mass punch instructions (500 kb - pdf)

ADCP-75-003 • Issue 11 • October 2003

1271503 Rev A © 2003, ADC Telecommunications, Inc.

Broadcast and Entertainment ProductsQCP™ Mark II

Installation InstructionsContent Page

INTRODUCTION............................................................................1

Revision History.....................................................................1

Trademark Information ................................................................1

Admonishments.....................................................................2

General Safety Precautions .............................................................2

1 GENERAL INFORMATION ................................................................2

1.1 Rules of Use...................................................................3

1.2 Different Wire Sizes or Types........................................................3

1.3 Fanning Strips and Cable Routing.....................................................3

1.4 Installing Bare Wires .............................................................3

1.5 Insertion Tools .................................................................3

PROCEDURE 1: FRONT SIDE WIRE TERMINATION INSTRUCTIONS .....................................5

PROCEDURE 2: REAR SIDE WIRE TERMINATION INSTRUCTIONS ......................................8

PROCEDURE 3: REPLACING A BROKEN WIRE MODULE............................................ 10

2 CUSTOMER INFORMATION AND ASSISTANCE.................................................. 13

INTRODUCTION

These instructions provide installation and maintenance procedures for the QCP Mark II wire termination system for QCP Mark II patch bays and broadcast jackfields.

Revision History

ISSUE DATE REASON FOR CHANGE

Issue 9 02/1999 Updated to QCP Mark II, and to add replacement tips and Q115 manual insertion tool description.

Issue 10 02/2001 Non-technical update.

Issue 11 10/2003 Updated to provide additional information on how to distinguish the wire retention side from the wire cut-off side on wire modules and to clarify various technical details in Procedures 1,2, and 3.

Trademark Information

ProPatch and QCP are trademarks of ADC Telecommunications, Inc.; ADC and ICON are registered trademarks of ADC Telecommunications, Inc.


© 2003, ADC Telecommunications, Inc.

Admonishments

Important safety admonishments are used throughout this manual to warn of possible hazards to persons or equipment. An admonishment identifies a possible hazard and then explains what may happen if the hazard is not avoided. The admonishments — in the form of Dangers, Warnings, and Cautions — must be followed at all times. These warnings are flagged by use of the triangular alert icon (seen below), and are listed in descending order of severity of injury or damage and likelihood of occurrence.

Danger: Danger is used to indicate the presence of a hazard that will cause severe personal

injury, death, or substantial property damage if the hazard is not avoided.

Warning: Warning is used to indicate the presence of a hazard that can cause severe

personal injury, death, or substantial property damage if the hazard is not avoided.

Caution: Caution is used to indicate the presence of a hazard that will or can cause minor

personal injury or property damage if the hazard is not avoided.

General Safety Precautions

Listed here are all general admonishments which apply throughout procedures within these instructions.

Warning: Never install electrical equipment in a wet location or during a lightning storm. When installing or modifying equipment lines, disconnect lines at the network interface before working with uninsulated lines or terminals to prevent electrical shock.

1 GENERAL INFORMATION

These instructions provide installation and maintenance procedures for the QCP Mark II wire termination system. QCP wire termination contacts were developed for Belden 8451, 9451 or equivalent twisted pair cables and are featured on the following ADC products:

• ProPatch Mark II patchbays,

• Ultra Patch cable termination panels,

• VAMP (Video Audio Modular Patchbays),

• ICON (Integrated Cable Organizations Network).

The QCP Mark II wire module consists of a split cylinder insulation displacement contact mounted in an individual color-coded plastic insulator. Wires may be terminated on both the front and rear side of the contact. Split cylinder contacts and insulators that become worn with use may be removed and replaced. New split cylinder contacts and insulators are available as accessory items.



1.1 Rules of Use

Each side (front and rear) of a split cylinder contact, shown in Figure 1, may be used to terminate either one or two, solid or stranded, copper wires. The following size wires may be terminated:

• 22 AWG

• 24 AWG

• 26 AWG

• 0.4 mm to 0.79 mm.

