Cabling method for fault managed power systems

Abstract

A power cable network architecture provides fault managed power (FMP) signals in a data center. The architecture provides patching connections between feeder lines from power pods and trunk cables within an overhead cable raceway, as well as patching connections between the trunk cables within the overhead cable raceway and drop lines to power distribution units associated with rack-mounted servers throughout the data center. Conductors within the trunk line are larger in diameter, as compared conductors within the feeder and / or drop lines. In one embodiment, the patching connections can occur at patch panels via a port and plug arrangement. In another embodiment, the patching connections can occur at fixtures with insulation displacement connectors.

Description

[0001] Attorney Docket: 4799 / 0738PW01

[0002] CABLING METHOD FOR FAULT MANAGED POWER SYSTEMS

[0003] BACKGROUND OF THE INVENTION

[0004] 1. Field of the Invention

[0005]

[0001] The present invention generally relates to a power cable network architecture for transmitting power in a data center. More particularly, the present invention relates to single-pair and multi-pair cables with one or more plug and port patch panel interfaces, and / or one or more insulation displacement connector (IDC) interfaces, establishing power transmission from a fault managed power system to receiver units supplying power to rack-mounted servers within the data center.

[0006] 2. Description of the Related Art

[0007]

[0002] A building housing a large data center has an average footprint of 100,000 square feet and runs about 100,000 servers. However, much larger data centers are known, such as the 4.6 million square foot data center owned by Meta Platforms in Prineville, Oregon, and smaller data centers are known, such as a data center with 1,000 or fewer servers. The typical power system for a data center is very robust as the power demand is very high, e.g., a three phase 480V power supply from the service provider is common. The power system typically supplies operating power to HVAC systems; transformers to convert the voltage down to lower-voltage, e.g., 110 - 220V to operate the servers, the lighting system, the security system, command / control rooms, and other typical amenities associated with onsite employees.

[0008]

[0003] When working with larger conductors at high voltages and carrying high amperages, the conductors must be protected within heavy duty conduits, which are typically buried within the foundation of the facility. Alternatively, the floor of the data center is elevated to create a crawlspace or chase area under removeable panels, and the high voltage cables are carried within conduits under the elevated floor. Alternatively, the high voltage cables are carried within steel conduits which are held by brackets attached to the walls or ceiling within the data center.

[0009]

[0004] Servicing the high voltage / high current carrying conductors is left to professional industrial electricians. There are many difficult and dangerous Attorney Docket: 4799 / 0738PW01

[0010] interconnections that need to be made to the panels, breakers, fuses and transformers, which carry and drop the three phase 480V power down to a single phase, lower voltage suitable for computer devices, e.g., servers, positioned throughout the data center.

[0011]

[0005] A particularly safe way to transfer power from a source to a destination is by means of a fault managed power system, which constantly monitors a power signal and immediately cuts off the power signal in the case of a fault, e.g., a short circuit, an open circuit, etc. One type of fault managed power system has been recognized in the 2023 version of NFPA 70, commonly referred to as the National Electrical Code (NEC), and in UL 1400-1 (Class 4 system requirements) and ULI 400-2 (Class 4 cable requirements). One method of class 4 power sends rapid pulses of the high voltage DC current, e.g., in excess of 300 volts and up to 450 volts. The destination receives the pulses, which may be reduced due to some voltage drop over the long transmission line. A primary advantage of class 4 power is that the transmission lines do not need to be large diameter conductors. Rather, UL 1400-2 allows for conductors in the size range of 6 to 24 American wire gauge (AWG).

[0012]

[0006] The destination has equipment to convert the received DC voltage pulses into a new supply voltage which is suitable for the equipment at the destination, e.g., a 110-220 volt AC signal or a 5, 12, 24, 48 or 54 volt DC signal. If any irregularity occurs in the pulses between the source and destination, e.g., due to an intermittent short or open circuit condition, the source immediately, e.g., within a few milliseconds, stops sending the high voltage DC voltage pulses to avoid an unsafe condition. Another advantage is that the fault management of the power signal allows for the elimination of many or all of the breakers and fuses.

[0013]

[0007] Several background references show systems for providing safe, high voltage pulses, e.g., exceeding 300 VDC. Such background art can be found in US Patent Nos. 8,781,637; 9,184,795; 9,419,436; 9,853,689; 9,893,521; 10,468,879; 10,541,543 and 10,714,930, and in US Published Application Nos. 2017 / 0229886; 2018 / 0313886; 2020 / 0295559 and 2021 / 0063447, which are owned by VoltServer of East Greenwich, Rhode Island, and are herein incorporated by reference.

[0014]

[0008] Recently, there has been an interest in using a fault managed power (FMP) system in a data center. The FMP system reduces the component costs and installation Attorney Docket: 4799 / 0738PW01

[0015] costs of numerous high voltage, high current large conductors and associated components, like transformers and breakers, used in the data center, which also improves the operational safety within the data center. Further, the FMP system components can be installed and maintained by technicians, such as network cabling technicians, instead of specialized, industrial electricians. A summary of the general use of FMP in a data center can be found in the following article, which is herein incorporated by reference, by Michael Starego and Stephen S. Eaves, “White Paper: A Comparison of Fault Managed Power (FMP) and Traditional AC Distribution in High Performance Data Centers,” May 2024, Southland Industries, https: / / southlandind.com / sites / default / fdes / media / documents / WP_PwerCompInDataCenters%20Draft%20FIN.pdf.

[0016] SUMMARY OF THE INVENTION

[0017]

[0009] The Applicant has appreciated some potential improvements to the network cabling architecture described in the article above. In the example of the network cabling architecture described therein, a pod is defined as an independent source of power and there are four pods shown. Each pod is capable of supplying about 2,000kW. Each insulated conductor pair is capable of carrying at least 2kW of power. In the example, the servers of the data center require about 6,000kW of power. During normal operation, the load is split with 25% of the load being allocated to each of the four pods, i.e., each pod outputs about l,500kW (75% of its maximum production capacity of 2,000kW), and each conductor pair carries about 1.5kW of power. Therefore, about 4,000 insulated conductor pairs are needed to connect the four pods to the FMP, power distribution units (PDUs) associated with the server cabinets in the data center, e.g., 4,000 x 1.5kW = 6,000kW. If one pod is inoperable, or the insulated conductor pairs connected to one of the pods are damaged, then the remaining three pods are operated at full capacity to provide the needed 6,000kW of power to the servers of the data center, with each of the 3,000 insulated conductor pairs connected to the three operable pods now carrying about 2kW of power, e.g., 3,000 x 2kW = 6,000kW.

