Alpha APP 9022S User Manual

APP 9015S

APP 9022S

Service Power Supply

© 2002

Installation and Operation Manual

Effective: January 2002

®

TM

This page intentionally blank

®

APP 9015S
APP 9022S

Service Power Supply

Installation and Operation Manual

016-537-B0-001, Rev. A

January, 2002

© 2002 Alpha Technologies

Purpose of this Manual: The purpose of the APP Service Power

Supply Manual is to detail system features,
system operation, options installation and
maintenance procedures. It is written
primarily for the system operator.

NOTE: Alpha Technologies products are subject to change through continual

improvement processes. Therefore, specifications and/or design
layouts may vary slightly from descriptions included in this manual.
Updates to the manual will be issued when changes affect form, fit or
function.

© 2002

TM

3

016-537-B0-001 Rev. A

Table of Contents

Contact Alpha ........................................................................... 6

Safety ...................................................................................... 7

Safety Symbols Used in this Manual ................................................................... 7

Safety Precautions ......................................................................................... 7

Utility Power Connection Notes ......................................................................... 8

Unpacking and Inspection ......................................................... 9

1. Introduction

1.1 The APP Service Power Supply ..................................................... 11

1.2 Theory of Operation..................................................................... 12

1.3 APP Service Power Supply Features ............................................... 12

2. Installation

2.1 APP SPS Installation and Power Module Removal............................... 16

3. Trouble-Shooting

3.1 Trouble-Shooting Guide ................................................................ 18

3.2 APP 9022S Schematic .................................................................. 20

3.3 Returns, Repair, and Parts Ordering ............................................... 21

Table of Figures

Figure 1-1; APP 9015S Service Power Supply, Front Panel ........... 14

Figure 1-2; APP 9022S Service Power Supply, Front Panel ........... 15

Figure 2-1; 20A Service Power Inserter .................................... 17

Figure 2-2; 25A Service Power Inserter .................................... 17

Figure 3-1; APP 9022S Service Power Supply Schematic ............. 20

List of Tables

Table 1-1; Specifications ....................................................... 11

© 2002

TM

5

016-537-B0-001 Rev. A

Contact Alpha

General product information

and customer service

7:00 AM to 5:00 PM Pacific Time

1-800-863-3930

To obtain complete technical support
7:00 AM to 5:00 PM Pacific Time

or

For after-hours emergency support

7 days per week, 24 hours a day

1-800-863-3364

016-537-B0-001 Rev. A 6

© 2002

TM

Safety

Safety Symbols Used in this Manual

CAUTION

HAZARDOUS CONDITION

To reduce the risk of electrical shock, injury or death caused by moving parts
or the explosion of fuel, and to ensure the safe operation of this unit, the
following symbols have been placed throughout this manual. Where these
symbols appear, servicing must only be performed by qualified personnel.

Dangerous Voltage

This symbol indicates that a dangerous voltage exists in this area of
the product. Use caution whenever working in the area to prevent
electrical shock.

Attention

This symbol indicates important installation, operation or maintenance
instructions. Always follow these instructions closely.

Safety Precautions

 The APP Service Power Supply must be installed and serviced by qualified

personnel.

 Always use proper lifting techniques whenever handling units, modules or

batteries.

 Verify the voltage requirements of the equipment to be protected (load),

the AC input voltage to the power supply (line), and the output voltage of
the system prior to installation.

 The utility service panel must be equipped with a properly rated circuit

breaker for use with this power supply.

© 2002

 Do NOT exceed the output rating of the power supply, when connecting

the load.

 Use a bucket truck or suitable climbing equipment, such as safety harness

and spikes, whenever installing or servicing pole-mount installations.

 Do not let exposed battery cables come in contact with the chassis or

enclosure.

TM

7

016-537-B0-001 Rev. A

Safety

Utility Power Connection Notes

CAUTION: Installation must be performed by qualified service personnel

only, and in compliance with local electrical codes. Connection
to utility power must be approved by the local utility before
installing the power supply.