18984-A

THE U-SHAPED NOTCH IS ON

THE WIRE RETENSION SIDE OF

THE SPLIT CYLINDER CONTACT

PLASTIC

INSULATOR

SPLIT CYLINDER CONTACT

(FRONT SIDE)

SPLIT CYLINDER CONTACT

(REAR SIDE)

Figure 1. QCP Mark II Split Cylinder Contact

1.2 Different Wire Sizes or Types

When terminating two wires on the same side of a split cylinder contact, both wires must be of the same type (solid or stranded) and of the same wire gauge. Wires terminated on opposite sides (front vs. rear) of the contact do not have to be the same wire gauge. If terminating a wire on a contact that was used previously, each wire must always be as large as or larger than any previously terminated wire.

1.3 Fanning Strips and Cable Routing

Route and dress all terminated wires through the fanning strips provided with the termination panel. Use the space between the insulators to route wires to each contact. Allow sufficient slack in each cable for future wiring changes before tying down cable bundle.

1.4 Installing Bare Wires

Bare wires, such as drain wires or ground wires, must be covered with PVC sleeving before being terminated. A limited quantity of PVC sleeving is supplied with each QCP termination product. Additional PVC sleeving is available as an accessory item (SLVG-1).



1.5 Insertion Tools

The QB-2 impact tool and Q115 manual tool, shown in Figure 2, are available for inserting and terminating wires on QCP split cylinder contacts. The QB-2 impact insertion tool is equipped with a removable square slotted tip assembly (either the QB-2T or the QB-2LT). The QB-2 impact tool applies force to the wire by means of a spring-loaded mechanism within the tool. The Q115 manual tool is a screwdriver-type tool with a non-removable tip. The Q115 manual tool is used to manually apply force to the wire.

QB-2T REPLACEMENT

TIP

QB-2LTREPLACEMENT

TIP

QB-2 IMPACT TOOL (CAN BE EQUIPPED WITH

EITHER QB-2T OR QB-2LT TIP)

Q115 MANUALINSERTION TOOL

NON-REMOVABLE TIP

12149-C

Figure 2. QB-2 Impact Tool with Replacement Tips and Q115 Manual Tool



PROCEDURE 1 FRONT SIDE WIRE TERMINATION INSTRUCTIONS


This procedure provides instructions for terminating wires on the front side of termination panels equipped with QCP Mark II wire modules. Because the orientation of the wire modules will vary depending on the panel type, use these procedures and illustrations as a general reference when terminating wires. All illustrations show typical examples of routing and terminating wires for panels equipped with QCP Mark II wire modules.

STEP PROCEDURE

Wire Installation

1 Trim the outer jacket of the cable to a convenient length. Tape or heat-shrink tubing may be used on the trimmed jacket if desired.

2 Install PVC (see Figure 3) sleeving over any bare wires.

3 Route the wires through the wire fanning strip that is closest to the split cylinder contacts that will be used to terminate the wires.

Note: Do not cut or strip the wire to be connected. The insertion tool and the split cylinder contact take care of these functions automatically.

4 Place each wire diagonally across the split cylinder contact (see Figure 4) and in line with the two corner slots in the color-coded insulator. Leave a convenient length of excess wire past the cutting edge of the contact.

Note: The wire retention side of the split cylinder contact has a U-shaped notch (see Figure 1) and the cut-off side of the contact has a square notch. If necessary, terminate a scrap piece of wire to verify which side of the wire is retained and which side is cut off.

5 Place the wire slot(s) of the tool tip over the wire (see Figure 5) and align the square sides of the tool tip with the square sides of the color-coded insulator.

6 Press the insertion tool against the wire until the spring-loaded mechanism (impact tool) releases to seat the wire into the cylinder slot (see Figure 6) or until the force applied to the manual tool is sufficient to seat the wire into the cylinder slot.

