Alpha BD-8 User Manual
Powernode
Series
Enclosures
®
®
PN-6 and BD-8
Enclosure Installation Manual
Effective: June, 2003
®
Powernode Enclosure Installation Manual
031-032-C2-002, Rev. B — © 2003 Alpha Technologies
Alpha Technologies
Power
Alpha PN-6 / BD-8
Effective: June, 2003
®
PN-6/BD-8
Enclosure Installation Manual
031-032-C2-002, Rev. B
Effective Date: June, 2003
Copyright© 2003
Alpha Technologies, Inc.
NOTE: Alpha denies responsibility for any damage or injury involving its
enclosures, power supplies, generators, batteries, or other
hardware when used for an unintended purpose, installed or
operated in an unapproved manner, or improperly maintained.
NOTE: Photographs contained in this manual are for illustrative purposes
only. These photographs may not exactly match your installation.
NOTE: Review the drawings and illustrations contained in this manual
before proceeding. If there are questions regarding the safe
operation of this powering system, please contact Alpha
Technologies or your nearest Alpha representative.
Contacting Alpha Technologies:
For general product information and customer service
1-800-863-3930
(7:00 AM to 5:00 PM Pacific Time )
For complete technical support
1-800-863-3364
(7:00 AM to 5:00 PM Pacific Time, or 24/7 emergency support)
Preface
Series
Powernode
Table of Contents
OVERVIEW
1.1 Introduction ....................................................................................................... 10
PRE-INSTALLATION
2.1 Site considerations ........................................................................................... 11
2.2 Concrete Pad Dimensions ................................................................................. 12
2.3 Site Cross Section ............................................................................................ 13
2.4 Enclosure Grounding ......................................................................................... 14
Enclosures
INSTALLATION
3.1 Enclosure Protection ......................................................................................... 15
3.2 Transportation and Lifting .................................................................................. 16
3.3 Enclosure Installation........................................................................................ 17
3.3.1 Attaching Enclosure to the pad .................................................................. 17
3.4 Utility Powering ................................................................................................. 18
3.4.1 Electrical Service Connection .................................................................... 18
3.5 Service Power Inserter ...................................................................................... 21
3.6 Battery Installation ............................................................................................ 22
3.6.1 Battery Safety ........................................................................................... 22
3.6.2 Battery Identification .................................................................................. 22
3.6.3 Battery Terminal Connections ..................................................................... 23
3.6.4 Battery Connection .................................................................................... 24
3.6.5 Battery Connection, 36 Volt Battery Pack (BD-8) ....................................... 25
3.6.6 Battery Connection, 48Volt Battery Pack (BD-8) ........................................ 26
3.6.7 Battery Monitor Connections with Optional Status Monitoring Module ........ 27
3.7 Power Supply Installation .................................................................................. 28
3.7.1 Power Supply Installation ........................................................................... 28
3.8 Battery Temperature Sensor .............................................................................. 30
3.9 Lightning Arrester (LA-P+) Options.................................................................... 31
3.10 Part Numbers for Optional Equipment ............................................................... 32
4
031-032-C2-002 Rev. B
Series
Powernode
List of Figures
OVERVIEW
Fig. 1-1 PN-6 with BD-8 battery enclosure .............................................................. 10
PRE-INSTALLATION
Fig. 2-1 PN-6, Single-wide Cabinet Pad dimensions ................................................ 12
Fig. 2-2 Pad Fabrication .......................................................................................... 13
Fig. 2-3 Enclosure Grounding ................................................................................. 14
INSTALLATION
Enclosures
Preface
Fig. 3-1 Enclosure protection .................................................................................. 15
Fig. 3-2 Enclosure Lifting Methods ......................................................................... 16
Fig. 3-3 Service Entrance Wiring ............................................................................. 19
Fig. 3-4 System Grounding ..................................................................................... 20
Fig. 3-5 Removing SPI Cover ................................................................................. 21
Fig. 3-6 Connecting COAX to SPI Output Port ....................................................... 21
Fig. 3-7 Battery Hazards, Date Code Label ............................................................. 22
Fig. 3-8 Battery Terminal Connections ..................................................................... 23
Fig. 3-9 BD-8 Battery Drawer .................................................................................. 24
Fig. 3-10 Battery power distribution, 36 VDC............................................................. 25
Fig. 3-11 Battery power distribution, 48 VDC............................................................. 26
Fig. 3-12 SSC Battery Monitor Connections ............................................................. 27
Fig. 3-13 Battery Remote Temp Sensor (RTS) placement ......................................... 30
Fig. 3-14 LAP Plus ................................................................................................... 31
Fig. 3-15 Line Surge Arrester .................................................................................... 31
031-032-C2-002 Rev. B
5
Product Safety
Important Safety Instructions Contained In This
Manual Read This Manual Before Proceeding!
