Alpha BD-8 User Manual

Download

Page 1

Powernode

Series Enclosures

PN-6 and BD-8

Enclosure Installation Manual

Effective: June, 2003

Page 2

Powernode Enclosure Installation Manual

Alpha Technologies

Power

Alpha PN-6 / BD-8

Effective: June, 2003

Page 3

PN-6/BD-8

Enclosure Installation Manual

031-032-C2-002, Rev. B

Effective Date: June, 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)

Page 4

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

031-032-C2-002 Rev. B

Page 5

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

Page 6

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.

031-032-C2-002 Rev. B

Page 7

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.

Page 8

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.

031-032-C2-002 Rev. B

Page 9

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.

Page 10

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

031-032-C2-002 Rev. B

Page 11

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

Page 12

2. Pre-Installation

2.2 Concrete Pad Dimensions

3.00 (Ref.)

64.00 (Ref.)

21.50

15.50

14.62

7.62

7.00

0.00

2.38

8.50

14.50

ENCLOSURE

REAR

Enclosure Mating

Surface

From Battery

Vault

4.62

36.0 (Ref.)

Meterbase Service

Entrance

Enclosure Mounting

Bolts or Insets

Service Disconnect

Entrance

Open area for coax

and grounding

sweeps

ENCLOSURE

FRONT

10.00

15.00

29.00

44.00

48.00

54.00

0.00

4.00

5.75

Fig. 2-1 PN-6, Single-wide Cabinet Pad dimensions

(Polymer Concrete Precast Pad P/N 641-089-10)

Pad can either be poured on site or precast by Alpha Technologies.

All dimensions shown in inches. Mounting holes and sweeps indexed from front left mounting stud or insert.

Alpha recomends a minimum distance of 6” from the enclosure wall and the edge of the pad.

All mounting hardware must be stainless steel, galvanized steel, or better to prevent corrosion.

A 25+ year continuous vapor barrier must be used between the enclosure and the pad to prevent moisture ingress and possible corrosion caused by metal to concrete contact. The vapor barrier material (such as 30 lb felt, neoprene pond liner, or heavy grade tar paper) must be initially extended at least 6" in all directions around the perimeter of the enclosure. After the enclosure is secured to the pad, the material can be cut closer to the enclosure, using the appropriate knife or cutting tool (see page 17).

031-032-C2-002 Rev. B

Page 13

2.3 Concrete Pad Installation

2. Pre-Installation

(Pour-in-place option shown)

Undisturbed Ground

Compacted Gravel (approx. 12")

Concrete Pad (3" to 6" thick)

Open area for output power and ground

1/2" -13 mounting studs or threaded inserts

Open area for utility power sweeps

Open area for Generator Interface Kit

Fig. 2-2 Site Cross Section

031-032-C2-002 Rev. B

Page 14

2. Pre-Installation

2.4 Enclosure Grounding

NOTE: Alpha Technologies recommends using the grounding method illustrated

Alpha Technologies recommends 5 ohms minimum ground resistance between enclosure and ground rods, in accordance with IEEE 1100-1999 Powering and Grounding Electronic Equipment. NEC minimum grounding standard is 25 ohms.

Alpha Technologies assumes no responsibility or liability for failure of the installer to comply with the requirements of all applicable local and national codes. Where allowed, exothermic welding may be used as an alternative to Burndy clamps and connectors.

below. The grounding method for a particular site will be dependant upon soil type, available space, local codes, NEC (National Electric Code), and other site- specific characteristics.

Burndy YGHP58C2W-3 or Equivalent

Two 8' Ground Rods 6' Apart (min)

Burndy YGHP58C2W-2TN or Equivalent

Terminate at Service Entrance Ground

Terminate at Enclosure Ground Bar

#2 AWG

Fig. 2-3 Enclosure Grounding

(The above drawing is for reference only, is not to scale, and may lack some details)

Service Grounding (required)

#6 bare copper wire from service entrance ground bar, with two ground rods 6' apart.

Lightning Protection (optional)

1/2" X 8' copper ground rods, four places.

#6 bare copper loop terminated at each ground rod, 30" below grade (min).

Corrosion-proof (25 yr. life-span) connections suitable for direct burial MUST be used.

