Westell NPTFD1009 Instructions for use

030-000223 Rev F
1009-03F
October 10, 2012
_____________________________________________________________________________________
Westell
Fuse Panel
Technical Practice
NPTFD1009
4 POSITION TFD (TLS)
FEATURES
¾Compatible with -24 or -48 Vdc battery voltages (polarity insensitive).
¾4 isolated TLS fuse positions, TFD style holder, 125 Amps each (500 Amps per panel).
¾TFD fuse holder accepts TLS Fuses (up to 125 Amps) or TPS Fuses (up to 70 Amps).
¾Normal and Fuse Alarm LEDs for each fuse position indicates power or fuse failure.
¾“Form C” relay contacts to extend alarm conditions for each fuse position.
¾1/4” stud input and output blocks (1/4” studs on 5/8” centers).
¾Brackets allow for mounting in 19” or 23” racks (1 RU).
¾NEBS level 3 verified, with zone 4 earthquake.

_____________________________________________________________________________________
2
1. GENERAL DESCRIPTION
1.1. The NPTFD1009 Fuse Panel provides
fused distribution of DC power to equipment.
The panel has 4 isolated fuse positions, each
consisting of a TFD fuse holder which can
accept both TLS and TPS style fuses. Alarm
circuits are provided to indicate and extend
alarm conditions for each fuse position.
1.2. Wiring for the panel is accessible on the
rear of the panel. Power is connected via the
stud input and output blocks. Alarms are
connected via wire-wrap to the connectors on
the rear of the panel. Figure 1.2.1 shows the
connectors available on the rear of the panel.
Figure 1.2.1
1.3. Power is provided to and distributed
from the panel by using properly rated cables
equipped with standard two hole lugs (1/4”
studs on 5/8” centers). Two hole lugs must
be used for this high current fuse panel to
function properly. Power is provided to the
load side equipment through TLS or TPS
style fuses. There is one fuse position for
each input position. Each fuse position can
distribute a maximum of 125 Amps.
1.4. Alarm circuits are provided to indicate
and extend alarm conditions. Each TFD fuse
holder houses the main TLS fuse as well as a
GMT alarm indicating fuse. When the
cartridge is removed, the alarm is de-
activated. When an alarm condition is
present a red Fuse Alarm LED !will
illuminate. As well, the green Normal
Operation LED 9will extinguish to signal a
fuse alarm or input power failure and the
appropriate relay contacts will change states.
A set of dry “Form C” contacts is provided for
each fuse position to extend alarm conditions.
Each relay has a common (COM), normally
open (NO), and normally closed (NC) contact.
The local alarm LEDs are located on the front
of the panel as shown in Figure 1.4.1.
LED SYMBOL SIGNIFICANCE
GREEN 9NORMAL OPERATION
RED !BLOWN FUSE
1234
Noran TelBy !
Ì
9
125A MAX FUSE
Figure 1.4.1
1.5. The Fuse Panel is constructed from
0.050” steel and painted off-white. The panel
is shipped with mounting brackets that allow it
to be installed in both 19” and 23” wide racks,
with either 1.75” or 1” panel hole spacing
(occupies 1 RU in a 1.75” pattern rack).
2. APPLICATION
2.1. NPTFD1009 Fuse Panel is designed to
be used in the rack level distribution of DC
power. It is a rack mount panel that provides
fused DC power for 4 isolated circuits using
TLS style fuses in a TFD style fuse holder.
2.2 The NPTFD family fuse panels are
suitable for installation as part of a Common
Bonding Network (CBN) for electrically
bonding the shelf type chassis of this fuse
panel to its equipment rack (via mounting
brackets or chassis bonding studs). Note that
all power return inputs (RTNs) are electrically
isolated from each other and from the fuse
panel chassis. As well, this family of fuse
panels is suitable for restricted access
locations in Network Telecommunications
Facilities, and OSP.