CAUTION: A high magnetic trip breaker must be used in order to

accommodate the high-inrush currents normally associated with
the start-up of ferroresonant transformers (400 Amp, no-trip,
first-half cycle). Do not replace this breaker with a conventional
service entrance breaker. Alpha recommends only Airpax
breakers because of increased reliability in this powering
application.

NOTE: UL and NEC require that a service disconnect switch (UL listed)

be provided by the installer and be connected between the
power source and the Alpha power supply. Connection to the
power supply must include an appropriate service entrance
weather head.

016-537-B0-001 Rev. A 8

© 2002

TM

Unpacking and Inspection

Verify that the following items have been included in the shipping container:

APP 9015S:

1. APP 9015S Service Power Supply

2. Power cord with 5-20P plug (120VAC)

NEMA 5-20 Plug

3. Power cord with 6-15P plug (240VAC)

NEMA 6-15 Plug

4. Output cable, single Jones

APP 9022S:

1. APP 9022S Service Power Supply

2. Power cord with 5-20P plug (120VAC)

3. Power cord with 6-15P plug (240VAC)

4. Y-cable with Jones connectors

NEMA 5-20 Plug

NEMA 6-15 Plug

© 2002

5. Y-cable with 25A connectors

TM

9

016-537-B0-001 Rev. A

Unpacking and Inspection

APP 9022S, continued

6. Optional 30-Ft Output kit,
includes:
a. Y cable adapter for Jones
connector

b. Y cable adapter for 25A
connector

c. 30-Ft cable

7. Optional 10-Ft cord with 30A connector
and Twist Lock plug (125VAC)

a

c

b

NEMA L5-30R Plug

Inspect the contents. If items are damaged or missing, contact Alpha Technologies
and the shipping company. Most shipping companies have a limited claim period, so it
is important to report damage immediately.

Save the original shipping container.

In the event that a unit must be returned for service, Alpha requests that it
be packaged in its original shipping container. If the original container is not
available, make sure the unit is packed with at least three inches of shock
absorbing material to prevent shipping damage.

NOTE: Do not use popcorn-type material. Alpha Technologies is

not responsible for damage caused by improper packing
on returned units.

016-537-B0-001 Rev. A 10

© 2002

TM

1. Introduction

1.1 The APP Service Power Supply

The APP Service Power Supply (SPS) is a portable device used to provide temporary
power while the existing power supply is being serviced. The APP SPS can be used in
either pole- or ground-mount enclosures to provide signal processing equipment in
Cable Television and Broadband LAN distribution systems with current-limited,
regulated AC power.

The APP SPS contains a front panel ammeter to measure the output current to the
load; an output breaker to protect against excessive short circuit currents; an
"Output" indicator to verify AC output power; an input breaker to provide additional
voltage protection; and a 60/75/90 VAC switch for output voltage selection.

LEDOM S5109PPA S2209PPA

)CAV(egatloVtupnI %51±042/021%51±042/021

)zH(

)A(

)CAV(

hsiniF kcalBtalFkcalBtalF

ycneuqerFtupnI

tnerruCtupnI

egatloVtuptuO

)A(tnerruCtuptuO 51)*niCAV042(A22

)AV(rewoPtuptuO

)suounitnoC(

ycneiciffE lacipyt%09

gnitarepO

)DxWxH(

)gk/sbl(thgieW 12/7472/06

epyTerusolcnE 1AMEN1AMEN

snoitacifitreC devorppAASC

%3±06%3±06

21*xamCAV042@5.21

05310071/0561/0531

timiLtnerruCtuptuO tuptuOfo%051

gnitaR

egnaRerutarepmeT

)mm/ni(snoisnemiD

%5±09/57/06%5±09/57/06

daoldetar@

F°221+otF°04-

943x922x142

*xamCAV021@81

)*niCAV021(A71

tuptuOfo%051

gnitaR

lacipyt%09

daoldetar@

)C°05+otC°04-(

/"57.31x"5.9x"9

F°221+otF°04-

)C°05+otC°04-(

/"57.31x"5.9x"9

943x922x142

© 2002

* Figures shown reflect use with power cord supplied with unit.

