CUSTOM POWER DISTRIBUTION

Power Distribution Solutions for

• Telecom Power Systems

• Industrial Control Equipment

• Electronic Business Equipment

From standard circuit protection products to custom power
distribution centers, Carlingswitch is your source for safe,
reliable, cost effective solutions.
Carlingswitch Power Distribution Centers (PDC’s), with custom en-
closures and components, provide power distribution solutions
for telecommunication power systems, electronic business equip-
ment, and industrial control equipment.

Quality By Design
“Quality By Design” is more than just our corporate mission; it’s the basis for
all facets of our organization. Since our founding in 1920, the key advantages
that Carlingswitch has always offered are expertise in engineering, tooling,
and manufacturing.

Working closely with your product development team, Carlingswitch will tailor
power distribution, circuit protection and control solutions to meet or exceed
your requirements. With four ISO certified manufacturing locations and tech-
nical sales offices worldwide, Carlingswitch ranks among the world’s largest,
privately owned manufacturers of power distribution, circuit protection and
control products.

Using industry leading integrated CAD/CAM software and 3-D technology, our
highly skilled product development teams design and deliver functionally su-
perior, aesthetically appealing products in a most cost effective manner. Al-
though many manufacturers out-source many tooling and manufacturing func-
tions, at Carlingswitch, we maintain our own in-house tooling and manufactur-
ing facility — one of the most extensive of its kind. State of the art molding,
metal processing and tool fabrication resources, complete our total manufac-
turing process, with unsurpassed quality and efficiency.

Providing our customers with products of the best possible quality

Our ability to readily customize products, with in-house molding, stamping,
forming and welding, allows us to ensure quality throughout the manufactur-
ing process.

The expanding growth in the telecommunications, electrical business equip-

ment and industrial control markets has created more sophisticated applica-
tions which require safe, reliable power distribution products that exceed the
tough demands of today’s applications. Carlingswitch’s commitment to excel-
lence offers you that and more... Safety, Durability, Reliability and Perfor-
mance on our custom Power Distribution Centers.

To discuss your new power distribution requirements or for “value engineer-

ing” of your present system, we urge you to consult with our technical staff.
With extensive test, research and development capabilities, we’ve assisted
many customers in solving unique design and application problems with cost
effective, standard, modified or customized solutions.
Today’s Engineers realize the important role a Power Distribution Center plays in a product’s design.
Our highly-qualified Design Engineers use the latest CAD software and
systems. By working closely with you and sharing electronic CAD
files, together we’ll make the best design decisions. This partnership
ultimately shortens lead times and helps to contain costs.
A team of highly skilled assembly workers specialize in producing
Power Distribution Centers of the highest quality.
Carlingswitch processes are backed with rigorous quality assurance
procedures. Frequent in-process assembly inspection is comple-
mented by 100% end-of-process product testing, to ensure you
receive product of the highest possible quality.
At Carlingswitch, we realize the importance of your
system’s design, and we’ll work with you up front,
to ensure your Power Distribution Center (PDC)
complements and supports your overall system
design. After reviewing your environmental and
electrical specifications, agency and safety require-
ments, we’ll design the best custom PDC to meet
your needs. We’ll review the various components,
with their unique design features, and also recom-
mend an enclosure which addresses any space
constraints. In addition to being willing to tailor
solutions for your system, Carlingswitch will provide
you with a safe, reliable, cost-effective solution –
thanks in large measure to our expertise in engi-
neering, tooling and manufacturing – and backed by
our extensive testing facility. Add up all the advan-
tages that Carlingswitch offers – and you’ll see that
we truly are your partner in product design.
Contents
Power Distribution Centers . . . . . . . . . . . . . . . 2
What is a Power Distribution Center? . . . . . . 2
Design Features . . . . . . . . . . . . . . . . . . . . . . 2
Environmental & Electrical Specifications . . . 2
Agency Standards . . . . . . . . . . . . . . . . . . . . 2
PDC Components . . . . . . . . . . . . . . . . . . . . . 3
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . 4
Circuit Protection for PDCs . . . . . . . . . . . . . . . 5
SmartGuard PD-Series Breakers . . . . . . . . . . 5
Hydraulic/Magnetic Circuit Breakers
M-Series . . . . . . . . . . . . . . . . . . . . . . . . . 5
A-Series . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B-Series . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C-Series . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D-Series . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E-Series . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Circuit Protection Literature . . inside back cover
Carlingswitch Contact Information . . . back cover
To discuss a custom Power Distribution
Center (PDC) for your equipment,
please refer to the contact information
listed on the back cover of this catalog.
Our knowledgeable staff is ready to
assist you.
1
 Power Distribution Centers

What is a Power Distribution Center?

