Alpha FlexPoint AX Series User Manual
TM
FlexPoint
Residential and MDU UPS System for NID/NIU/ONTs
AX
Installation Manual
FlexPoint AX
Effective: May 2008
Alpha Technologies
Alpha Technologies
Power
®
FlexPoint AX
Installation Manual
010-318-C0-007, Rev. G
Effective Date: May 2008
Copyright
© 2008
Alpha Technologies, Inc.
member of The Group
NOTE:
Photographs contained in this manual are for illustrative purposes only. These photographs may not match
your installation.
NOTE:
Operator is cautioned to 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.
NOTE:
Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators,
batteries, or other hardware if used or operated in any manner or subject to any condition not consistent with
its intended purpose, or is installed or operated in an unapproved manner, or improperly maintained.
TM
Contacting Alpha Technologies: www.alpha.com
or
For general product information and customer service (7 AM to 5 PM, Pacifi c Time), call
1-800-863-3930
For complete technical support, call
1-800-863-3364
7 AM to 5 PM, Pacifi c Time and 24/7 emergency support
3
Table of Contents
Safety Information ..........................................................................................................................................5
1. Introduction ........................................................................................................................................9
2. Applications .......................................................................................................................................12
2.1 Outdoor Non-UPS Confi guration ..........................................................................................12
2.2 Indoor to Outdoor Non-UPS Confi guration ...........................................................................12
2.3 Outdoor UPS Confi guration ..................................................................................................13
2.4 Indoor to Outdoor UPS Confi guration ...................................................................................13
3. Specifi cations ....................................................................................................................................14
3.1 General System Specifi cations, Power Supply and Battery Box ..........................................14
3.2 Power-Ring Converter ..........................................................................................................15
3.3 Home Converter ...................................................................................................................16
3.4 7.2Ah and 17Ah Battery Modules .........................................................................................17
4. Installation .........................................................................................................................................19
4.1 Installing the Power-Ring ......................................................................................................19
4.2 Installing the Power-Ring Converter .....................................................................................20
4.3 Installing the Home Converter ..............................................................................................21
4.4 Installing the Battery Module ................................................................................................22
4.4.1 Installing the AX-12D-BBPS-17 ...............................................................................22
4.4.2 Installing the AX-12D-BBPS-7.2 ..............................................................................23
4.5 Component Interconnection .................................................................................................24
4.5.1 Input Cable Wiring ...................................................................................................24
4.5.2 Output Cable Wiring ................................................................................................24
4.5.3 Alternate Connection Method for AX-12D-UPS Module ..........................................25
5. Activation ...........................................................................................................................................26
5.1 Activating the Power-Ring Converter ...................................................................................26
5.2 Activating the Home Converter .............................................................................................27
5.3 System Runtime and Charging .............................................................................................28
5.4 Battery Management ............................................................................................................29
6. Frequently Asked Questions ..............................................................................................................30
7 Glossary ............................................................................................................................................32
Figures & Tables
Fig. 4-1, Interior View, AX-12D-BBPS-17 ..........................................................................................................................22
Fig. 4-2, Front and Rear View, AX-12D-BBPS-7.2 ............................................................................................................23
Fig. 4-3, Input/Output Connection Points ..........................................................................................................................24
Table 4-1, Pin Out, Battery Module 7-pin connector ..........................................................................................................24
Fig. 4-4, Inner Label, AX-12D-BBPS-7.2 ...........................................................................................................................24
Fig. 4-5, Rotating the Microboard ......................................................................................................................................25
Fig. 5-1, Power Ring Installation........................................................................................................................................26
Fig. 5-2, AX-12D-BBPS-7.2 Locking Feature ....................................................................................................................26
Table 5-1, LED Indications.................................................................................................................................................27
Table 5-2, AX-12D-BBPS-7.2 UPS Runtimes as a function of Temperature and Load .....................................................28
Table 5-3, AX-12D-BBPS-17 UPS Runtimes as a function of Temperature and Load ......................................................28
Table 5-4, Battery Capacity Retention and Charging ........................................................................................................29
4
010-318-C0-007, Rev. G
Safety Information
Safety Notes
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, 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.
ATTENTION:
The use of ATTENTION indicates specifi c regulatory/code requirements that may affect the placement of
equipment and /or installation procedures.
NOTE:
A NOTE provides additional information to help complete a specifi c task or procedure.
CAUTION!
The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment.
WARNING!
A WARNING presents safety information to PREVENT INJURY OR DEATH to the
technician or user.
Safety Precautions
• Only qualifi ed personnel may service the system.
• 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.
• Verify the utility service panel is equipped with a properly rated circuit breaker for use with this system.
• When connecting the load, DO NOT exceed the output rating of the power supply.
• If batteries are being stored prior to installation, charge at least once every three months to
ensure optimum performance and maximum battery service life.
• The battery pack, which provides backup power, contains dangerous voltages. Only qualifi ed personnel
should inspect or replace batteries.