For 22A @120V, use optional 30A 125V cord (27 A max).

Table 1-1; Specifications

TM

11

016-537-B0-001 Rev. A

1. Introduction

1.2 Theory of Operation

The APP SPS contains a ferroresonant transformer and a resonant capacitor. During
AC LINE operation, utility power is fed into the primary winding of the ferroresonant
transformer, T1. An AC capacitor, C1, forms the resonant circuit of the ferroresonant
transformer which provides excellent noise and spike attenuation, short circuit current
limiting, and output voltage regulation. Note: The ferroresonant transformer produces
a "quasi" square wave output which resembles a rounded square wave.

AC power enters the Service Power Supply where it is regulated (at the required
output voltage) and passed onto the load via the Service Power Inserter (SPI)
located inside the power supply enclosure. A switch, located on the SPI, toggles
output power from the power supply requiring service to the APP SPS.

NOTE: When measuring the output voltage of ferroresonant transformers,

use only a true RMS AC voltmeter. Non-RMS reading meters are
calibrated to respond to pure sine waves and will not provide an
accurate reading when measuring a "quasi" square wave output.

1.3 APP Service Power Supply Features

Output Current (Ammeter)

The Ammeter displays output current flowing from the power module to the
load. When there is no load at the output, the Ammeter reads zero.

Output Breaker

The AC output breaker protects the load from excessive durations of short
circuit current, or an out-of-phase (or buck) condition. If the front panel
ammeter reads zero, indicating no output to the load, this breaker must be
checked, and reset if necessary.

Input Breaker / Power Switch

The AC input breaker protects the Service Power Supply from short circuit
conditions, especially when it is used in conjunction with a generator during
outage conditions. If the unit does not turn ON when power is applied, first
verify that the unit is plugged into the convenience outlet and that the main
AC circuit breaker is in the ON position.

Output Power Indicator (9022) / Pilot Light (9015)

The Output Power Lamp displays the presence of output AC voltage.

016-537-B0-001 Rev. A 12

© 2002

TM

1.3 APP Service Power Supply Features, continued

Output Voltage Selector

The VAC switch is used to select the desired output voltage. Output options
are 60, 75 and 90 Volts.

NOTE: Verify that output voltage settings are correct before operating

power supply. Do not rotate switch when unit is in operation.
Always remove power from unit when selecting output settings.

60/ 75/ 90 VAC Output Connector

The 60/ 75/ 90 VAC output connector supplies up to 22 Amps of power to a
Service Power Inserter (SPI) through an output cable.

Output Cables

9015S:

Included with the APP 9015S is an output cable used to connect the Service
Power Supply to the SPI, via a four-pin Jones connector.

1. Introduction

9022S:

Included with the APP 9022S are two 6-ft output "Y" cables. One cable
terminates with two Jones connectors, and provides service power to one or
two separate 20A SPIs. The other cable terminates with two 25A connectors,
for 25A SPIs.

Input Connector

Input Connector is used to connect the APP SPS to line power through an AC
line cord. The cord plugs directly into enclosure convenience outlet.

The APP 9022S includes two power cords: One with a 5-20P plug to set
voltage to 120 VAC; and one with a 6-15P plug to set voltage to 240 VAC.

9022s Option: 30-Ft Output Cables

A 30-foot output kit is available. This kit provides "Y" cables for both 25A and
Jones connectors. Alpha part number: 745-094-20.

9022S Option: 10-Ft Cord w/30A Connector and Twist Lock Plug (125VAC)

For use with a twist lock receptacle, this line cord is equipped with a NEMA
L5-30P plug. Alpha part number: 874-935-22.