#6 bare copper wire from loop to enclosure ground bar

031-032-C2-002 Rev. B

Page 15

3.1 Enclosure Protection

Alpha Technologies, Inc. cannot anticipate all of the ways a vehicle may potentially threaten an installed system or the specific type of protection that is appropriate for a particular location. The determination of the threat to the equipment and the means of protection are the responsibility of the end user of the equipment and the authority having jurisdiction. The following installation drawing for Alpha’s Standby Power systems are general recommendations and not intended to be a specific guideline for protecting the equipment. The numbers of Bollard posts (or other protection devices) depend upon equipment locations, site surveys, and traffic patterns.

3. Installation

PAD

PN-6

Optional

Generator

POSTS

SIDEWALK

031-032-C2-002 Rev. B

Fig. 3-1 Enclosure protection

Page 16

3. Installation

3.2 Transportation and Lifting

The PN-6 cabinet as shipped, is extremely heavy. A safe means of transportation to the site and a safe procedure for unloading the enclosure is necessary. Do not transport or lift with a device that may not be able to bear the unit's weight, and do not place the unit upon a surface that will not be able to fully support it. Verify that the transport path is free of obstructions.

NOTE: Enclosure must always remain in the upright position during the

shipping, storage and installation process. Damage may result from enclosure being shipped or stored on its side.

NOTE: Electronic modules, batteries or other components must NOT be

installed until the enclosure is securely set in place at its permanent location.

Fig. 3-2 Enclosure Lifting Methods

031-032-C2-002 Rev. B

Page 17

3.3 Enclosure Installation

3.3.1 Attaching Enclosure to the pad

Tools Needed:

Ratchet set with 6” extension. Vapor Barrier Utility Knife

Procedure:

3. Installation

NOTE: A 25+ year

enclosure and pad to prevent moisture ingress and possible corrosion caused by metal to concrete contact. The vapor barrier material (such as 30 lb. felt, neoprene pond liner, or heavy grade tar paper) should initially extended at least 6" in all directions around the perimeter of the enclosure.

1. Unwrap the enclosure and inspect the contents. If items are missing or damaged, contact Alpha Technologies and the shipper immediately.

2. Place the vapor barrier material on the pad.

3. Unbolt the enclosure from the shipping pallet.

4. Using an appropriate crane and spreader bar, lift the enclosure off the shipping pallet, and place over the mounting studs or inserts on the pad.

5. Secure the enclosure to the pour in place pad using four stainless steel flat

washers, lockwashers, and nuts. Secure the enclosure to the pre cast pad using stainless steel bolts, flat washers and lock washers.

6. Trim the vapor barrier material.

continuous vapor barrier

must be used between the

031-032-C2-002 Rev. B

Page 18

3. Installation

3.4 Utility Powering

3.4.1 Electrical Service Connection

The XM2 Power Supplies are powered by either 120Vac or 240Vac (120/120 grounded neutral), attached to an external service entrance. The size of the service conductors must be based upon the actual size of the utility service and be in accordance with applicable electrical code requirements.

The utility conduit may be placed in two locations, depending upon the utility service entrance requirements. Note the optional conduit location for use with meter base and the standard location for entry directly to the load center.

Proper grounding is critical. The enclosure MUST have a hardwired ground to the service entrance. A qualified electrician should verify that grounding is in compliance with applicable electrical codes.

NOTE: All applicable codes must be adhered to when installing a system,

pouring concrete, or placing a preformed pad. These codes supersede any procedures outlined in this document.

NOTE: All mounting hardware should be

on local environmental conditions. Use of improper hardware may cause corrosion which is not covered under warranty.

NOTE: Soil conditions vary and may affect the integrity of the pad. Alpha

Technologies recommends that proper steps be taken to ensure that the soil supporting the pad is stable. Improper installation of the pad may cause uneven settling or cracking which is not covered under warranty.

CAUTION: The following should be performed only by qualified service personnel

and in compliance with local electrical codes.

Verify electrical codes prior to installation. Codes may vary and contain specific conduit and wire sizes for connection to the service entrance.

Connection to utility power must be approved by the local utility before installing the power supply.