7 Remove the tool and the salvage end of wire from the contact. Keep the tool perpendicular to the panel during wire termination and withdrawal.

8 After the wires are terminated, secure cable to the cable tray or cable tie bar using plastic cable ties.

Wire Removal

1 To change and/or re-terminate a wire, remove wire from the fanning strip and grasp the wire by hand. Pull the wire straight out from the panel until the wire slides out of the split cylinder contact. Install the new wire as described in the installation instructions.



6890-B

SLIDE PVC SLEEVEOVER BARE WIRE

Figure 3. Install PVC Sleeving Over Bare Wire

6891-B

1 49 2 50 3 51 4 52

25 73 26 74 27 74 28 75

T

R

S

T

R

S

Figure 4. Position Wire Over Split Cylinder Contact (Front Side of Typical Panel)



1 49 2 50 3 51 4 52 5 53 6 54 7 55 8 56 9 57 10 58 11 59 12 60 13 61 14 62

T

R

S

T

R

S

6892-A

Figure 5. Place Tool Over Wire (Front Side of Typical Panel)

1 49 2 50 3 51 4 52 5 53 6 54 7 55 8 56 9 57 10 58 11 59 12 60 13 61 14 62

T

R

S

T

R

S

6893-A

Figure 6. Wire Installed and Seated in Contact (Front Side of Typical Panel)



PROCEDURE 2 REAR SIDE WIRE TERMINATION INSTRUCTIONS


This procedure provides instructions for terminating wires on the rear side of termination panels equipped with QCP Mark II wire modules. Because the orientation of the wire modules will vary depending on the panel type, use these procedures and illustrations as a general reference when terminating wires. All illustrations show typical examples of routing and terminating wires for panels equipped with QCP Mark II wire modules.

STEP PROCEDURE

Wire Installation

1 Trim the outer jacket of the cable to a convenient length. Tape or heat-shrink tubing may be used on the trimmed jacket if desired.

2 Install PVC sleeving (see Figure 3) over any bare wires.

3 Route the wires through the wire fanning strip that is closest to the split cylinder contacts that will be used to terminate the wires.

Note: Do not cut or strip the wire to be connected. The insertion tool and the split cylinder contact take care of these functions automatically.

4 Place wire diagonally across the end of the contact (see Figure 7) and in line with the two notches in the end of the split cylinder contact. Leave a convenient length of excess wire past the cutting edge of the contact.

Note: The wire retention side of the split cylinder contact has a U-shaped notch (see Figure 1) and the cut-off side of the contact has a square notch. If necessary, terminate a scrap piece of wire to verify which side of the wire is retained and which side is cut off.

5 Place the wire slot(s) of the tool tip (see Figure 8) over the wire.

6 Hold a wooden block (or similar device) against the front side of the contact to prevent the split-cylinder from being forced out of the plastic insulator when the wire is terminated.

7 Press the insertion tool against the wire until the spring-loaded mechanism (impact tool) releases to seat the wire into the cylinder slot or until the force applied to the manual tool is sufficient to seat the wire into the cylinder slot.

8 Remove tool and the salvage end of wire from the contact. Keep the tool perpendicular to the panel during wire termination and withdrawal.

9 After the wires are terminated, secure cable to the cable tray or cable tie bar using plastic cable ties.

Wire Removal

1 To change and/or re-terminate a wire, remove wire from the fanning strip and grasp the wire by hand. Pull the wire straight out from the panel until the wire slides out of the split cylinder contact. Install the new wire as described in the installation instructions.



6894-B

Figure 7. Position Wire Over Split Cylinder Contact (Rear Side of Typical Panel)

6895-B

Figure 8. Tool and Wire Aligned With Split Cylinder Contact (Rear Side of Typical Panel)



PROCEDURE 3 REPLACING A BROKEN WIRE MODULE


This procedure provides instructions for replacing a damaged or worn QCP Mark II wire module. Replacement split cylinder contacts and color-coded plastic insulators are available separately as accessory items.