[0018]

[0010] Each of the server cabinets in the data center includes four PDUs (Fig. 6 of the article) . Each PDU is fed by “an individual cable,” i.e., “one continuous FMP cable,” from the four pods. The individual cable includes four pairs of 12AWG Attorney Docket: 4799 / 0738PW01

[0019] conductors (Fig. 5), each pair brings a FMP signal from a different one of the four pods. The average cable run length is about 500 feet. The entire length of the cable needs to be considered in order to select a conductor sizing or American wire gauge (AWG) so that a proper low resistance will be encountered by the power pulses and the cable will not overheat.

[0020]

[0011] Excessive heat could damage the insulation layer and lead to a fault. An elevated level of heat would also increase the HVAC operation costs. Larger conductor sizes, such as the 12AWG shown in the example of Fig. 5 of the article, offer less resistance and operate at cooler temperatures as compared to smaller conductor sizes, such as 14AWG or 16AWG. However, a larger conductor size makes the four pair cable less flexible and more difficult to route to the pod terminals and to the PDU terminals. Also, the increase in conductor size makes the cable more expensive.

[0021]

[0012] To this end, it would be desirable to provide a cable link between the pods and the PDUs which has a large conductor diameter over the long distance, primarily relatively straight spans between the pods and the PDU, such as when the cable is laying flat in the overhead trays, and the cable link transitions to a smaller conductor diameter in the portions outside of, or at the exit of, the overhead cable trays. The smaller diameter conductors would allow the cable to be more flexible, so that it can be routed to the terminals of the pods and the terminals of the PDUs in a neat and orderly fashion, which is always needed and expected in a data center environment to facilitate trouble shooting / cable tracing, and MAC (move, add, change) operations.

[0022]

[0013] In the data center described in the article, to interconnect a four pair cable between the first, second, third and fourth pods and a first PDU, a length of the cable’s jacket, e.g., a couple of dozen feet, is removed at the pod end of the cable. A first pair of insulated conductors is routed to a terminal set associated with the first pod, a second pair is routed to terminal set associated with the second pod, a third pair is routed to a terminal set associated with the third pod and a fourth pair is routed to a terminal set associated with the fourth pod. Then, at the PDU end of the four pair cable, a length of the cable jacket, e.g., three or four inches, is removed, and the first through fourth pairs are connected to first through fourth input terminal sets of the first PDU. Attorney Docket: 4799 / 0738PW01

[0023]

[0014] It is believed that the required stripping of the overall jacket from the four pair cable may lead to damage to the insulation layers and conductors of the pairs within the four pair cable, which could lead to a fault in the FMP system. Further, the stripping of the overall jacket of the four pair cable is time consuming and subjects the technicians to fatigue which may add to the potential of connection errors to the terminals of the PODs or PDUs, as the pairs are routed between four different PODs and numerous PDUs over the course of interconnecting the 4,000 pairs of conductors. Further, there is a very long length of jacket striped at the pod end of the four pair cable to enable the twisted pairs to be routed to the four separate, spaced-apart pods, shown in Figure 2 of the Article. Such an excessive length of insulated twisted pairs outside of the four pair cable jacket increases the risk of confusion during the connection process to the four pods, and also exposes a long length of the insulated conductors to potential damage, as they are no longer protected by the outer jacket of the four pair cable.

[0024]

[0015] The Applicant has appreciated a new power cable network architecture, which should reduce the cost drawbacks of using large gauge conductors over the entire length of the cable to reduce resistive heating on the long spans of the cabling. The power cable network architecture also improves the flexibility of the cables at the connection ends of the cables so that a more neat and orderly routing of the cables can occur adjacent to the terminals of the pods and PDUs. Moreover, the Applicant has appreciated a new power cable network architecture, which can simplify the tasks performed by the network cabling technician, and reduce the fatigue associated with jacket and insulation stripping operations.

[0025]

[0016] These and other objects of the invention are accomplished by a power cable network architecture providing for transmitting FMP power, such as class 4 power, signals in a data center. The architecture provides patching connections between feeder lines from power pods and trunk cables within an overhead cable raceway, as well as patching connections between the trunk cables within the overhead cable raceway and drop lines to power distribution units associated with rack-mounted servers throughout the data center. Conductors within the trunk line are larger in diameter, as compared conductors within the feeder and / or drop lines. In one embodiment, the patching connections can occur at patch panels via a port and plug arrangement. In another Attorney Docket: 4799 / 0738PW01

[0026] embodiment, the patching connections can occur at fixtures with insulation displacement connectors (IDCs).

[0027]

[0017] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

[0028] BRIEF DESCRIPTION OF THE DRAWINGS

[0029]

[0018] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limits of the present invention, and wherein:

[0030]

[0019] Fig. 1 is an overall system view of the fault managed power system of the present invention;

[0031]

[0020] Fig. 2A is a perspective view of a patch cable with plugs at each end;

[0032]

[0021] Fig. 2B is a perspective view of a trunk cable with ports at each end;

[0033]

[0022] Fig. 3 A is an end view of a cable configuration, in accordance with a first embodiment of the present invention;

[0034]

[0023] Fig. 3B is an end view of a cable configuration, in accordance with a second embodiment of the present invention;

[0035]

[0024] Fig. 3 C is an end view of a cable configuration, in accordance with a third embodiment of the present invention;

[0036]

[0025] Fig. 3D is an end view of a cable configuration, in accordance with a fourth embodiment of the present invention;

[0037]

[0026] Fig. 4 is an exploded view of a patch panel configuration with ports on the trunk cable and plugs on the patch cable;

[0038]

[0027] Fig. 5 is an exploded view of a patch panel configuration with plugs on the trunk cable and ports on the patch cable;

[0039]

[0028] Fig. 6 is a front view of side-by-side short server racks with a patch panel mounted to the top of the rack; Attorney Docket: 4799 / 0738PW01

[0040]

[0029] Fig. 6A is a front view of side-by-side tall server racks with two patch panels mounted to the top of the rack;

[0041]

[0030] Fig 7 is a front view of side-by-side tall server racks with two patch panels mounted to the overhead raceway;

[0042]

[0031] Fig 8 is a front view of side-by-side tall server racks with first and second exit ramps having ZDC panels mounted to the overhead raceway;

[0043]

[0032] Fig. 9 is a close-up perspective view of the first exit ramp with the first IDC panels in Fig. 8;

[0044]

[0033] Fig. 10 is a cross sectional view taken along line X — X in Fig. 9;

[0045]

[0034] Fig. 11 is a cross sectional view taken along line XI — XI in Fig. 10;

[0046]

[0035] Fig. 12 is a cross sectional view taken along line XII — XII in Fig. 10;

[0047]

[0036] Fig. 13 is a cross sectional view similar To Fig. 10, but showing an alternative configuration; and

[0048]

[0037] Fig. 14 is a cross sectional view taken along line XIV — XIV in Fig. 13.