Power Distribution Center (PDC) is Carlingswitch’s term for a custom
power distribution panel or enclosure that’s factory wired and contains
overcurrent and shortcircuit circuit protection devices. It may also
contain auxiliary devices such as surge suppressors, ground fault
circuit interrupters, power receptacles, etc. A PDC is usually supplied
by the main feeder and then divides the power into smaller branch
circuits. The PDC provides the required circuit control and overcurrent
protection needed to all the circuits and power consuming loads
connected to it.
Design Features Agency Standards
• 16 gauge Cold Rolled Steel (standard) We’ve designed Power Distribution Centers
• lockable, hinged door, or main cover with to meet agency approvals and safety stan-
dards including UL, CSA, TUV, UL, IEC,
captive fasteners
NEMA, and NEC.
• custom powder coat finish
• custom locations for main and branch UL67 – ”Panelboards“ - Control and protec-
conductors tion of electric lighting, appliance branch
circuits and power circuits.
• power selector for primary and auxiliary
circuits
UL1950, IEC 950, EN60950 – ”Safety of
• safety guards for circuit breaker actua- Information Technology Equipment including
tors, preventing inadvertent switching Electrical Business Equipment” - Control and
• insulated copper bus bars protection of mains - powered or battery,
powered information technology equipment,
• bus bar safety shrouds
including electrical business equipment
• modular “back panel” circuit breaker rated 600 V or less.
mounting brackets
• front panel hole plug for future branch UL508 – ”Industrial Control Equipment”
circuit expansion including accessory devices for starting,
stopping, regulating, controlling, or protect-
ing electric motors. In addition, industrial
Environmental and Electrical Specifications control devices or systems that store, or
process information and are provided with
• main breaker ratings to 100 amps output motor control functions.
• maximum branch circuit current rating:
100 amps
• maximum branch circuit voltage rating:
125VDC, 480VAC
• maximum branch circuit interrupting
capacity: 10,000 amps
• operating temperature (ambient):
-40°C to +85°C
Note: Derating of Carlingswitch circuit
breakers is not required.

2
 Power Distribution Centers

Eliminate unproductive development time.

Utilizing our comprehensive range of quality circuit protection and control products, Carlingswitch can
design and build a custom Power Distribution Center (PDC) to meet your specific requirements. As a
custom designed product, you may specify the physical size of the enclosure. Adding your compo-
nent requirements, including temperature stable Carlingswitch hydraulic/magnetic circuit breakers,
ground fault circuit protectors, transient voltage surge suppressors, meters, power receptacles,
relays, busbars, hole plugs and LEDs, we can help configure and design a PDC to fit your needs.
From initial design to full scale manufacturing, Carlingswitch has a dedicated commitment to manu-
facturing exactly the product that meets your power distribution needs.

power ground fault

receptacles LEDs power selector busbar circuit protectors

hydraulic/magnetic ground transient voltage

circuit breakers bar surge suppressors
hydraulic/magnetic
circuit breakers hydraulic/magnetic
neutral busbar circuit breakers

Available Carlingswitch Components Other Optional Components

Carlingswitch Hydraulic/Magnetic Power Receptacles, including GFCI

Circuit Breakers provide highly pre- versions, can be designed in to your
cise, reliable and cost effective custom PDC.
overload and short circuit protection.

Carlingswitch SmartGuard breakers For power indication, add LEDs to

provide overload, short circuit and your panel.
equipment ground fault protection in
a single package.

Carlingswitch Power Selector pro- Transient Voltage Surge Supressors

vides safe and reliable insurance (T.V.S.S.) can be designed in to
against simultaneously energizing meet your system’s requirements.
primar y and auxiliary circuits.