STEP PROCEDURE

1 Remove each wire from both the front and rear sides of the split cylinder contact as described in Procedures 1 and 2.

2 From the rear side of the panel, place the insertion tool over the split cylinder contact (see Figure 9) and align the square sides of the tool tip with the square sides of the insulator.

3 Rap sharply on the end of the tool handle to break the insulator. Note: The force required to break the insulator with the insertion tool is

approximately twice that required for wire installation.

4 Remove all pieces of the wire module from both sides of the panel.

5 Insert the front-side end of the replacement insulator (not the metal contact) onto the end of the insertion tool.

6 From the front side of the panel, insert the replacement insulator (see Figure 10) into the insulator mounting hole.

Note: The two slots in the insulator must be oriented to match the existing insulators.

7 Carefully apply pressure to the insertion tool to force the insulator into the panel mounting hole.

8 When the insulator is fully seated, carefully withdraw the insertion tool from the insulator.

9 From the front of the panel, insert the metal split cylinder contact (see Figure 11) into the insulator as far as possible.

Note: The U-shaped and square notches in the end of the split cylinder contact must be oriented to match the existing split cylinder contacts.

10 Carefully place the tip of the insertion tool over the split cylinder contact and align the square sides of the tool tip with the square sides of the insulator.

11 Carefully apply pressure to the insertion tool until the split cylinder contact locks into position within the insulator.

12 Carefully remove the installation tool from the wire module. Keep the tool perpendicular to the panel as it is withdrawn.

13 Reinstall the wires (removed in step 1) on the new wire module as described in Procedures 1 and 2.



6896-A

Figure 9. Placement of Insertion Tool for Module Removal (Rear Side of Typical Panel)

6897-A

1 49 2 50 3

T

R

S

T

R

S

Figure 10. Split Cylinder Contact Insulator Mounting Position (Front Side of Typical Panel)



6898-B

1 49 2 50 3

T

R

S

T

R

S

ORIENT THE SPLITCYLINDER CONTACT

TO MATCH THEADJACENT CONTACTS

Figure 11. Contact Metal Cylinder in Position For Installation (Front Side of Typical Panel)


2 CUSTOMER INFORMATION AND ASSISTANCE

13944-J

WRITE:

ADC TELECOMMUNICATIONS, INCPO BOX 1101,MINNEAPOLIS, MN 55440-1101, USA

ADC TELECOMMUNICATIONS (S'PORE) PTE. LTD.100 BEACH ROAD, #18-01, SHAW TOWERS.SINGAPORE 189702.

ADC EUROPEAN CUSTOMER SERVICE, INCBELGICASTRAAT 2,1930 ZAVENTEM, BELGIUM

PHONE:

EUROPESales Administration: +32-2-712-65 00Technical Assistance: +32-2-712-65 42EUROPEAN TOLL FREE NUMBERS

UK: 0800 960236Spain: 900 983291France: 0800 914032

Germany: 0180 2232923

U.S.A. OR CANADASales: 1-800-366-3891 Extension 73000Technical Assistance: 1-800-366-3891 Extension 73475ASIA/PACIFICSales Administration: +65-6294-9948Technical Assistance: +65-6393-0739ELSEWHERESales Administration: +1-952-938-8080Technical Assistance: +1-952-917-3475

PRODUCT INFORMATION AND TECHNICAL ASSISTANCE:

Contents herein are current as of the date of publication. ADC reserves the right to change the contents without prior notice.In no event shall ADC be liable for any damages resulting from loss of data, loss of use, or loss of profits and ADC furtherdisclaims any and all liability for indirect, incidental, special, consequential or other similar damages. This disclaimer ofliability applies to all products, publications and services during and after the warranty period. This publication may beverified at any time by contacting ADC's Technical Assistance Center.

[email protected]

[email protected]

[email protected]

© 2003, ADC Telecommunications, Inc.All Rights Reserved

Printed in U.S.A.

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