• In the event of a short-circuit, batteries present a risk of electrical shock and burns from high current .
Observe proper safety precautions.
• Always wear protective clothing, insulated gloves and eye protection (i.e. safety glasses or a face shield)
whenever working with batteries.
• Always carry a supply of water, such as a water jug, to wash the eyes or skin in the event of exposure to
battery electrolyte.
010-318-C0-007, Rev. G
5
Safety Information
Battery Maintenance Guidelines
The battery maintenance instructions listed below are for reference only. Battery manufacturer’s instructions
for transportation, installation, storage or maintenance take precedence over these instructions.
• To prevent damage, inspect batteries every 3 months for:
Signs of battery cracking, leaking or swelling. The battery should be replaced immediately by
authorized personnel using a battery of the identical type and rating.
Signs of battery cable damage. Battery cable should be replaced immediately by authorized personnel
using replacement parts specifi ed by vendor.
Loose battery connection hardware. Refer to battery manufacturer’s documentation for the correct
torque and connection hardware for the application.
• Apply battery manufacturer’s specifi ed antioxidant compound on all exposed connections.
• Verify battery terminals and/or exposed connection hardware is not within 2 inches of a conductive
surface. Reposition batteries as necessary to maintain adequate clearance.
• Clean up any electrolyte (battery emission) in accordance with all federal, state, and local regulations or
codes.
• Proper venting of the enclosure is recommended. Follow the battery manufacturer’s approved
transportation and storage instructions.
• 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 potentially
dangerous gas.
Recycling and Disposal Instructions
Spent or damaged batteries are considered environmentally unsafe. Always recycle used batteries or dispose
of the batteries in accordance with all federal, state and local regulations.
Electrical Safety
• Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical
connection or conductor is not energized. Check the circuit with a volt meter with respect to the grounded
portion of the enclosure (both AC and DC) prior to any installation or removal procedure.
• Always use the buddy system when working under hazardous conditions.
• A licensed electrician is required to install permanently wired equipment.
• Input voltages can range up to 240 Vac. Ensure that utility power is disabled before beginning installation
or removal.
• Ensure no liquids or wet clothes contact internal components.
• Hazardous electrically live parts inside this unit are energized from batteries even when the AC input
power is disconnected.
Mechanical Safety
• Keep hands and tools clear of fans. Fans are thermostatically controlled and will turn on automatically.
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components and sharp edges.
6
010-318-C0-007, Rev. G
Safety Information
Battery Safety Notes
WARNING!
Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery
installation, maintenance, service and replacement must be performed only by authorized
personnel.
Chemical Hazards
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, and 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 fl ames 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.
• Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with
a solution of one pound Bicarbonate of soda to one gallon 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 potentially
dangerous gas.
• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have
developed on your body.
• 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 make contact with an unintended surface that can result in arcing,
fi re, or possible explosion.
• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by authorized
personnel using a battery of identical type and rating.
010-318-C0-007, Rev. G
7
Safety Information
General Safety Precautions
To avoid injury:
• This enclosure and its associated hardware must be serviced only by authorized personnel.
• 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 fi re, or possible explosion.
• A battery that shows signs of cracking, leaking or swelling must be replaced immediately by authorized
personnel using a battery of identical type and rating.
• Avoid any contact with gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery.
Emissions contain dilute sulfuric acid which is harmful to the skin and eyes. Emissions are electrolytic and
are electrically conductive and corrosive. Follow the Chemical Hazards notes if contact occurs.
• 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 that is
explosive. Proper venting of the enclosure is required.
• Follow the battery manufacturer’s approved transportation and storage instructions.
CAUTION!
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
010-318-C0-007, Rev. G
The FlexPoint AX solution is a simple, modular, cost-effective way to provide local power to
Fiber to the Home (FTTH), cable telephony, or other telecom services for Customer Premise
Equipment (CPE). The FlexPoint AX system can be confi gured as a fully accessible outdoor
powering solution, or as a partial outdoor system that keeps critical items, including the battery, outside and available to the service technician.
ATTENTION:
Compatibility Statement -Early Battery Modules with New Power Converters:
Early FlexPoint AX 30Watt 17Ah battery modules (P/N 031-192-20) and new power
converters (P/N 010-318-34 and 010-318-39) are not compatible and if installed together
will result in continuous nuisance AC fail alarms and failed batteries due to an inability
to properly charge deeply discharged batteries. New Power Converters must only be
used with new 30Watt 17Ah battery modules.
1. Introduction
New power converters (P/N 010-318-34 and 010-318-39) are compatible with early
18Watt 7.2Ah battery modules (P/N 031-191-20) provided the cable length between
the power converter and the battery module is less than 15-feet and the wire gauge is
18AWG or heavier.