Eliminate the need to rework your Analog or digital meters can be

panel as load demand increases by added for precise current and/or
simply removing a Panel Hole Plug voltage readings.
and adding a breaker.

3
 Power Distribution Centers

Example: PDC Schematic

LOCKOUT

Line 1
120V, 70A

Line 2
120V, 70A

MB #1 MB #2 CB #1 CB #2 CB #3 CB #4 CB #5 CB #6 CB #7 CB #8 CB #9
Main Line
Connection
MB
#1 & 2 L1 L2
LED

A
1 Utility 6 Branch 1 Generator Neutral
Neutral Neutral Bar Connection,
Connection Connections Right Terminal
Left Terminal Auxiliary Switch
1/4" Quick Connects,
2 Utility & Generator 12 Branch and BTS Ground 10.1 AMP, 250 VAC
Ground Connections, Bar Connections Equipment
Left Terminals -
Grounding Terminal
Assembly

Example: PDC Schematic

4
 Circuit Protection for PDC’s

SmartGuard™ PD-Series Breakers

This equipment ground fault protection device
functions as a standard high quality Carlingswitch
hydraulic/magnetic circuit breaker, offering cus-
tomized overload and short circuit protection. In
addition, this breaker senses and guards against
faults to ground using a state of the art integrated
circuit developed by Carlingswitch

Number of Poles Leakage To Ground

1-4 poles Standard Must-Trip Leakage Current Ratings: 10 - 100
milliamps
Available Delays Trip Time: 300 milliseconds max @ 100%; 40 milliamps
max @ 500%
Instant, Short, Medium, Long
Maximum Interrupting Capacity
Maximum Current & Voltage Ratings
120/208 VAC, 5000 Amp
1.0 - 50 amp, 480Y VAC 120/240 VAC, 5000 Amp
208/220 VAC, 2000 Amp
Agency Certifications 480 VAC, 2000 Amp

Available Circuits
Series Trip

M-Series Hydraulic/Magnetic Circuit Breakers

M-Series miniature breakers are available with
push to reset, push/pull, solid color rocker or
handle actuators; LED or neon bulb illumina- 1.56
tion, and Visi-Rocker two-color rocker actuators.
Rockerguard™ prevents inadvertent actuation of
rocker. Available in a variety of base and actua- 1.63 .77

tor colors.

Number of Poles Maximum Interrupting Capacity

1-2 poles 1000A

Available Delays Available Circuits

Instant, Short, Medium, High Inrush Series Trip, Switch Only, Series Trip with Auxiliary Switch

Maximum Current & Voltage Ratings Agency Certifications

0.02-15FLA, 32VDC, 125VAC, 1-pole
15.1-25GPA, 32VDC, 125VAC, 1-pole
0.02-15FLA, 65VDC, 250VAC, 2-pole
15.1-25GPA, 65VDC, 250VAC, 2-pole
0.02-12FLA, 250VAC, 1-pole
0.02-7.5GPA, 50VDC, 1-pole

5
 Circuit Protection for PDC’s

A-Series Hydraulic/Magnetic Circuit Breakers

A-Series breakers offer compact, temperature
stable design for precision operation in OEM
markets requiring general purpose and full load
2.0
amp applications. They are available with solid
color handle or rocker actuators, Visi-Rocker™
two-color rocker actuators, and the new Push-to- 1.84 .74

reset rocker.

Number of Poles Maximum Interrupting Capacity

1 - 6 poles (handle) 3000A @ 80VDC
1 -3 poles (rocker) 3000A @ 125/250VAC
5000A @ 277VAC
Available Delays
Available Circuits
Instant, Short, Medium, Long , High Inrush
Series, Shunt, Relay, Switch Only, Series with Remote
Maximum Current & Voltage Ratings Shutdown, Series with Auxiliar y Switch, Relay Dual Coil,
Shunt Trip Dual Coil
0.02-30A @ 277VAC, 80VDC
31.0-50A @ 125/250VAC, 65VDC Agency Certifications

