DC Quick Connect Kit

(For use with NEWMAR PM/PFM and RPS Power Systems)

Models:
QCK-3
QCK-6
INSTALLATION GUIDE

I) General Information

The QCK quick connect kit simplifies parallel wiring installation of multiple Power
Modules (PM Series) with the Power Function Manager (PFM), and also facilitates “hot
change-out” of modules for repair or replacement. Note: The QCK is for use only with
systems which incorporate NEWMAR PM Series Power Modules and the NEWMAR Power
Function Manager, and is designed for relay rack or cabinet (rear access) installation.
The QCK may also be factory installed as part of an RPS Rackmount Power System.

The kit consists of a DC power wiring harness with wires which are pre-cut to proper
length and terminated with appropriately-sized ring lugs. The harness is factory tie-
wrapped into proper position for a simple and professional installation.

Model QCK-3 is used for wiring the PFM and two to three PM's; model QCK-6 is for
wiring the PFM and four to six PM's.

II) Materials List

Prior to installation, check to ensure that the following hardware items have been
included with the QCK installation kit. For any missing items please contact the
factory.

QCK-3
(1) Cable Harness/Assembly (for 3 PM units max.)
(3) Hex Head Screws, 1/4"-20
(3) Hex Nuts, 1/4"-20
(3) Flat Washers, 1/4"
(3) Splitlock Washers, 1/4"

QCK-6
(1) Cable Harness/Assembly (for 6 PM units max.)
(4) Hex Head Screws, 1/4"-20
(4) Hex Nuts, 1/4"-20
(4) Flat Washers, 1/4"
(4) Splitlock Washers, 1/4"
M-QCK
As of JAN 2002

U.S.A. HEADQUARTERS EURO WAREHOUSE

P.O. Box 1306, Newport Beach, CA 92663 Telecom Power Products Phone:+31-35-603-2494
Phone: 714-751-0488 Fax: 714-957-1621 Fax:+31-35-603-2149
E-Mail: sales@newmarpower.com www.newmartelecom.com
 III) Installation Guidelines

A) PM/PFM Rack Arrangement: In order to properly install the QCK, the Power
Modules must be installed one atop another with all PM's stacked above the PFM and
the return/ground bus bar (BBA-400, provided with PFM) installed above the topmost
PM (see Wiring Illustration).

B) AC and Battery Power: Both AC input to the Power Modules and battery input to
the PFM should be disconnected during installation. However, once the QCK is prop-
erly installed, it is not necessary to remove AC or battery power to connect or discon-
nect individual Power Modules using the keyed quick connect terminals (though the
PM must be shut off prior to removal).

C) Proper Polarity Attachment: The Power Module/Power Function Manager system

may be used in either positive or negative ground applications. Therefore, the wires
are not color coded, nor labeled (+) and (-). Instead, the wires are all black and labeled
“HOT” and “RTN/GND” where the ring lug terminals are attached.

1) PFM and Return/Ground Bus Bar

The wires which connect to the bus bar (return/ground) and PFM (hot) are bundled at
each end of the harness and those which connect to each Power Module in the system
are free and detachable in the middle of the harness.

For All installations: The multiple bundled wires labeled “RTN/GND” are ori-
ented to the top of the rack and attached to the bus bar (BBA-400) as shown in
the photo illustration. The multiple bundled wires labeled “HOT” are oriented
toward the bottom of the rack with all heavy gauge (6 AWG) wires attached to
the bus bar labeled “INPUT (POWER MODULE)” on the rear of the PFM, and the
light gauge (12 AWG) wire attached to the terminal labeled “RETURN/GND”. To
avoid accidental shorts, it is recommended that all of these wires be attached
as indicated, even if there are fewer Power Modules in the system than the QCK
can accommodate.

2) Power Modules

With the bundled ends of the QCK attached, the position of each free individual con-
nector pair will be at the proper height and length for attachment to the adjacent
Power Module.

Note: The V2 terminal of the Power Module is not used in parallel installations--no con-
nection will be made to the V2 terminal in this installation.