[0049] DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0050]

[0038] The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0051]

[0039] Like numbers refer to like elements throughout. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity. Broken lines illustrate optional features or operations unless specified otherwise.

[0052]

[0040] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in Attorney Docket: 4799 / 0738PW01

[0053] commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and / or clarity.

[0054]

[0041] As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as "between X and Y" and "between about X and Y" should be interpreted to include X and Y. As used herein, phrases such as "between about X and Y" mean "between about X and about Y." As used herein, phrases such as "from about X to Y" mean "from about X to about Y."

[0055]

[0042] It will be understood that when an element is referred to as being "on", "attached" to, "connected" to, "coupled" with, "contacting", etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, "directly on", "directly attached" to, "directly connected" to, "directly coupled" with or "directly contacting" another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed "adjacent" another feature may have portions that overlap or underlie the adjacent feature.

[0056]

[0043] Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “lateral”, “left”, “right” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is Attorney Docket: 4799 / 0738PW01

[0057] inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the descriptors of relative spatial relationships used herein interpreted accordingly.

[0058]

[0044] Fig 1 is an overall system view of the fault managed power system of the present invention. Fig. 1 shows a high level schematic of the conductive pathways 1 established between fault managed power generating cabinets 3, located a “gray space” 5 of a data center, and server racks or cabinets 7, located in a “white space” 9 of the data center. Each bank of power generating cabinets 3 can be referred to as a “power pod.” On the right side of Figure 1, there are four power pods 11, 13, 15 and 17, and each includes sixteen power generating cabinets 3. More or fewer power generating cabinets 3 may be included in a power pod 11, 13, 15 or 17. More or fewer power pods 11, 13, 15 and 17 may be included in the gray space 5.

[0059]

[0045] As best seen in Fig. 2A, first patch cables 19A (such as feeder or supply patch cables 19A) are connected at first ends 21 to terminals of the power pods 11, 13, 15 and 17 to receive fault managed power (FMP). The connection may be made by mating a plug 23 into a port arrangement on the power pod 11, 13, 15 or 17, such as by using the plug and port arrangement shown in the Applicant’s provisional application serial No.

[0060] 63 / 670,205, filed July 12, 2024, which is herein incorporated by reference, and in the Applicant’s corresponding, pending, PCT applications PCT / US2025 / 037160 and PCT / US2025 / 037175, both filed on July 10, 2025, which are herein incorporated by reference. Alternatively, the connection may be made by terminal to wire connections, such as a punch down to an IDC, screw pressure terminals, biting clamp terminals, etc. Second ends 25 of the first patch cables 19A are preferably terminated to plugs 23 (formed the same as plugs 23 at the first ends 21) and mate into ports 27 in a first patch panel 29. Although a single first patch panel 29 is shown in Figure 1, there would typically be numerous first patch panels 29 in network racks to accommodate all of the power producing units in the first pod 11 which produce FMP.

[0061]

[0046] As best seen in Fig. 2B, trunk cables 31, such as a trunk cable 31 with four pairs of twisted insulated conductors, is terminated at a first end 33 to four ports 27. The four ports 27 reside within openings in the first patch panel 29. A second end 35 of the Attorney Docket: 4799 / 0738PW01

[0062] trunk cable 31 is terminated to four ports 27 (formed the same as ports 27 at the first ends 33) and reside within openings in a second patch panel 37. If there are eight trunk cables 31, the first and second patch panels 29 and 37 will be fully populated with ports 27. Again, the plug and port arrangement shown in the Applicant’s provisional application serial No. 63 / 670,205 and in the Applicant’s corresponding, PCT applications PCT / US2025 / 037160 and PCT / US2025 / 037175, may be used in both of the first and second patch panels 29 and 37.

[0063]

[0047] First ends 21 of second patch cables 19B (distribution or drop patch cables 19B) are terminated to plugs 23, which may be mated within the ports 27 of the second patch panel 37. If there are four twisted pairs in a second patch cable 19B, there would be eight second patch cables 19B to fully occupy all of the thirty two ports 27 within the second patch panel 37. Second ends 25 of the second patch cables 19B are terminated to power distribution unit (PDU) ports or terminals. The PDUs 39 (shown in Figs. 6-8) are typically mounted into server racks or cabinets 7, which racks or cabinets 7 are placed side-by-side into rows throughout the white space 9 of the data center. Fig. 1 shows a single row of eight server racks or cabinets 7, however it is understood that hundreds of rows of server racks or cabinets 7 may be located in the white space 9 of the data center.

[0064]

[0048] Fig 2A shows the supply and distribution patch cables 19A and 19B having four twisted pairs per cable. However in a preferred embodiment, the supply and / or distribution patch cables 19A and 19B may be single pair cables. Single pair cables are smaller in diameter and more flexible, and hence easier to manage in the data center environment to achieve tight and orderly routing to the ports 27 or terminals of the pods 11, 13, 15 and 17 and PDUs 39. Also, in the preferred embodiment, the PDUs and pods would have ports 27, and the ends of the supply and distribution patch cables 19A and 19B would have plugs 23, formed in accordance with the Applicant’s pending provisional application serial No. 63 / 670,205, filed July 12, 2024 and in the Applicant’s corresponding, pending, PCT applications PCT / US2025 / 037160 and PCT / US2025 / 037175. Such ports 27 and plugs 23 would reduce the labor associated with manual termination of insulated conductor wires to terminals on the PDUs 39 and pods 11, 13, 15 and 17. Attorney Docket: 4799 / 0738PW01

[0065]

[0049] Fig 3A shows an end view of one potential embodiment of a supply or distribution patch cable 19A or 19B prior to being attached to a termination. The embodiment of Fig. 3 A is a single pair cable 19C with nineteen strand copper conductors of sixteen AWG size and a floating aluminum shield 41 with a thickness of 0.003 inches. Examples of dimensions are shown in Fig. 3 A, which would result in a weight of approximately twenty-seven pounds per 1,000 feet of the single pair cable 19C.

[0066]

[0050] Fig 3B shows an end view of one potential embodiment of a trunk cable 31 prior to being attached to a termination. The embodiment of Fig. 3B is a single pair cable 31A with nineteen strand copper conductors of fourteen AWG size and a floating aluminum shield 41 with a thickness of 0.003 inches. Examples of dimensions are shown in Fig. 3B, which would result in a weight of approximately thirty-eight pounds per 1,000 feet of the single pair cable 31 A.