© 2002

TM

13

016-537-B0-001 Rev. A

1. Introduction

1.3 APP Service Power Supply Features, continued

8

1

7

5

6

Figure 1-1; APP 9015S Service Power Supply, Front Panel

2

3

4

1. Output Current

2. 120/240V Input Voltage Selector

3. 20 AMP AC Input Breaker/Power Switch

4. 120/240V Input Connector

5. Output Voltage Selector

6. 60/75/90V Output Connector

7. 20 AMP Output Breaker

8. Pilot Light

016-537-B0-001 Rev. A 14

© 2002

TM

1.3 APP Service Power Supply Features, continued

1. Introduction

1

7

5

6

Figure 1-2; APP 9022S Service Power Supply, Front Panel

2

3

4

© 2002

1. Output Current

2. Output Power Indicator

3. 30 AMP Output Breaker

4. 60/75/90V Output Connector

5. Output Voltage Selector

6. 120/240V Input Connector

7. 25 AMP AC Input Breaker/
Power Switch

TM

15

016-537-B0-001 Rev. A

2. Installation

2.1 APP SPS Installation and Power Module Removal

Procedure

1. Locate Service Power Inserter (SPI) in enclosure. (Refer to Figures 2-1

2 Determine the line voltage of the UPS.

3. For APP 9015S model only:

4. Select and connect appropriate line cord to Input Connector and plug into

and 2-2.) For 20A SPI, plug APP SPS "Jones" connector into SPI. (Figure
2-1.) For 25A SPI (9022S model only), plug APP SPS into red and white
25A connectors. (Figure 2-2.)

Select appropriate line voltage (120/240 VAC) by using the Input Voltage
Selector switch.

outlet.

CAUTION: Do not use the 120 VAC cord to plug into GFCI outlet!

The GFCI outlet is intended for lights and tools only.
If necessary, remove the LAP and use that outlet.

5. Set the 60/75/90 VAC selector switch to the desired voltage. Plug the
APP SPS power cord into the enclosure's convenience outlet. (See
Figures 2-3 and 2-4.) Switch the APP SPS ON, and verify that the
output power indicator is lit.

6. Toggle the SPI's ALT/ON switch to ALT. This transfers output power from
the module to the APP SPS which can now be used to maintain regulated,
non-standby power to the cable plant until a replacement power module
has been installed.

7. Switch the battery breaker on the power module OFF.

8. Unplug the power module LINE cord from the enclosure convenience
outlet.

9. Wait approximately 1 minute for the power module capacitors to fully
discharge.

10. Disconnect the wires from the power module.

CAUTION: Do not let exposed battery cables come in contact with

the chassis or enclosure.

11. Reverse this procedure when reinstalling a module.

CAUTION: The ferroresonant transformer generates heat and may

cause burns if handled with bare hands.

NOTE: Always test the power module for proper operation before

toggling the SPI's "ALT/ON" switch back to the ON position.

016-537-B0-001 Rev. A 16

© 2002

TM

2. Installation

2.1 APP SPS Installation and Power Module Removal, continued

"ALT/ON" Switch

Jones Connector

accepts mating plug

from APP SPS

Anderson connector

from power supply

Figure 2-1; 20A Service Power Inserter

(shown in PWE and UPE/M enclosures)

"ALT/ON" Switch

Anderson Connector

from power supply

25A Connectors

accept mating plug

from APP SPS

Figure 2-2; 25A Service Power Inserter

(shown in PWE and UPE/M enclosures)

© 2002

TM

17

016-537-B0-001 Rev. A

3. Trouble-Shooting

3.1 Trouble-Shooting Guide

The trouble-shooting guide is designed to display typical symptoms, causes and
solutions, starting with the most obvious and working systematically through the unit.
Alpha Technologies recommends that the power supply maintenance log accompany
units brought in for bench service to aid the technician in trouble-shooting the
problem.

Symptom #1:

No output to cable; No AC line power; Green Output Power indicator OFF:

Probable Cause:

AC line cord unplugged

AC input circuit breaker tripped (or

Solution:

Plug in AC line cord

Reset AC circuit breaker

input fuse open)

Utility power outage

Use voltmeter to verify correct voltage
(120/240 VAC) at receptacle. Connect
generator in the event of an extended
power outage.