Review the drawings and illustrations contained in this manual before proceeding. If there are any questions
regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha
representative. Save this document for future reference.
To reduce the risk of injury or death caused by electrical shock, explosion of fuel or moving parts; and to ensure the
continued safe operation of this product, the following symbols have been placed throughout this manual. Where
these symbols appear, use extra care and attention.
DANGEROUS VOLTAGE
This symbol indicates a “dangerous voltage” may exist in this area of the product. Use caution whenever
working in the area to prevent electrical shock.
INHALATION HAZARD - DON’T BREATHE VAPORS
This symbol indicates an “inhalation hazard” may exist in this area of the product. Use caution whenever
working in the area to prevent possible inhalation of harmful (fuel or exhaust) vapors.
NO MATCHES OR OPEN FLAMES
This symbol indicates a “fire or explosive hazard” may exist in this area of the product. Use caution
whenever working in the area to prevent possible combustion of fuel vapors.
MECHANICAL OR MOVING PARTS HAZARD
These symbols indicate a “mechanical or moving parts hazard” may exist in this area of the product.
Use caution whenever working in the area to prevent possible injury to the operator or service personnel.
LEAK HAZARD
This symbol indicates a “leak hazard” may exist in this area of the product. Use caution whenever
working in this area to prevent and correct any leaks detected.
ATTENTION
This symbol indicates important installation, operation or maintenance instructions. Always follow
these instructions closely.
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.
6
031-032-C2-002 Rev. B
Product Safety
General Safety Precautions
A “Warning” identifies conditions and actions that pose a hazard to the user.
A “Caution” identifies conditions and actions that may damage the power supply or
associated equipment.
Warnings
NOTE: This enclosure and its associated hardware (power supply, batteries, cabling)
may contain equipment, batteries or parts which have accessible hazardous
voltage or currents.
To avoid injury
• This enclosure and its associated hardware must be serviced by authorized personnel only.
• Enclosure must remain locked at all times, except when authorized service personnel are
present.
• Remove all conductive jewelry or personal equipment prior to servicing equipment, parts,
connectors, wiring, or batteries.
• Read and follow all installation, equipment grounding, usage, and service instructions included
in this manual.
• Use proper lifting techniques whenever handling enclosure, equipment, parts, or batteries.
• Batteries contain dangerous voltages, currents and corrosive material. Battery installation,
maintenance, service and replacement must be performed by authorized personnel only.
• Never use uninsulated tools or other conductive materials when installing, maintaining,
servicing or replacing batteries.
• Use special caution when connecting or adjusting battery cabling. An improperly connected
battery cable or an unconnected battery cable can result in arcing, a fire, or possible
explosion.
:
• A battery that shows signs of cracking, leaking or swelling must be replaced immediately by
• Avoid any contact with gelled or liquid emissions from a valve-regulated lead-acid (VRLA)
• Do not smoke or introduce sparks in the vicinity of a battery.
• Under certain overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas
• Follow the battery manufacturer’s approved transportation and storage instructions.
031-032-C2-002 Rev. B
authorized personnel using a battery of identical type and rating.
battery. Emissions contain dilute sulfuric acid which is harmful to the skin and eyes.
Emissions are electrolytic, which are electrically conductive and are corrosive. Follow the
Chemical Hazards notes if contact occurs.
which isexplosive. Proper venting of the enclosure is required.
7
Product Safety
General Safety Precautions
Cautions
NOTE: Enclosure, equipment or parts may be damaged or cause damage if used or
installed improperly.
To avoid damage
• Prior to installation, verify that the AC input voltage to the enclosure and its equipment match
with respect to voltage and frequency.
• Prior to installation, verify that the output voltage from the enclosure or its equipment match
the voltage requirements of the connected equipment (load).
• Prior to installation, verify that the enclosure’s utility service panel is equipped with a properly
rated circuit breaker for use with the equipment inside. Refer to manufacturer’s
recommendations.
• Review and upgrade utility service panel circuit breaker requirements whenever the equipment
within the enclosure is changed.
• Prior to installation, contact local utilities, local building maintenance departments, and cable/
piping locator services to ensure that installation does not interfere with existing utility or
building cables/piping.