[0067]

[0051] Fig 3C shows an end view of another potential embodiment of a trunk cable 31 prior to being attached to a termination. The embodiment of Fig. 3C is a single pair cable 3 IB with nineteen strand copper conductors of twelve AWG size and a floating aluminum shield 41 with a thickness of 0.003 inches. Examples of dimensions are shown in Fig. 3C, which would result in a weight of approximately fifty-four pounds per 1,000 feet of the single pair cable 3 IB.

[0068]

[0052] Fig. 3D shows an end view of another potential embodiment of a trunk cable 31 prior to being attached to a termination. The embodiment of Fig. 3D is a four pair cable 3 ID with nineteen strand copper conductors of fourteen AWG size and a floating aluminum shield 41 with a thickness of 0.006 inches. Examples of dimensions are shown in Fig. 3D, which would result in a weight of approximately one hundred thirty-seven pounds per 1,000 feet of the four pair cable 3 ID. Reducing a thickness of the floating aluminum shield 41 down to 0.003 inches would the result in a weight of approximately one hundred thirty-five pounds per 1,000 feet of the four pair cable 3 ID. Adding an individual dielectric sub-jacket to surround each of the four twisted pairs of conductors would the result in a weight of approximately one hundred seventy pounds per 1,000 feet of the four pair cable 3 ID, while having sub-jackets and increasing the conductor size to twelve AWG would the result in a weight of approximately two hundred forty-two pounds per 1,000 feet of the four pair cable 3 ID. The four dielectric Attorney Docket: 4799 / 0738PW01

[0069] sub-jackets could prove useful to routing the twisted pairs from the breakout point of the trunk cable 31C to the ports 27 on the power pods 11, 13, 15 and 17, if the trunk cable 3 ID were used in connection with Fig. 4, described below. Although trunk cables 31 A, 3 IB and 31C have been shown with nineteen strand conductors, other strand counts are possible and a solid conductor is possible.

[0070]

[0053] The floating shield layers 41 within the outer jackets surround the overall cable core and are primarily provided for heat shielding and heat dissipation reasons. The floating shielding layers 41 may be formed of aluminum with an insulative coating on one or both sides. The floating shield layers 41 may not be needed for the supply or distribution patch cables 19A or 19B, since the run length of the supply or distribution patch cables 19A or 19B is short, e.g., 10, 20, 25, 30 or 35 feet, as compared to the run length of the trunk cable 31, .e.g., 200, 250, 300, 350 or 500 feet. Therefore, heat buildup within the core of the supply or distribution patch cables 19A or 19B is less likely.

[0071]

[0054] Fig. 4 is a high level schematic of a power cable network architecture, which includes only the second patch panel 37, instead of the first and second patch panels 29 and 37. In the alternative embodiment of Fig. 4, the second end 35 of the trunk cable 3 ID is factory terminated to the four ports 27, as shown in Fig. 2B. The first end 33 of the trunk cable 3 ID is cut to length in the field and field terminated to plugs 23, compatible with ports 27 in the power pods 11, 13, 15 and 17. Alternatively, the trunk cable 3 ID may be cut to length in the field and the insulated conductor pairs may be directly connected to the terminals of the power pods 11, 13, 15 and 17 to receive power therefrom, if the power pods 11, 13, 15 and 17 do not have ports 27 installed therein.

[0072]

[0055] Although the first patch panel 29 is not used, many of the benefits of the present invention are achieved, since more flexible distribution patch cables 19B are used in the server cabinet rows of the white space throughout the data center. One disadvantage is that the more flexible supply patch cables 19A are not used to assist in the orderly connections to the power pods 11, 13, 15 and 17. Since the power pods 11, 13, 15 and 17 are present in the gray space 5 of the data center, e.g., in a different room of the data center, less orderly routing of cables may be acceptable in the gray space 5. The data technicians that perform move, add and change (MAC) operations and server Attorney Docket: 4799 / 0738PW01

[0073] repair are working in the white space 9, where a highly orderly cable arrangement is required.

[0074]

[0056] Fig. 4 also illustrates that it is an option to provide the second ends 25 of the distribution patch cables 19B not pre-terminated to any plug 23. Rather, the distribution patch cable 19B may be cut to length at its second end 25 and field terminated to plugs 23. Alternatively, the distribution patch cable 19B may be cut to length and directly connected to the terminals of the PDUs 39 to transmit power thereto, if the PDUs 39 do not have ports 27 installed therein. Of course, it is a preferred embodiment to have the distribution patch cables 19B terminated on each end to plugs 23 and available in several lengths, e.g., six, ten, fourteen and eighteen feet. Such an embodiment is more convenient and less time consuming for the installation technician.

[0075]

[0057] Fig. 5 is the same as Fig. 4, but illustrates how the positioning of the ports 27 and plugs 23 may be reversed. Such a reversal would satisfy the power connection in a same manner. Such a reversal of the ports 27 and plugs 23 may occur at either end, or both ends of trunk cable 31 shown in Fig. 2B as well. Although Figs. 4 and 5 have shown the distribution patch cables 19B as having four pairs each, in a preferred embodiment, the distribution patch cables 19B are single pair cables, or at most two pair cables, so that the flexible and orderly routing of the distribution patch cables 19B is easy for the installation technician.

[0076]

[0058] Fig. 6 depicts an overhead raceway, such as a cable tray 43 with trunk cables 31 exiting the cable tray 43 via an exit ramp 44 and being terminated to ports 27 captured within openings of the second patch panels 37. Each second patch panel 37 is attached to a top of a rack or cabinet 7, which is located in the white space 9 of the data center. The PDU 39 is mounted in the middle of the rack or cabinet 7, with two server blocks 45 being located above the PDU 39 and two server blocks 45 being located below the PDU 39. The central placement of the PDU 39 allows for shorter power cords and only two sizes of power cords being needed to connect the PDU 39 to the server blocks 45. In one example, the PDU 39 occupies one unit of space in the rack or cabinet 7, and each server block 45 holds four servers and occupies four units of space in the rack or cabinet 7. Attorney Docket: 4799 / 0738PW01

[0077]

[0059] To supply power to the PDU 39, sixteen single pair distribution patch cables 19B, such as shown in Fig. 3 A, are plugged into the sixteen ports 27 on the left side of the second patch panel 37. The sixteen distribution patch cables 19B are routed to the left side rail of the rack or cabinet 7 and inserted into one or more guides 47 along the left side rail down to the PDU 39. Likewise, sixteen single pair distribution patch cables 19B are plugged into the sixteen ports 27 on the right side of the second patch panel 37, and are routed through guides 47 on the right side rail down to the PDU 39. At the PDU 39, the plugs 23 of the thirty -two single pair distribution patch cables 19B are connected into thirty-two ports 27 on the front face of the PDU 39. To simplify Fig. 6, only two of the distribution patch cables 19B and two of the ports 27 on each PDU 39 have been illustrated on each of the racks or cabinets 7.