B-Series Hydraulic/Magnetic Circuit Breakers

B-Series breakers are designed specifically for
world market applications requiring compliance
to VDE and IEC spacing requirements. They are 2.0
available with handle actuators in a variety of
colors.
1.73 2.23

Number of Poles Maximum Interrupting Capacity

1-6 poles 3000A @ 65VDC
3000A @ 125/250VAC
Available Delays 5000A @ 277VAC

Instant, Short, Medium, High Inrush Available Circuits

Maximum Current & Voltage Ratings Series, Shunt, Relay, Switch Only, Series with remote
shutdown, Series with Auxiliary Switch, Relay Trip Dual
0.02-30A @ 277VAC, 80VDC Coil, Shunt Trip Dual Coil, Mid-trip with Alarm Switch
31.0-50A @ 125/250VAC, 65VDC
Agency Certifications

6
 Circuit Protection for PDC’s

C-Series Hydraulic/Magnetic Circuit Breakers

C-Series breakers are designed for those
applications requiring higher current and
voltage capability while retaining a compact 2.50
size. They are available with solid color handle
or rocker actuators, and as Visi-Rocker two
color actuators. 1.85 1.49

Number of Poles Maximum Interrupting Capacity

1 - 6 poles (handle) UL Listed
1 -3 poles (rocker) 50000A @ 80VDC (single pole)
10000A @ 80VDC,120VAC
Available Delays 5000A @ 125VDC,240VAC
UL Recognized
Instant, Short, Medium, Long , High Inrush 7500A @ 80VDC
3000A @ 125/250VAC (UL only)
Maximum Current & Voltage Ratings 5000A @ 250VAC with fuse backup
5000A @ 480WYE/277VAC with fuse backup
UL Listed
0.02-100A @ 80VDC
Available Circuits
0.02-50A @ 125VDC
Series, Shunt, Relay, Switch Only, Series Mid-Trip with
0.02-70A @ 120VAC
Alarm Switch, Series with Remote Shutdown, Relay
0.02-20A @ 240VAC
Dual Coil, Shunt Trip Dual Coil
UL Recognized
0.02-30A @ 480WYE/277VAC 2-pole 1Ø, 3-pole 3Ø
0.02-50A @ 277VAC Agency Certifications
0.02-70A @ 250VAC, 80VDC
0.02-100A @ 120/240VAC, 65VDC

Construction Options

• Handleguard™ • Plug-In Stud Type • Mid-Trip handle Actuator

– helps prevent Terminals – allows visual
inadvertent actuation - allow easy assembly indication of electrical
of actuator into custom power overload with or without
• Clip Terminals and distribution centers alarm feature
• Back Panel Mounting
Bracket
- allow easy assembly
into custom power
distribution centers

7
 Circuit Protection for PDC’s

D-Series Hydraulic/Magnetic Circuit Breakers

Designed for DIN rail mounting on either a 1.48

35mm x 7.5mm, or a 35mm x 15mm Sym-

metrical DIN rail, the D-Series breakers are
available with a handle or Visi-Rocker two-color 3.61

actuator. They also feature dead-front, wire-

ready screw terminals.
2.16

Number of Poles Maximum Interrupting Capacity

1 - 4 poles (Handle) 1500A @ 65VDC, 250VAC (VDE only)
1 - 3 poles (Rocker) 5000A @ 65VDC
5000A @ 480WYE/277VAC with fuse backup
Available Delays 3000A @ 125/250VAC (UL only)

Instant, Short, Medium, Long, High Inrush Available Circuits

Maximum Current & Voltage Ratings Series, Switch Only, Series with Remote Shutdown

0.02-50A @ 277VAC, 65VDC Agency Certifications

0.02-30A @ 480WYE/277VAC 2-pole 1Ø, 3-pole 3Ø

E-Series Hydraulic/Magnetic Circuit Breakers

Ideally suited for higher current and voltage
applications, the E-Series are available as
Branch Circuit Breakers, Manual Motor Con- 5.12

trollers or Supplementary Protectors. They

feature front and back terminals and other
2.61 3.07
mounting options.