_____________________________________________________________________________________
3
3. CIRCUIT DESCRIPTION
3.1. Power is connected to the fuse panel
through the ¼” stud input blocks. There is
one set of inputs for each fuse position to be
supplied from battery (BAT IN) and return
(RTN IN) feeds. See figure 3.1.1.
RTN OUT BAT OUTBAT IN RTN IN
2
Figure 3.1.1
NOTE: The panel is designed to work with
either 24 or 48 Vdc batteries in either polarity
(+ or – battery). Please connect the supply
voltage from the power plant (that is not
connected to earth ground) to the “BAT IN”
input. Connect the side that is at ground
potential to the “RTN IN” input.
3.2. Power distribution is provided by either
TLS or TPS style fuses in the TFD style fuse
holder. The output for each fuse position is
made available through a ¼” stud output
block. See Figure 3.1.1. When distributing
power from each fuse position use the
corresponding battery (BAT OUT) and return
(RTN OUT) connections.
3.3. Alarm circuitry provides visual alarm
indicators and an alarm extension for each
fuse position. Alarm contacts are located on
the back of the panel on wire wrap terminals.
On the front of the panel, a red FUSE ALARM
LED !will indicate a fuse failure.
Otherwise, a green NORMAL OPERATION
LED 9will be lit provided there is no power
failure. Figure 1.4.1 shows the alarm LED
layout.
3.4. There is one set of dry “Form C”
contacts to extend alarms for each fuse
position. In the event of a “Fuse Alarm” or a
power failure, a connection between common
(C) and normally open (NO) is made. Under
“Normal Operation” there is a connection
between common (C) and normally closed
(NC). A 1 Amp PTC protects each of the
relay contacts.
4. INSTALLATION
Please read completely before beginning.
CAUTION:For safety reasons, all wiring
should be performed with all power sources
removed, and by a trained Installer
experienced with DC power systems.
4.1. Unpack and inspect the Fuse Panel for
possible damage incurred during shipping. If
damage is found, file a claim immediately with
the carrier, and please notify Customer
Service.
4.2. Once the panel is unpacked, verify that
there are three mounting brackets (two on the
panel one in the box). The bracket with the
vertical slot is universal and used on both 1”
and 1.75” spacing rails. There will be two
brackets with horizontal slots which will fit 1”
or 1.75” spacing. All three brackets are
universal for 19” and 23” rack spacing and
can be installed with a flush mounting or 5”
offset. See Figure 4.2.1 for the bracket
mounting configurations. Adjust the position
and orientation of the brackets such it will fit
properly in your application. The brackets
should be attached to the chassis using
screws with external tooth lock washers.

_____________________________________________________________________________________
4
Mounting Options
Figure 4.2.1
4.3. Mount the fuse panel in the required
position on the equipment rack using #12-24
thread forming rack mounting screws with
external tooth lock washers that are provided
with the panel.
WARNING: For safety reasons all wiring
should be done with power source removed.
4.4. Remove the distribution fuse or breaker
feeding the input cables that are to be
connected to the new panel. Note this panel
can handle a maximum of 125 Amps per
input. Please do not fuse/breaker the input
cables at more than 150 Amps each. Using
input cables specified by the Job Engineer,
hook up the battery input cables to the input
blocks on the back of the fuse panel (“BAT
IN” & “RTN IN” for each input). Each input
terminal uses a two hole compression lug
(1/4” on 5/8” centers, torque to 3 ft-lbs). See
Figure 4.5.1.
4.5. Battery outputs (“BAT OUT” & “RTN
OUT”) for each fuse position are also
accessible through ¼” stud terminal blocks at
the rear of the panel. Each fuse position is
numbered on the face plate and that circuits
output is available at the back of the panel
with the same number. Note that each return
is isolated from the chassis frame and
isolated from all other returns. See Figure
3.1.1.
Note: For this high current panel, a two hole
lug must be used on all stud blocks (input and
output, battery and return) for the fuse panel
to function properly.
4.6. Each fuse position has a common (C),
normally open (NO) and normally closed (NC)
set of contacts for extending alarms. (See
figure 4.6.1 for the location and layout of the
alarm relay contacts). Wire wrap the alarm
connections as per your alarm systems
requirements. For example; to achieve a
“ground alarm extension”, connect a ground
supply to the common (C) contact and
connect the alarm signal wire to the normally
open (NO) contact. In an alarm state a
“ground” will be sent out from the panel.
COM
NC
NO
1234
CHASSIS
GND BAT INBAT OUT
ALARMS
Figure 4.6.1
Note: To protect the alarm wiring and
circuitry, the current will be limited through the
alarm contacts to 1A by a self-resetting over
current device (1Amp P.T.C.). See the
attached schematic (drawing 1009-10).
4.7 Chassis Grounding; for safety reasons,
the chassis should be electrically connected
to the rack ground. From step 4.3, the panel
should already be bonded to the rack via the
#12-24 thread forming rack screws and
outside tooth lock washers used to pierce the
paint (this hardware must be used to pierce
paint on the panel and the rack). In addition
to grounding via the mounting brackets, it is
recommended that the chassis be further
grounded using a separate ground bonding

_____________________________________________________________________________________
5
cable that is a minimum 6 AWG, 90C, copper
cable (green with yellow stripe insulation
recommended). Please use an appropriate
UL® listed 2 hole lug (¼” on 5/8” centers).
Fasten the lug to the provided ¼” studs at the
rear of the chassis or on the side (Figure
4.7.1 and 4.7.2), using ¼” external tooth
lockwashers and nuts, and torque to 5.5 foot-
pounds.
Figure 4.7.1
Figure 4.7.2
4.8. Power up the panel by installing a Listed
or Recognized fuse rated for at least 60Vdc,
with a trip rating of 150 Amps Max. If the
TFD cartridges are either removed or installed
with operational TLS and GMT fuses, the
panel should power up with green Normal
Operation LEDs 9for each input that has
been connected, and have no red Fuse Alarm
LEDs !illuminated.
4.9. Install fuses in each of the TFD
cartridges as required. Unless otherwise
specified, be sure to size fuses to no more
than 70% of their rating. For example, 49A
max for a 70A fuse. The TFD holders will
accept TLS (Maximum 125Amp) or TPS
(Maximum 70Amp) style fuses. Install a GMT
alarm indicating fuse into the TFD holder
(GMT-A is recommended).
4.10. If you wish to verify the alarm circuit,
you can insert a blown GMT alarm indicating
fuse into the TFD cartridge. The red Fuse
Alarm LED !for that fuse position should
light on the face plate, the Normal Operation
LED 9should extinguish, and the alarm
extensions contact should change state to
indicate an alarm condition.
4.11 Please use the provided designation
card to keep a record of which equipment is
connected to which circuit and what the fuse
rating is.