[0078]

[0060] To speed the insertion and removal of plugs 23 into the ports 27 of the PDU 39 and / or the second patch panel 37, it may be possible to use a switch pack as shown in the Applicant’s US Patent 9,069,149, which is herein incorporated by reference. Eight plugs 23 at a time may be inserted and removed from the second patch panel 37 using the primary embodiment of US Patent 9,069,149. Hence, four switch packs could be used to fully populate the ports 27 of the second patch panel 37. Four switch packs may also be used when connecting the plugs 23 into the ports 27 of the first patch panel 29 and / or the PDUs 39 and / or the power pods 11, 13, 15 and 17.

[0079]

[0061] Fig. 6 shows two racks or cabinets 7 located side-by-side in a row. Of course, more racks or cabinets 7 would be in the row, e.g., dozens. Further, there is rather large space between the right and left racks or cabinets 7 in Fig. 6. The space can be removed to provide more efficient use of the floor space. The right side rack or cabinet 7 would be configured the same as the left side rack or cabinet 7. A single exit ramp 44 is located between the right and left racks or cabinets 7 and serves to bring the trunk cables 3, e.g., eight trunk cables 31 with four twisted pairs per trunk cable 31, out of the overhead cable tray 43 to populate the thirty-two ports 27 of the left side second patch panel 37, and eight trunk cables 31 with four twisted pairs per trunk cable 31, out of the cable tray 43 to populate the thirty-two ports 27 of the right side second patch panel 37. Attorney Docket: 4799 / 0738PW01

[0080]

[0062] The PDU 39 has thirty-two input ports 27, with each input port 27 having two electrical contacts. Alternatively, each PDU 1, 2, 3 or 4 has sixty -four separate terminals to receive sixty-four conductors of sixty-four individual wires. Each grouping of eight input ports 27 (or sixteen terminals) would receive power from a different one of the four power pods 11, 13, 15 and 17. In a normal operating condition, each of the power pods 11, 13, 15 and 17 would supply 1 / 4 of the power consumed by the PDU 39. If one of the power pods 11, 13, 15 and 17 fails, the PDU 39 would sense the lack of power at that grouping of eight input ports 27 and would proceed to pull more power from the remaining three power pods presented to the twenty-four input ports 27 associated with the remaining three power pods, with each of the remaining three power pods supplying 1 / 3 of the power consumed by the PDU 39.

[0081]

[0063] One way to configure the second patch panel 37 would be to make the leftmost grouping of eight ports 27 associated with the first power pod 11. Those eight ports 27 and / or the surface of the second patch 37 surrounding those eight ports 27 could be distinguished from the other ports 27 and surface areas by a common color, e.g., red. All of the single pair distribution patch cables 19B plugged into the leftmost grouping of eight ports 27 would be mated to the eight ports 27 associated with the first grouping on the PDU 39. The grouping system of the second patch panel 37 would continue across the face of the second patch panel 37 such that the rightmost grouping of eight ports 27 on the second patch panel 37 would be associated with the fourth power pod 17, and might be colored blue. The second and third groupings in the middle of the second patch panel 37 might be colored green and yellow, respectively.

[0082]

[0064] Fig. 6A is the same as Figure 6, but shows that two PDUs 39 may be mounted within each of the racks or cabinets 7 to support the power demands of eight server blocks 45 per rack or cabinet 7. A second patch panel 37 is mounted to the top of the rack or cabinet 7 to serve the power inputs to the second PDU 39, i.e., thirty-two more ports 27 are provided in the second patch panel 37 to provide FMP to the second PDU 39. The upper four server blocks 45 are supplied AC power by the upper or first PDU 39 in the rack, while the lower four server blocks 45 are supplied AC power by the lower or second PDU 39. Each rack or cabinet 7 receives sixteen four pair trunk cables Attorney Docket: 4799 / 0738PW01

[0083] 31 from the cable tray 43 via the exit ramp 44 in order to fully populate the openings in both of the second patch panels 37.

[0084]

[0065] Fig. 7 shows an alternative configuration, similar to Fig. 6A. The embodiment of Fig. 7 has elevated racks 49 mounted to the overhead cable tray 43, proximate to the exit ramp 44. The elevated racks 49 may hold one or more of the second patch panels 37. This arrangement is advantageous in that rack space within the rack or cabinet 7 is not consumed by the second patch panels 39. This frees up more rack space for server blocks 45, PDUs 39 and other equipment and / or shortens the height of the rack or cabinet 7. Also, the rather stiff trunk cables 31 are not routed down to the racks or cabinets 7. Hence, the more flexible distribution patch cables 19B, e.g., single pair patch cables, are routed down to the racks and cabinets 7, which allows for a more neat and orderly arrangement of cabling. Fig. 7 also illustrates that the first and second PDUs 39 may be vertically mounted to the outside of one of the left or right rails of the rack or cabinet 7, so as to take up no unit space. This vertical mounting of the PDUs 39 would further free up more rack space for server blocks 45 and other equipment.

[0085]

[0066] Fig 8 illustrates that the elevated racks 49 and second patch panels 37 may be replaced by an adapter panel 58, which is built into the exit ramp 44 or attached beneath the exit ramp 44. The adapter panel 58 holds a plurality of large and a plurality of small insulation displacement connector (IDC) fork terminals. The adapter panel 58 is located between a cable exit point from the cable tray 43 and the PDUs 39, e.g., just outside the cable exit ramp 44 and attached to the cable tray 43, or integrated into the exit ramp 44 itself, which is attached to the cable tray 43.

[0086]

[0067] A similar exit ramp guide device is shown in the Assignee’s US Patent 9,632,274, granted April 25, 2017, which is herein incorporated by reference. The new adapter panel 58 modification “adapts” the larger diameter electrical conductor of a trunk cable 31 to a smaller diameter electric conductor of a distribution patch cable 19B. The distribution patch cables 19B are then routed to the PDUs 39 in the rack or cabinet 7 in the same manner as discussed in the embodiments above. It should be noted that the adapter panel 58 could instead be mounted to the rack or cabinet 7.

