebar ground. Amphenol Telect recommends the use of isolation pads on all nrgBDFB-
XLW frame installations to protect against inadvertent rebar grounds.
5. Drill a 5/8" (18mm) diameter hole to the appropriate depth. Use a HEPA filter shop vacuum while drilling to
prevent concrete dust contamination of adjacent equipment.
NOTE: Anchor will be flush with the concrete surface when installed at each of the four anchor locations.
6. Using a HEPA filter shop vacuum, clear the drilled holes of any debris.
7. Install the anchor using the proper setting tool (P/N 145616). Tool should be driven into the anchor until the
tool shoulder meets the top of the anchor.
8. Place the isolation pad over the newly installed anchors.
9. Set nrgBDFB-XLW frame in place on the isolation pad.
10. Place the shoulder washer, anchor plate, flat washer, lock washer and hex nut over each anchor location.
11. Torque bolt assembly to 22 ft/lbs.
1/
2
-13 Hex Nut
1/
2
Lock Washer
1/
2
Flat Washer
2 x 2 Anchor Plate
1/
2
Shoulder Washer
1/
2
-13 x 3.75 Threaded Rod
Rack Section
For Reference
Floor Section
For Reference
Universal Strut Nut
Steel “U” Struct Section
Fig. 3-3: DR-ANCRF anchor kit