Number of Poles Maximum Current & Voltage Ratings

1-6 poles UL Listed
0.02-100A @ 240VAC, 125VDC
Available Delays UL Recognized
0.02-100A @ 277VAC, 125VDC, 1-pole
Instant, Short, Medium, High Inrush 0.02-100A @ 600VAC, 2-pole 1Ø, 3-pole 3Ø

Maximum Interrupting Capacity Available Circuits

3000A @ 65VDC Series, Shunt, Relay, Switch Only, Series with Remote
3000A @ 125/250VAC Shutdown, Series with Auxiliar y Switch
5000A @ 277VAC
Agency Certifications

8
Complete Technical Information Available
For complete catalog information including general specs, circuit and terminal drawings, form & fit
drawings, and complete ordering information, please visit our web site www.carlingswitch.com, or
contact any one of our locations and request the following literature:

Circuit Protection #402 catalog SmartGuard SGPD catalog

A Worldwide Sales Network To Assist You

Carlingswitch professionally supports your needs with a worldwide stocking distribution network, backed
by an international organization of technical sales representatives. Our four North American facilities are
supported by subsidiaries located throughout Europe and Asia.

Whether you’re in the U.S., Europe, Asia or elsewhere in the world, you’ll find knowledgeable
Carlingswitch technical sales and support teams covering your area. We can answer application ques-
tions, assist in the selection of products, and be your partner in product design.

www.carlingswitch.com

Disclaimer: The product information published in this catalog is subject to change without notice. Modification of material, finishes, technical specifications and agency certifications may occur
as part of our continual pursuit of product enhancement. All statements, technical information and recommendations are based on facts and tests we believe to be reliable. The products
described may be used in a variety of applications. Since the user’s product information, specific use application and conditions of use are all outside of Carlingswitch’s control, it is the
responsibility of the purchaser to determine the suitability of these products for the purchaser’s specific use and the purchaser assumes all associated risks. The purchaser should review
applicable codes and standards such as UL, NEMA, CSA, VDE, OSHA and others for recommended practices and safety standards along with electrical ratings as marked on product to ensure
compatibility of product performance to applicable requirements.
 Worldwide Headquarters
CARLINGSWITCH, INC.
60 Johnson Avenue, Plainville, CT USA 06062-1177
(860) 793-9281 • Fax: (860) 793-9231
Regional Sales Offices
Eastern U.S. and Eastern Canada:
(781) 937-3308 • Fax: (781) 937-3422
Midwestern U.S.:
(815) 653-9333 • Fax: (815) 653-2206
Western U.S., Western Canada, Mexico & South America:
(805) 527-0202 • Fax: (805) 527-1465
Europe/Middle East/Africa Headquarters
CARLINGSWITCH LTD.
4 Airport Business Park, Exeter Airport
Clyst Honiton, Exeter, Devon EX5 2UL ENGLAND
Int + 44 1392-364422 • Fax: Int + 44 1392-364477
Regional Sales Offices
Northern Europe:
Int + 46-8-601-3090 • Fax: Int + 46-8-601-3091
Central Europe:
Int + 49 6104-959157 • Fax: Int + 49 6104-959158
Southern Europe:
Int + 44 1392-364422 • Fax: Int + 44 1392-364477
Asia-Pacific Headquarters
CARLINGSWITCH ASIA-PACIFIC LTD.
1730 Ocean Centre, 5 Canton Road
Tsimshatsui, Kowloon HONG KONG
Int + 852-2737-2277 • Fax: Int + 852-2736-9332
Regional Sales Offices
China:
Int + 86-21-6390-6916 • Fax: Int + 86-21-6390-6918
Japan:
Int + 852-2737-2277 • Fax: Int + 852-2736-9332
Manufacturing Facilities
CARLINGSWITCH, INC.
60 Johnson Avenue, Plainville, CT USA 06062-1177
(860) 793-9281 • Fax: (860) 793-9231
3734 International Blvd., Brownsville, TX USA 78521
(956) 546-5564 • Fax: (956) 546-0323
INTERRUPTORES DE MEXICO
Matehuala, Mexico
OROCONTROL DE ZACATECAS
Concepcion del Oro, Mexico

www.carlingswitch.com
PDC.CAT5/99