Materials Required:

1" dia. conduit - PVC or Galvanized Steel (threaded) #6 AWG - Red /stranded insulated wire #6 AWG - Black / stranded insulated wire #6 AWG - White / stranded insulated wire #2 AWG or larger - Stranded copper ground wire

stainless

galvanized steel

, depending

031-032-C2-002 Rev. B

Page 19

3. Installation

3.4 Utility Powering,

3.4.1 Electrical Service Connection,

Tools Needed:

No. 1 Flat Head Screwdriver Adjustable Pliers (Channel-Lock)

Procedure:

1. Locate the service entrance panel on the enclosure (exterior). Remove the cover to access the circuit breaker assembly. If this service panel is to be used as the primary service entrance, neutral must be bonded to ground.

2. Connect one of the black #6 wires to the bottom of the left side of the input circuit breaker (Line 1), and the remaining black (or red) #6 wire to the right side of the input circuit breaker (Line 2). Connect the #6 white wire to the top of the neutral bus to the right of the circuit breakers.

continued

240 VAC

Installation

Line 1 Line 2

Neutral

Ground

031-032-C2-002 Rev. B

Fig. 3-3 Service Entrance Wiring

Page 20

3. Installation

3.4 Utility Powering,

3.4.1 Electrical Service Connection,

3. Connect the #6 green ground wire to the large terminal on the ground bar.

4. Notify the electrical inspector to approve the service entrance wiring. Once approved, contact the local power utility for electrical service.

continued

Fig. 3-4 System Grounding

031-032-C2-002 Rev. B

Page 21

3.5 Service Power Inserter

1. The SPI box(es) are mounted on a bracket behind the top power supply.

2. Remove the two screws on the face of the SPI and lift off the cover to gain access to the Seizure Screw Assembly. Loosen the Seizure Screw several turns so that the stinger will pass through the clamp (Fig. 3-5).

3. Insert the Coaxial Termination into the output port on the bottom of the SPI. Verify the stinger goes through the Seizure Screw Assembly. Tighten the Coaxial Termination (Fig. 3-6).

4. Tighten the seizure screw to 35.0 Inch-

Pounds. Replace the SPI cover and screws. Inadequatly tightened seizure screws will result in high resistance contact, increased contact heat, and possible contact failure.

"Innergy" connector

3. Installation

Seizure Scr ew

Assembly

15 Amp-rated SPI

Verify the switch on the top or the

SPI is in the ON position. The AUX position is used only when an alternate power source is connected to the 'Jones’ (in 15A rated SPI units) or ‘Innergy’ connector (in 25A rated SPI units) on the top of the SPI.

Enclosure

Coaxial Termi nation

Stinger

Output

Port

Wall

Seizure Screw

Assembly

Side View of SPI Case

Seizure Screw

Assembly

25 Amp-rated SPI

Fig. 3-5 Removing SPI Cover

Circuit Board

031-032-C2-002 Rev. B

Fig. 3-6 Connecting COAX to SPI Output Port

Page 22

3. Installation

3.6 Battery Installation

3.6.1 Battery Safety

Battery systems represent a risk of electrical shock and high short circuit currents. The following precautions must be observed when maintaining batteries:

• Remove all personal metal objects (watches, rings, etc.).

• Use insulated tools.

• Wear eye protection, rubber gloves and protective vest.

• Observe circuit polarities.

• Do not make or break live circuits.

• Do not lay metal tools and hardware on top of the batteries.

The battery is enclosed in cabinets with limited access. Again, extreme caution must be exercised when maintaining and collecting data on the battery system.

3.6.2 Battery Identification

Each battery contains a DATE CODE usually located on a sticker near the center of the battery or stamped in white ink near the POS terminal. This date code must be recorded in the battery’s maintenance log. If batteries other than those installed by Alpha are used, consult the battery’s manufacturers’ documentation for date code type and placement.

Battery Date Code

CALIF. PROPOSITION 65

DANGER/POISON

SHIELD EYES EXPLOSIVE GASES

CAN CAUSE BLINDNESS OR INJURY

NO SPARKS, FLAMES, OR SMOKING SULFURIC ACID CAN CAUSE

BLINDNESS OR SEVERE BURNS

FLUSH EYES IMMEDIATELY WITH WATER

GET MEDICAL HELP FAST. KEEP OUT OF REACH OF CHILDREN

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of Calif. to cause cancer and reproductive harm. Wash hands after handling.

MMYY

located in this box

(0103 = Jan. 2003)

Fig. 3-7 Battery Hazards, Date Code Label

031-032-C2-002 Rev. B

Page 23

3. Installation

3.6 Battery Installation,

3.6.3 Battery Terminal Connections

The accompanying drawings are for batteries with different mounting styles and hardware may be shipped with the system.