[0087]

[0068] Now with reference to Figs. 9-14, potential embodiments for the adapter panel 58 are described in more detail. Fig. 9 is a close-up perspective view of the exit Attorney Docket: 4799 / 0738PW01

[0088] ramp 44 of Fig. 8 with the adapter panel 58. Fig. 10 is a cross sectional view taken along line X — X in Fig. 9. Fig. 11 is a cross sectional view taken along line XI — XI in Fig. 10. Fig. 12 is a cross sectional view taken along line XII — XII in Fig. 10.

[0089]

[0069] In Fig. 9, a trunk cable 31 is brought over a sidewall of the cable tray 43 an onto a bend limiting curved surface 51 of the exit ramp 44. The trunk cable 31 is held on the bend limiting curved surface 51 by facing, upstanding side guides 53. Of course, multiple trunk cables 31 would be residing on the bend limiting curved surface 51, but for the sake of clarity only one trunk cable 35 is shown in Fig. 9.

[0090]

[0070] An outer jacket of the trunk cable 35 is removed to exposed the two or more insulated conductors 55 within the trunk cable 35. Each insulated conductor 55 is routed into a respective IDC slot 61, formed between slot walls 59, which extend perpendicularly away from the adapter panel 58. The insulated conductor 55 of the trunk cable 31 is punched down between wide slot walls 63, into a large IDC fork terminal. Likewise, an insulated conductor 57 of the distribution patch cable 19B is punched down between narrow slot walls 65 and into a small IDC fork terminal.

[0091]

[0071] As can be seen in Fig. 11, the large IDC fork terminal has a V-shaped channel and can terminate the larger diameter insulated conductor (of the trunk cable 31) near a middle of the channel to establish an electrical connection between the conductor within the trunk cable 31 and the large IDC fork terminal. As can be seen in Fig. 12, the small IDC fork terminal has a V-shaped channel and can terminate the smaller diameter, insulated conductor (of the distribution patch cable 19B) near a middle of the channel to establish an electrical connection between the conductor within the the distribution patch cable 19B and the small IDC fork terminal.

[0092]

[0072] The small and large IDC fork terminals are conductive, and an electrical connection can be made between them via a conductive path on a printed circuit board (PCB) 67 onto which they are mounted, as shown in Figure 10. As part of the mounting to the PCB 67, tabs of the large IDC fork terminal may pass through the PCB 67 and a board of the adapter panel 58 and be bent to form anchoring tabs 64. Likewise, tabs of the small IDC fork terminal may pass through the PCB 67 and the board of the adapter panel 58 and be bent to form anchoring tabs 66. The conductive path on the PCB 67 will establish electrical conductivity between the two differently sized conductors within the Attorney Docket: 4799 / 0738PW01

[0093] insulated conductor 57 of the distribution patch cable 19B and the electrical conductor within the insulated conductor 55 of the trunk cable 31.

[0094]

[0073] After all of the IDC fork terminal terminations are made, an optional snaplocking cap 71 with a resilient pusher may be attached over each of the slot walls 59, individually. More preferably a one-piece cap 71 may be simultaneously attached over all of the slot walls 59 collectively. The cap 71 will hold the terminations in place within the IDC fork terminals should adjacent trunk cables 31 being adjusted or pulled in the cable tray 43, or should the distribution patch cables 19B be subjected to movement or vibration.

[0095]

[0074] Figure 13 shows a view along line X — X in Figure 9 of an alternative IDC fork terminal structure. Figure 14 is a cross sectional view taken along line XIV — XIV in Figure 13. The alternative IDC fork terminal has wide slot walls 63 on one side to accept the larger diameter conductor of the trunk cable 31 and a narrow slot walls 65’ on the opposite side to accept the smaller diameter conductor of the distribution patch cable 19B. The alternative IDC fork terminal may be mounted to the board of the adapter panel 58 by the two outermost anchoring tabs 64, while the narrow slot walls 65’ pass through a slot formed in the board of the adapter panel 58. As a result, the wide slotwalls 63 and the narrow slot walls 65’ end up being located on opposite sides of the board of the adapter panel 58, as best seen in Figure 14.

[0096]

[0075] Since the wide slot walls 63 and narrow slot walls 65’ are formed within one continuous piece of conductive material, there is no need for a conductive path on a PCB 67 to establish electrical conductivity between the two differently sized conductors. Identical or similar adapter panels 58 with IDC fork terminals may replace the first and / or second patch panels 29 and 37 of Figs. 1, 4 and 5, and may also be rack mounted or drawer mounted to the racks or cabinets 7 of Figs. 6-8 , and may also be rack mounted or drawer mounted to racks or cabinets proximate the power pods 11, 13, 15 and 17.

[0097]

[0076] With the first and second patch panels 29 and 37 and / or the adapter panels 58, it may be beneficial to paint or adhere a labeling decal thereto. For example, the decal may be color coded red, green, yellow or blue, to indicate the power pods 11, 13, 15 or 17 associated with the terminations to be made in the port 27 of the first and second Attorney Docket: 4799 / 0738PW01

[0098] patch panels 29 and 37 or within the TDC slots 61 of the adapter panel 58. This color coding will assist the technician with making the correct connections.

[0099]

[0077] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.

Claims

Attorney Docket: 4799 / 0738PW01Claims:

1. A power cable network architecture for transmitting fault managed power (FMP) in a data center comprising:a plurality of power pods, each power pod receiving an alternating current (AC) power signal and producing a pulsing, power signal in excess of 300 volts;a plurality of power distribution units (PDUs), each PDU receiving the pulsing power signal from said plurality the power pods;a cable tray;a first patch panel holding a plurality of first plugs / ports, said first patch panel being located between a cable entrance to said cable tray and said plurality of power pods;a second patch panel holding a plurality of second plugs / ports, said second patch panel being located between a cable exit from said cable tray and said plurality of PDUs;a plurality of trunk cables, each trunk cable having a first end connected to at least one first plug / port of said plurality of first plugs / ports of said first patch panel, and each trunk cable having an opposite, second end connected to at least one second plug / port of said plurality of second plugs / ports of said second patch panel;a plurality of first patch cables, each first patch cable having a first end connected to at least one port or terminal of at least one power pod of said plurality of power pods, and each first patch cable having an opposite, second end connected to at least one first plug / port of said plurality of first plugs / ports of said first patch panel; anda plurality of second patch cables, each second patch cable having a first end connected to at least one second plug / port of said plurality of second plugs / ports of said second patch panel, and each second patch cable having an opposite, second end connected to at least one port or terminal of at least one PDU of said plurality of PDUs.