Symptom #2:

No output to cable; AC line power available; Green Output Power indicator ON;
And Ammeter reads "0":

Probable Cause:

Solution:

AC output breaker has tripped

SPI "ALT/ON" switch in wrong position

"Jones" connector loose or not
connected to SPI

Loose seizure screw inside SPI

016-537-B0-001 Rev. A 18

Reset output breaker

Move switch to "ALT" position

Check connection

Tighten screw

© 2002

TM

3. Trouble-Shooting

3.1 Trouble-Shooting Guide, Continued

Symptom #3:

Incorrect output voltage; And/or Ammeter reads excessive current (above rated
output of APP SPS):

Probable Cause:

60/75/90 VAC switch in wrong position

Wrong type of voltmeter used

Under-loaded output (less than 1 Amp)

Overloaded output

Short exists in load

MOV shorted in SPI

APP 9015S only: 120/240 V switch in
wrong position

Solution:

Move switch to required position

Use true RMS voltmeter

Connect load

Reduce load

Locate and remove short

Replace SPI

Set switch to correct line voltage

© 2002

TM

19

016-537-B0-001 Rev. A

3. Trouble-Shooting

3.2 APP 9022S Schematic

'
$
2
/

(
1

,
/

Preliminary

Figure 3-1; APP 9022S Service Power Supply Schematic

016-537-B0-001 Rev. A 20

© 2002

TM

3.3 Returns, Repair, and Parts Ordering

Returns for Repair

For units that must be returned for repair, Alpha requires a Return Material
Authorization (RMA). An RMA can be obtained from Alpha Customer Service,
using either method listed below:

 Download the necessary forms directly from Alpha's Web site, under

"Customer Service": www.alpha.com

 Or call [phone] for assistance.

Clearly mark the RMA on the units original shipping container. If the original
container is not available, make sure the unit is packed with at least three
inches of shock absorbing material to prevent shipping damage.

NOTE: Do not use popcorn-type material. Alpha Technologies is not

responsible for damage caused by improper packing on returned
units.

3. Trouble-Shooting

In addition to the returned unit, please include a copy of the power supply
maintenance log and any information relevant to the power supply failure.

Returns for Credit

For returns for credit, call [phone].

Parts and Ordering Information

To order parts, contact the Alpha Technologies Customer Service Department
directly at:

United States
and Latin America: [phone]
Canada: [phone]
United Kingdom: 44-279-422110
Germany: 49-9122-997303
Middle East: 357-5-375675

To obtain

emergency technical support

(7 days/week, 24 hours/day) call:

© 2002

1-800-322-5742

(USA)

1-800-667-8743

(CANADA)

TM

21

016-537-B0-001 Rev. A

UNITED STATES
ASIA PACIFIC
LATIN AMERICA

Alpha Technologies
3767 Alpha Way
Bellingham, WA 98226

Tel: [phone]
Fax: [phone]

www.alpha.com

CANADA

Alpha Technologies
4084 McConnell Court
Burnaby, B.C. V5A 3N7

Tel: [phone]
Fax: [phone]

UNITED KINGDOM

Alpha Technologies
Cartel Business Estate
Edinburgh Way
Harlow, Essex CM20
2DU

Tel: [phone]
Fax: [phone]

www.alpha.com

Protecting The Power in Communications.

GERMANY

Alpha Technologies
Hansastrasse 8
D-91126 Schwabach

Tel: [phone]
Fax: [phone]

MIDDLE EAST

Alphatec
P.O. Box 6468
3307 Limassol, Cyprus

Tel: [phone]
Fax: [phone]

AUSTRALIA

Alpha Technologies
8 Anella Ave., Unit 6
Castle Hill, NSW 2154

Tel: [phone]
Fax: [phone]



Due to continuing product development Alpha reserves the right to change specifications without notice. Copyright © 2002 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies. 016-537-B0-001 Rev. A