Mounting hardware requirements may vary with battery manufacturers. Use only the hardware recommended by your particular battery manufacturer.

The following illustration shows the typical terminal assembly for vertically mounted battery posts. The battery cables should be in direct contact with the battery post. All additional battery cables should be either in contact with the battery post or another battery cable, the battery cable stack-up should be limited to only two cables per side.

Using the hardware that is shipped with the Battery Cable Kit, make all battery connections as shown below. For AlphaCell™ batteries, follow the torque figures printed on the batteries. For other batteries, ALWAYS refer to the manufacturers’ specifications for correct mounting hardware and torque requirements. During maintenance procedures, refer to the manufacturers’ specifications for maintenance torque requirements.

continued

illustrative

purposes only. Various types of

Fig. 3-8 Battery Terminal Connections

Bolt

Flat Washer

Battery Post

Battery Cable

Flat Washer

Lock Washer

Nut

031-032-C2-002 Rev. B

Page 24

3. Installation

3.6 Battery Installation,

3.6.4 Battery Connection

Tools Needed:

Two 7/16” open end wrenches

Procedure:

Note: The BD-8 battery enclosure is an option, and may not be present.

1. Place batteries on the PN-6 battery trays, as shown in Fig. 3-10 or 3-11.

2. If the BD-8 enclosure is used, route the cables through the opening in the right front corner of the enclosures.

3. Connect the battery packs to the Battery Interface Unit at the top of the right side of the PN-6 enclosure.

continued

Fig 3-9 BD-8 Battery Drawer

031-032-C2-002 Rev. B

Page 25

3. Installation

3.6 Battery Installation,

3.6.5 Battery Connection, Numbering for 36 Volt Battery Pack

PN-6

Enclosure

continued

Battery Interface Unit

Optional BD-8

Connection

Neg

Pos

Neg

Pos

Neg

Pos

Neg

Upper

Pos

Neg

Tray

BD-8

Enclosure

(Option)

Lower

Tray

031-032-C2-002 Rev. B

NOTE: Battery numering scheme in accordance with SCTE guidelines

for battery status monitoring.

Fig 3-10 Battery Power Distribution, 36 VDC

Page 26

3. Installation

3.6 Battery Installation,

3.6.6 Battery Connection, Numbering for 48 Volt Battery Pack

PN-6

Enclosure

continued

or Generator Connection

From

Generator

Output

Optional BD-8

Pos

Neg

Battery Interfac e Unit

Pos

Neg

Upper

Tray

Pos

Neg

Pos

Neg

Pos

Neg

BD-8

Enclosure

(Option)

Lower

Tray

NOTE: Battery numering scheme in accordance with SCTE guidelines

for battery status monitoring.

Fig 3-11 Battery Power Distribution, 48 VDC

031-032-C2-002 Rev. B

Page 27

3. Installation

3.6 Battery Installation,

3.6.7 Battery Monitor Connection with optional Status Monitoring Module

The BATT connection (8-pin Mini Mate-n-Lok), on an optional Status Monitoring Module is an interface which enables the measuring of two sets of 36V or 48V battery strings. Refer to the status monitor’s installation and operation manual for detailed instructions on wiring the battery packs.

continued

031-032-C2-002 Rev. B

Page 28

3. Installation

3.7 Power Supply Installation

3.7.1 Power Supply Installation

Tools Needed:

None

Procedure:

1. Place an XMS2 power supply on one of the trays inside the enclosure.

2. Verify the input AC breaker

is in the OFF position.

Plug the XMS2 into an available outlet on the left wall of the enclosure.

031-032-C2-002 Rev. B

Page 29

3. Installation

3.7 Power Supply Installation

3.7.1 Power Supply Installation,

3. Verify that the Battery Circuit Breaker is in the OFF position. Connect the

red and black battery cable to the BATTERY INPUT connection.

, continued

continued

4. Connect the black and white wire from the SPI(s) to the OUTPUT connection

on the front of the XMS2 power supply.

031-032-C2-002 Rev. B

Page 30

3. Installation

3.8 Battery Remote Temperature Sensor (RTS)

Tools Needed:

Adhesive Tape

Procedure:

1. Attach the RTS Probe to the inner side of one of the batteries with adhesive tape.

2. For enclosures with multiple battery strings, the RTS must be located with the WARMEST battery string. This ensures proper operation of the battery charger’s temperature compensation circuit. Failure to locate the RTS with the warmest battery string could result in overcharging and premature battery failure.