2. The power cable network architecture according to claim 1, wherein conductors of said plurality of trunk cables have larger diameters as compared to conductors of said plurality of second patch cables.Attorney Docket: 4799 / 0738PW013. The power cable network architecture according to claim 1, wherein conductors of said plurality of trunk cables have larger diameters as compared to conductors of said plurality of first patch cables.

4. The power cable network architecture according to claim 1, wherein conductors of said plurality of trunk cables are formed as solid conductors and conductors of said plurality of second patch cables are formed as stranded conductors.

5. The power cable network architecture according to claim 4, wherein conductors of said plurality of first patch cables are formed as stranded conductors.

6. The power cable network architecture according to claim 1, wherein conductors of said plurality of trunk cables are formed as solid or stranded conductors having a diameter of 10 to 14 AWG, and conductors of said plurality of second patch cables are formed as stranded conductors having a diameter of 15 to 20 AWG, and conductors of said plurality of first patch cables are formed as stranded conductors having a diameter of 15 to 20 AWG.

7. The power cable network architecture according to claim 1, wherein each trunk cable includes a trunk cable outer jacket surrounding at least two twisted pairs of insulated conductors, wherein a twist length of each twisted pair is greater than three inches and / or each twisted pair is less than ten inches.

8. The power cable network architecture according to claim 7, wherein said at least two twisted pairs of each trunk cable are stranded together with a strand lay, and wherein the strand lay is greater than sixteen inches and / or the strand lay is less than thirty inches.

9. The power cable network architecture according to claim 7, wherein each first patch cable includes a first patch cable outer jacket surrounding at least one twisted pair of insulated conductors, wherein a twist length of each twisted pair of each first patch cable is greater than one inch and / or the twist length is less than three inches; andAttorney Docket: 4799 / 0738PW01wherein each second patch cable includes a second patch cable outer jacket surrounding at least one twisted pair of insulated conductors, wherein a twist length of each twisted pair of each second patch cable is greater than one inch and / or the twist length is less than three inches.

10. The power cable network architecture according to claim 9, wherein said at least one twisted pair of each first patch cable includes at least two twisted pairs and said at least two twisted pairs of said first patch cable are stranded together with a strand lay, and wherein the strand lay is greater than twelve inches and / or the strand lay is less than twenty inches; andwherein said at least one twisted pair of each second patch cable includes at least two twisted pairs and said at least two twisted pairs of said second patch cable are stranded together with a strand lay, and wherein the strand lay is greater than twelve inches and / or the strand lay is less than twenty inches.

11. The power cable network architecture according to claim 1, wherein said plurality of power pods includes four power pods, and each PDU of said plurality of PDUs receives the pulsing power signal from said four power pods.

12. The power cable network architecture according to claim 1, wherein each trunk cable of said plurality of trunk cables includes at least one first port of said plurality of first plugs / ports as a termination at said first end of said trunk cable, and also includes at least one second port of said plurality of second plugs / ports as a termination at an opposite, second end of said trunk cable, wherein said at least one first port is attached within an opening or openings of said first patch panel and said at least one second port is attached within an opening or openings of said second patch panel.

13. The power cable network architecture according to claim 12, wherein each trunk cable includes a trunk cable outer jacket surrounding two twisted pairs of insulated conductors, with a respective first port connected to each twisted pair of insulated conductors at said first end of said trunk cable and with a respective second portAttorney Docket: 4799 / 0738PW01connected to each twisted pair of insulated conductors at said second end of said trunk cable, such that each trunk cable terminates to two first ports within said first patch panel and to two second ports within said second patch panel.

14. The power cable network architecture according to claim 12, wherein each trunk cable includes a trunk cable outer jacket surrounding four twisted pairs of insulated conductors, with a respective first port connected to each twisted pair of insulated conductors at said first end of said trunk cable and with a respective second port connected to each twisted pair of insulated conductors at said second end of said trunk cable, such that each trunk cable terminates to four first ports within said first patch panel and to four second ports within said second patch panel.

15. The power cable network architecture according to claim 12, wherein each first patch cable includes a first patch cable outer jacket surrounding a single twisted pair of insulated conductors with a first plug connected to said single twisted pair of insulated conductors at said second end of said first patch cable, such that said first patch cable terminates to said first plug at said second end of said first patch cable, and said first plug is dimensioned to fit into one first port of said plurality of first ports of said first patch panel.

16. The power cable network architecture according to claim 12, wherein each first patch cable includes a first patch cable outer jacket surrounding two twisted pairs of insulated conductors, with a respective first plug connected to each twisted pair of insulated conductors at said second end of said first patch cable, such that said first patch cable terminates to two first plugs at said second end of said first patch cable, and said two first plugs are dimensioned to fit into two first ports of said plurality of first ports of said first patch panel.

17. The power cable network architecture according to claim 1, wherein each trunk cable of said plurality of trunk cables includes at least one first plug as a termination at said first end of said trunk cable, and also includes at least one second plug as aAttorney Docket: 4799 / 0738PW01termination at an opposite, second end of said trunk cable, wherein said at least one first plug is mated within a first port of said plurality of first plugs / ports within said first patch panel, and said at least one second plug is mated within a second port of said plurality of second plugs / ports within said second patch panel.

18. The power cable network architecture according to claim 1, wherein each trunk cable of said plurality of trunk cables includes at least one first plug of said plurality of first plugs / ports as a termination at said first end of said trunk cable, and also includes at least one second port of said plurality of second plugs / ports as a termination at an opposite, second end of said trunk cable, wherein said at least one first plug is mated within a first port of said plurality of first plugs / ports within said first patch panel and said at least one second port is attached within an opening or openings of said second patch panel.

19. The power cable network architecture according to claim 1, wherein each trunk cable of said plurality of trunk cables includes at least one first port of said plurality of first plugs / ports as a termination at said first end of said trunk cable, and also includes at least one second plug of said plurality of second plugs / ports as a termination at an opposite, second end of said trunk cable, wherein said at least one first port is attached within an opening or openings of said first patch panel and said at least one second plug is mated within a second port of said plurality of second plugs / ports within said second patch panel.

20. The power cable network architecture according to claim 1, wherein said first patch panel is mounted to a network rack proximate said plurality of power pods, and wherein said second patch panel is mounted to a network rack proximate said plurality of PDUs.