FlexPoint AX components (outdoor installations)
Power-Ring: an electrical utility meter base extender. It fi ts between an
outdoor, subscriber-located electrical utility power meter and the utility meter
socket (or base). The Power-Ring Converter can tap the utility power, either
before or after the meter, and comes supplied with the Blanking Plate (see
below).
200A Continuous, 240A Rated
AX-Power-Ring-A (power tap after meter) — P/N 021-053-21
AX-Power-Ring-B (power tap before meter) — P/N 021-053-20
320A Continuous, 400A Rated
Distinguished by orange collar and more robust connectors
AX-400ARING-A (power tap after meter) — P/N 021-053-30
AX-400ARING-B (power tap before meter) — P/N 021-053-31
200A Model
320A Model
Power-Ring Blanking Plate: covers the opening in the Power-Ring when
the Power-Ring Converter is not used.
Cover Plate, Meter Adapter, AX18/30 — P/N 564-931-10
010-318-C0-007, Rev. G
9
1. Introduction
Power-Ring Converter: a modular power converter that slides into the Power-Ring. The
Power-Ring Converter converts 240Vac at the meter to a nominal 12Vdc
which feeds either the outdoor battery module, or when a UPS is not
required, directly to the subscriber’s NID/NIU/ONT.
AX-12D-PC (30 Watts) — P/N 010-318-34
Weight (lb/kg) 0.7/0.32
Dimensions (in/mm) 8.0"H x 2.0"W x 2.0"D/209H x 51W x 51D
FlexPoint AX components (indoor installation)
Home Converter: An indoor version of the Power-Ring Converter. It is located inside the subscriber’s home
and plugs into a standard AC utility outlet to convert the AC voltage into a nominal
12Vdc. Low voltage feeds from the Home Converter to an indoor or outdoor
battery module. When the battery module or NID/NIU/ONT is located outside,
a cable passes through an exterior wall to connect this product to the outdoor
battery module or directly to the subscriber’s NID/NIU/ONT.
AX30-12D-HC, 120Vin, 15V, 30W — P/N 010-318-39
CR-AX30-12D-HC, 240VIN, 15V 30W, EU Line Cord — P/N 010-318-33
CR-AX30-12D-HC, 240VIN, 15V 30W, AU Line Cord — P/N 010-318-40
CR-AX30-12D-HC, 240VIN, 15V 30W, BS1363 — PN 010-318-22
Weight (lb/kg) 0.7/0.32
Dimensions (in/mm) 2.75"H x 8.25"W x 1.5"D/70H x 209W x 38D
Battery Modules: Small plastic clamshell housings for UPS batteries available in two sizes. It is typically
located outdoors on the subscriber's residence. The Battery Module connects to either the Power-Ring
Converter or Home Converter and provides 30 Watts of 12V DC power and alarms to the NID/NIU/ONT.
Battery Backup Power Supply (BBPS) — w/alarms and LED indicators; supports battery to -40°C/-40F
AX-12D-BBPS-7.2 (7.2Ah Battery Backup Power Supply) — 031-264-21
Weight (lb/kg) 1.5/.68
Dimensions: (in/mm) 8.0"H x 9.0"W x 4.0"D/203 x 230 x 102
AX-12D-BBPS-17 (17Ah Battery Backup Power Supply) — 031-192-31
Weight (lb/kg) 4.5/2.04
Dimensions: (in/mm) 14"H x 9.5"W x 5.0"D/355 x 241 x 127
10
7.2Ah Battery Backup Power Supply
AX-12D-BBPS-7.2
17Ah Battery Backup Power Supply
AX-12D-BBPS-17
010-318-C0-007, Rev. G
1. Introduction
FlexPoint AX components (outdoor installations)
UPS Modules (Microprocessor Modules): 30 Watt UPS Module 12Vdc w/alarms and indicators.
The FlexPoint AX UPS modules are small microprocessor-based battery management systems providing
UPS power to residential and multiple dwelling FTTp optical network terminals (ONT). The UPS modules
are comprised of the same electronics as used in the AX-12D-BBPS products without battery and without
battery heating. They are used with the three wire FlexPoint AX Home Converter (HC) and Power
Converter (PRC).
AX-12D-7.2Ah (for 7.2Ah battery) — 745-816-23
AX-12D-17Ah (for 17Ah battery) — 745-816-22
AX-12D-7.2Ah UPS Module
(wire harness terminated with Fast-On connectors)
AX-12D-17Ah UPS Module
(wire harness terminated with ring lugs)
Batteries (separately ordered and shipped)
AX-STDBAT-7 — 181-036-10 Weight (lb/kg): 5/2.27 (1-year warranty)
AX-LONGBAT-7 — 181-063-10 Weight (lb/kg): 5/2.27 (3-year warranty)
AX-STDBAT-17 — 181-022-10 Weight (lb/kg): 13/5.9
010-318-C0-007, Rev. G
AX-STDBAT-7
AX-LONGBAT-7
7.2Ah Battery
AX-STDBAT-17
17Ah Battery
11
Loading...