3. The other side of the Temp Probe is attached to the front panel of the XMS2 power supply, in the jack labeled TEMP PROBE.

Fig 3-13 Battery Remote Temp Sensor (RTS) Placement

031-032-C2-002 Rev. B

Page 31

3.9 Lightning Arrester Option

Alpha’s LA Series voltage suppressors provide reliable protection of power supplies and related equipment from the damaging powerline disturbances common to cable TV and broadband applications. The LA Series incorporates MOV’s that effectively limit voltage surges and absorb excessive energy levels. Housed in a durable polymer casings with standard electrical plugs, the LA Series plugs directly into any electrical outlet.

NOTE: LED On - Operation Normal, LED Off - LAP has failed, Replace LAP

3. Installation

LA - P PLUS

120VAC 20A 50/60Hz

RATED AMBIENT 55 C MAX

P/N 020-098-24

REPLACE UNIT WHEN LAMP BE COME S DI M OR IS OUT

P/N 020-098-24

LED

LA - P PLUS

240VAC 20A 50/60Hz

RATED AMBIENT 55 C MAX

P/N 020-098-25

REPLA CE UNIT WHEN LAMP BECOMES DIM OR IS OUT

P/N 020-098-25

LED

Fig. 3-14 LAP Plus

This hard-wired surge arrester is designed to protect against lightning induced surges for electrical equipment and wiring. When installed, the arrester will quickly divert to ground the lightning surges attempting to enter your electrical system. The surge protector is designed to handle repetitive operations. Excessive severe lightning can cause the device to fail, and it should be replaced under the following conditions: If any portion of the indicating window is black, or if the indicating window is completely black.

031-032-C2-002 Rev. B

P/N 162-026-10 (120V) P/N 162-025-10 (240V)

Fig. 3-15 Line Surge Arrester

Page 32

3. Installation

3.10 Part Numbers for Optional Equipment

Item: Part Number:

Star Lock Security Bolt (X4) 744-897-20 Security Key 647-089-10

Cooling Fan Replacement Fuse 460-192-10

Tamper Switch TS-CE6-NC 745-023-20 Tamper Switch TS-CE6-BD8-NC 745-023-21

Lightning Arrester LA-P+ 120V (L-N, L-G, N-G) 020-098-24 LA-PC+ 120V (L-N, L-G, N-G) 020-098-26 LA-PE+ 240V (L1-L2, L1-G, L2-G) 020-098-25

Extra SPI (20 Amp) 744-279-22 Extra SPI (25 Amp) 744-789-21 Extra SPI (25 Amp) 60” lead 744-789-25

NOTE: Alpha part numbers are correct at the time of printing. As part

numbers are subject to change, please contact your Alpha Representative prior to ordering to ensure that numbers are correct.

031-032-C2-002 Rev. B

Page 33

Page 34

Alpha Technologies

Power

Corporate

Alpha Technologies 3767 Alpha Way Bellingham, WA 98226

USA

Tel: (360) 647-2360 Fax: (360) 671-4936 Web: www.alpha.com

Alpha Technologies Ltd. 4084 McConnell Court Burnaby, BC, V5A 3N7

CANADA

Tel: (604) 430-1476 Fax: (604) 430-8908

Alpha Technologies Europe Ltd. Cartel Business Estate Edinburgh Way Harlow, Essex CM20 2TT

UNITED KINGDOM

Tel: +44-1279-422110 Fax: +44-1279-423355

Alpha Technologies Hansastrasse 8 D-91126 Schwabach

GERMANY

Tel: +49-9122-79889-0 Fax: +49-9122-79889-21

Alphatec 339 St. Andrews Street Suite 101 Andrea Chambers Limassol, Cyprus

CYPRUS

Tel: +357-25-375675 Fax: +357-25-359595

Alpha Technologies Unit R5-R7 Regents Park Estate Corner Park Rd and Prince’s Rd East Regents Park, NSW 2143

AUSTRALIA

Tel: +61-2-9722-3320 Fax: +61-2-9722-3321

Due to continuing product improvements, Alpha reserves the right to change specifications without notice.