21. The power cable network architecture according to claim 1, wherein said cable tray is an overhead cable tray, wherein said first patch panel is mounted to said cable tray, and wherein said second patch panel is mounted to said cable tray.Attorney Docket: 4799 / 0738PW0122. A power cable network architecture for transmitting fault managed power (FMP) in a data center comprising:a plurality of power pods, each power pod receiving an alternating current (AC) power signal and producing a pulsing, power signal in excess of 300 volts;a plurality of power distribution units (PDUs), each PDU receiving the pulsing power signal from said plurality the power pods;a cable tray;a first adapter panel holding a plurality of large insulation displacement connector (IDC) fork terminals and a plurality of small IDC fork terminals, said first adapter panel being located between a cable entrance to said cable tray and said plurality of power pods;a second adapter panel holding a plurality of large IDC fork terminals and a plurality of small IDC fork terminals, said second adapter panel being located between a cable exit from said cable tray and said plurality of PDUs;a plurality of trunk cables, each trunk cable having a first end connected to at least one large IDC fork terminal of said plurality of large IDC fork terminals of said first adapter panel, and each trunk cable having an opposite, second end connected to at least one large IDC fork terminal of said plurality of large IDC fork terminals of said second adapter panel;a plurality of first patch cables, each first patch cable having a first end connected to at least one port or terminal of at least one power pod of said plurality of power pods, and each first patch cable having an opposite, second end connected to at least one small IDC fork terminal of said plurality of small IDC fork terminals of said first adapter panel; anda plurality of second patch cables, each second patch cable having a first end connected to at least one small IDC fork terminal of said plurality of small IDC fork terminals of said second adapter panel, and each second patch cable having an opposite, second end connected to at least one port or terminal of at least one PDU of said plurality of PDUs.Attorney Docket: 4799 / 0738PW0123. The power cable network architecture according to claim 22, wherein said first adapter panel is rack-mountable to a network rack proximate said plurality of power pods, and wherein said second adapter panel is rack-mountable to a network rack proximate said plurality of PDUs.

24. The power cable network architecture according to claim 22, wherein said cable tray is an overhead cable tray, wherein said first adapter panel is mounted to said cable tray, and wherein said second adapter panel is mounted to said cable tray.

25. The power cable network architecture according to claim 22, wherein said plurality of large IDC fork terminals and said plurality of small IDC fork terminals of said first adapter panel include a first large IDC fork terminal which is electrically connected to a first small IDC fork terminal via a conductive path on a printed circuit board (PCB), and a second large IDC fork terminal which is electrically connected to a second small IDC fork terminal via a second conductive path on a same or different PCB;wherein each trunk cable includes a trunk cable outer jacket surrounding at least one twisted pair of insulated conductors, said at least one twisted pair having first and second insulated conductors press fitted into said first large IDC fork terminal and said second large IDC fork terminal of said first adapter panel, respectively, proximate a first end of said trunk cable; andwherein each first patch cable includes a first patch cable outer jacket surrounding at least one twisted pair of insulated conductors, said at least one twisted pair having first and second insulated conductors press fitted into said first small IDC fork terminal and said second small IDC fork terminal of said first adapter panel, respectively, proximate said second end of said first patch cable.

26. The power cable network architecture according to claim 25, wherein each large IDC fork terminal is dimensioned to cut through an insulation layer of said first or second insulated conductors of said at least one twisted pair of said trunk cable and engage and establish electrical continuity with a conductor therein; andAttorney Docket: 4799 / 0738PW01wherein each small TDC fork terminal is dimensioned to cut through an insulation layer of said first or second insulated conductors of said at least one twisted pair of said first patch cable and engage and establish electrical continuity with a conductor therein.

27. The power cable network architecture according to claim 22, wherein said plurality of large IDC fork terminals and said plurality of small IDC fork terminals of said first adapter panel include a first large IDC fork terminal which is formed at one end of a first conductive member and a first small IDC fork terminal formed at another end of said first conductive member, and a second large IDC fork terminal which is formed at one end of a second conductive member and a second small IDC fork terminal formed at another end of said second conductive member;wherein each trunk cable includes a trunk cable outer jacket surrounding at least one twisted pair of insulated conductors, said at least one twisted pair having first and second insulated conductors press fitted into said first large IDC fork terminal and said second large IDC fork terminal of said first adapter panel, respectively, proximate a first end of said trunk cable; andwherein each first patch cable includes a first patch cable outer jacket surrounding at least one twisted pair of insulated conductors, said at least one twisted pair having first and second insulated conductors press fitted into said first small IDC fork terminal and said second small IDC fork terminal of said first adapter panel, respectively, proximate said second end of said first patch cable.

28. A power cable network architecture for transmitting fault managed power (FMP) in a data center comprising:a plurality of power pods, each power pod receiving an alternating current (AC) power signal and producing a pulsing, power signal in excess of 300 volts;a plurality of power distribution units (PDUs), each PDU receiving the pulsing power signal from said plurality the power pods;a cable tray;Attorney Docket: 4799 / 0738PW01a second adapter panel holding a plurality of large TDC fork terminals and a plurality of small IDC fork terminals, said second adapter panel being located between an exit to said cable tray and said plurality of PDUs;a plurality of trunk cables, each trunk cable having a first end connected to at least one port or terminal of at least one power pod of said plurality of power pods, and each trunk cable having an opposite, second end connected to at least one large IDC fork terminal of said plurality of large IDC fork terminals of said second adapter panel; and a plurality of second patch cables, each second patch cable having a first end connected to at least one small IDC fork terminal of said plurality of small IDC fork terminals of said second adapter panel, and each second patch cable having an opposite, second end connected to at least one port or terminal of at least one PDU of said plurality of PDUs.

29. The power cable network architecture according to claim 28, wherein said cable tray is an overhead cable tray.

30. A power cable network architecture for transmitting fault managed power (FMP) in a data center comprising:a plurality of power pods, each power pod receiving an alternating current (AC) power signal and producing a pulsing, power signal in excess of 300 volts;a plurality of power distribution units (PDUs), each PDU receiving the pulsing power signal from said plurality the power pods;a cable tray;a second patch panel holding a plurality of second plugs / ports, said second patch panel being located between a cable exit from said cable tray and said plurality of PDUs;a plurality of trunk cables, each trunk cable having a first end connected to at least one port or terminal of at least one power pod of said plurality of power pods, and each trunk cable having an opposite, second end connected to at least one second plug / port of said plurality of second plugs / ports of said second patch panel; anda plurality of second patch cables, each second patch cable having a first end connected to at least one second plug / port of said plurality of second plugs / ports of saidAttorney Docket: 4799 / 0738PW01second patch panel, and each second patch cable having an opposite, second end connected to at least one port or terminal of at least one PDU of said plurality of PDUs.

31. The power cable network architecture according to claim 30, wherein said cable tray is an overhead cable tray.

Images