• Do not exceed the output rating of equipment. Verify load requirements prior and during
connection process.
• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge
that may have developed in your body.
:
8
031-032-C2-002 Rev. B
Product Safety
Battery Safety Notes
Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery installation,
maintenance, service and replacement must be performed by authorized personnel only.
Chemical Hazards
NOTE: Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery
contain dilute sulfuric acid, which is harmful to the skin and eyes. Emissions are
electrolytic, which are electrically conductive and corrosive.
To avoid injury:
• Servicing and connection of batteries shall be performed by, or under the direct supervision of,
personnel knowledgeable of batteries and the required safety precautions.
• Always wear eye protection, rubber gloves, and a protective vest when working near batteries.
Remove all metallic objects from hands and neck.
• Batteries produce explosive gases. Keep all open flames and sparks away from batteries.
• Use tools with insulated handles, do not rest any tools on top of batteries.
• Batteries contain or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm. Battery post terminals and related accessories contain
lead and lead compounds. Wash hands after handling. (California Proposition 65)
• Wear protective clothing (insulated gloves, eye protection, etc.) whenever installing,
maintaining, servicing, or replacing batteries.
• If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow
your company’s approved chemical exposure procedures.
• If any battery emission contacts the eye, wash immediately and thoroughly with water for 10
minutes with pure water or a special neutralizing eye wash solution and seek immediate
medical attention. Follow your company’s approved chemical exposure procedures.
• Neutralize any spilled battery emission with the special solution contained in an approved spill
kit or with a solution of 1 lb. Bicarbonate of soda to 1 gal of water. Report chemical spill using
your company’s spill reporting structure and seek medical attention if necessary.
• Always replace batteries with those of an identical type and rating. Never install old or
untested batteries.
• Do not charge batteries in a sealed container. Each individual battery should have at least 0.5
inches of space between it and all surrounding surfaces to allow for convection cooling.
• All battery compartments must have adequate ventilation to prevent an accumulation of
031-032-C2-002 Rev. B
potentially dangerous gas.
9
1. Overview
1.1 Introduction
Alpha's PN Series Powernode enclosures offer complete flexibility and modular
expandability for Cable TV powering applications. The PN-6 is designed for up to
three XMS2 power supply and up to eight batteries. A 7.5 kW generator can be
co-located for extended back-up power. For additional battery capacity, the BD-8
battery enclosure may be added.
PN-6
BD-8
Fig. 1-1 PN-6 with BD-8 battery enclosure
10
031-032-C2-002 Rev. B
2.1 Site considerations
The site must be planned so that the enclosure will receive good air flow. If
possible, in areas of extreme heat, it is best to position the enclosure so that it
will be shaded from the afternoon sun. In areas of prevailing winds, it is best that
the enclosure be located so that the sides of the cabinet face the winds instead of
the doors. This will greatly reduce the buildup of sand or snow against the
enclosure’s air vents.
In areas of potential flooding, the geographical site and concrete pad must be
located above the 100 year flood plain.
The enclosure must be placed where it will be free of obstructions, allowing easy
access to the doors for service or equipment access. For ventilation and
maintenance, allow a minimum space of 36 inches in the front and 36 inches in
the rear, between the enclosure and other solid structures.
Place the enclosure well away from ground level sources of forced water, such as
underground sprinkler systems and direct roadway splash.
2. Pre-Installation
The concrete pad drawing provided in this manual contains all of the required
mounting details, including electrical service and cable plant entrances.
For ease of installation, lightweight polymer concrete pads are available from
Alpha Technologies for all PN series enclosures.
The vapor barrier material (such as 30 lb. felt, neoprene pond liner, or heavy grade
tar paper) must initially extend at least 6" in all directions around the perimeter of
the enclosure and be trimmed closer to the enclosure, after installation.
WARNING: Never transport the unit with batteries installed. Batteries must
ONLY be installed after the unit is transported to the site and
secured to the pad. Transporting the unit with batteries installed
may cause a short circuit, fire, explosion, and/or damage to the
battery pack, enclosure and installed equipment. Damage caused
by improper shipping or transporting a unit with batteries installed is
not covered by the warranty.
The batteries used in this application may vary slightly depending upon optional
configurations, battery types, or customer requirements. The batteries are
typically gelled-electrolyte, valve-regulated such as the AlphaCell™. Should a
battery be found damaged, refer to the battery manufacturer's documentation
regarding the safe handling of the battery.
031-032-C2-002 Rev. B
11
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