Harness System Voltage

Conductor -48V +24V +12V
HOT = - + +
RTN/
GND = + - -

U.S.A. HEADQUARTERS EURO WAREHOUSE

P.O. Box 1306, Newport Beach, CA 92663 Telecom Power Products Phone:+31-35-603-2494
Phone: 714-751-0488 Fax: 714-957-1621 Fax:+31-35-603-2149
E-Mail: sales@newmarpower.com www.newmartelecom.com
 For Positive Ground installations: Connect the “RTN/GND” wire to the (+) V
OUT terminal and the “HOT” wire to the (-) V OUT terminal of the Power Mod-
ule.

For Negative Ground installations: Connect the “RTN/GND” wire to the (-) V
OUT terminal and the “HOT” wire to the (+) V OUT terminal of the Power Mod-
ule.

Ensure that the keyed quick connects are securely plugged into one another after
attaching the wires. If there are fewer than three (QCK-3) or fewer than six (QCK-6)
Power Modules in the system, store the extra 10" leads labeled “HOT” and “RTN/GND”
for potential future system expansion. The conductor in the keyed plug which remains
on the harness is recessed to prevent the possibility of accidental shorting.

D) Polarity Verification Test: Before connecting the battery or applying power to the
Power Modules, perform the following test with an ohmmeter in the R X 1 resistance
measuring position:

1) Verify near-zero resistance between the the return/ground bus bar and each
RTN/GND connection on the rear of each Power Module.

2) Verify near-zero resistance between the "INPUT (POWER MODULE) HOT" bus
bar on the rear of the PFM and the "HOT" terminal on the rear of each Power
Module.

3) Measure resistance between the "INPUT (POWER MODULE) HOT" bus bar on
the rear of the PFM and the return/ground bus bar. You should read 10 ohms
or more with the ohmmeter probes connected in either direction. Caution: If
less than 10 ohms is measured, recheck all QCK wiring connections.

With the QCK properly installed, batteries may be attached and (assuming all other
aspects of installation are complete) AC applied to the PM/PFM system. Using the
QCK disconnects (and easily disconnected Status Contact wiring plugs which are
included with the PFM) there will be no need to shut down the system should an
individual Power Module need removal or replacement, or when adding another PM
(though the PM must be shut off prior to removal or installation). Note: Quick replace-
ment of Power Modules assumes installation of plug-type AC input.

U.S.A. HEADQUARTERS EURO WAREHOUSE

P.O. Box 1306, Newport Beach, CA 92663 Telecom Power Products Phone:+31-35-603-2494
Phone: 714-751-0488 Fax: 714-957-1621 Fax:+31-35-603-2149
E-Mail: sales@newmarpower.com www.newmartelecom.com
 Wiring Illustration
(Model QCK-6 Shown)

6 AWG Cable 12 AWG Cable

RTN/GND
(Return/Ground Bus)

A B C D A B C D

POWER MODULE OUTPUT

WIRING

Negative Ground Systems:

1) Connect RTN/GND wire to
Status Contact Wire (-) V OUT terminal
Color Codes: 2) Connect HOT wire to
(+) V OUT terminal
Brown: PM # 1
Red: PM # 2 Positive Ground Systems:
Orange: PM # 3 1) Connect RTN/GND wire to
Yellow: PM # 4 (+) V OUT terminal
Green: PM # 5 2) Connect HOT wire to
Blue: PM # 6 (-) V OUT terminal

Note: Status Contact

Wiring Harness is
provided with PFM A
6 AWG B
installation kit. Refer to Cable C
PFM instructions for
color coding with fewer
than six PM's installed.

PFM-400

A HOT Hardware Codes:

B
12 AWG Cable C RTN/GND A: Hex Nut, 1/4"-20
(Return/Ground) B: Lock Washer, 1/4"
C: Flat Washer, 1/4"
D: Hex Head Screw, 1/4"-20
D

U.S.A. HEADQUARTERS EURO WAREHOUSE

P.O. Box 1306, Newport Beach, CA 92663 Telecom Power Products Phone:+31-35-603-2494
Phone: 714-751-0488 Fax: 714-957-1621 Fax:+31-35-603-2149
E-Mail: sales@newmarpower.com www.newmartelecom.com