_____________________________________________________________________________________
6
5. SPECIFICATIONS
5.1 Voltage +/-24 or +/-48 Vdc
+/-22 to +/- 58Vdc Max.
5.2 Fuse size 125 Amps Max per fuse*
125 Amps Max (TLS)*
70 Amps Max (TPS)*
5.3. Current/Input 125 Amps Max.**
5.4. Current/Panel 500 Amps Max.**
5.5. Power 13 Watts per position
Dissipation (at max load)
5.6. Input Blocks Two ¼” studs on
5/8” centers
(Torque 3ft-lbs)
5.7. Output Blocks Two ¼” studs on
5/8” centers
(Torque 3ft-lbs)
5.8. Alarm Block 0.045” sq wire-wrap pins
5.9. Alarm Fuses 1 Amp Max (GMT)
(GMT18/100A referred)
5.10. Dimensions 1.75”H, 17”W, 11”D
5.11. Mounting 19” and 23” Racks
1.75” and 1” Spacing
5.12. Weight Approx 11 lbs
5.13. Operating -40 to +50 C (ambient)
Temperature (-40 to 131 F)
5.14. Color Off-White
5.15. Relay current 1Amp/58Vdc max
*We recommend that you size fuses such that they do
not run at more than 70% of their rating. Thus a 70A fuse
should not be run at more than 49 A.
**The sum of the fuse ratings must not exceed the
panels rating.
Compatible lugs for Input and Output Blocks
(2 hole compression lugs for 1/4” studs on 5/8” centers (torque 3ft-lbs)).
Cable Size T & B Burndy Panduit
#8 542040410 YA8CL2TC14 LCD8-14A
#6 54205 YA6CL2TC14 LCD6-14A
#4 54206 YA4CL2TC14 LCD4-14A
#2 54207 YA2CL2TC14 LCD2-14A
We suggest you heat shrink the barrels of the compression lugs for added safety.
NOTE: If fuse size is not specified in the
equipment manual, fuses should be selected
such that they do not run at more than 70%
of their rating. When installing fuses, the
sum of the fuses installed in the panel should
not exceed the panel’s rating (500 Amps) or
input fuse rating.

_____________________________________________________________________________________
7
6. TECHNICAL SERVICES
6.1 If technical or customer assistance is
required, contact Westell by calling or using
one of the following options:
Voice: [phone]
email: [email protected]
For additional information about Westell, visit
the Westell World Wide Web site at
http://www.Westell.com.
6.2 This equipment is identified by a
model number ie. NPTFD1009. Be sure to
have the model number and serial number
available when making inquiries about the
equipment.
7. WARRANTY & REPAIRS
7.1 Westell warrants this product to be free
of defects at the time of shipment. Westell
also warrants this product to be fully
functional for the time period specified by the
terms and conditions governing the sale of
the product. Any attempt to repair or modify
the equipment by anyone other than an
authorized Westell representative will void
the warranty.
7.2 Westell will repair or replace any
defective Westell equipment without cost
during the warranty period if the unit is
defective for any reason other than abuse,
improper use, or improper installation. To
return defective equipment, first request a
Return Material Authorization (RMA) number
from Westell by calling or emailing
(Customer Service) at the address below.
Once an RMA number is obtained, return the
defective unit (freight prepaid), along with a
brief problem description, to the address we
will provide to you when you contact us.
email: [email protected]
Voice: [phone]
Replacements will be shipped in the fastest
manner consistent with the urgency of the
situation. Westell will continue to repair or
replace faulty equipment beyond the
warranty period for a nominal charge.
Contact Westell for details.

_____________________________________________________________________________________
8
COM
NC
NO
12 34
1234
CHASSIS
GND BAT IN RTN IN RTN OUT BAT OUT
RTN OUT BAT OUTBAT IN RTN INRTN OUT BAT OUTBAT IN RTN INRTN OUT BAT OUTBAT IN RTN IN
4321
1234
ALARMS
Noran Tel
TRQ nuts to 3 ft-lbs max
Noran TelBy !
Ì
9
125A MAX FUSE

_____________________________________________________________________________________
9
Noran Tel
5 " OFFSET MOUNTING
FLUSH MOUNTING
0.2500
4.2700

_____________________________________________________________________________________
10