Alpha MPS48-12M Technical Manual

Technical Manual

MPS48-12M

Effective: October 2007

Alpha Technologies

Alpha Technologies

Power

®

MPS48-12M

Technical Manual

021-514-B2-001, Rev. A

Effective Date: October 2007

Copyright© 2007

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.

Notice of FCC Compliance

Per FCC 47 CFR 15.21:

Changes or modifi cations not expressly approved by the party responsible for compliance could void the user’s authority to operate the
equipment.

Per FCC 47 CFR 15.105:

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.

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 or 24/7 emergency support

To report errors in this manual, send email to [e-mail]

3

Table of Contents

Safety Notes .......................................................................................................................... 6

1.0 Introduction ................................................................................................................11

2.0 Theory of Operation .................................................................................................. 12

3.0 Specifi cations............................................................................................................ 13

4.0 Installation................................................................................................................. 15

4.1 Unpacking the MPS48-12M ........................................................................... 15

4.2 Enclosure Installation, Wall-mount or Wooden Pole-mount ........................... 15

4.3 Enclosure Installation, Steel or Concrete Pole............................................... 17

4.4 AC Input (115/230Vac) Connection Procedure .............................................. 19

4.5 AC Connection with High Voltage Transformer.............................................. 20

4.5.1 Installing the Transformer.................................................................... 20

4.5.2 Installing the Streetlight AC Power Tap Cable ..................................... 21

4.6 Radio Cable Connection Procedure .............................................................. 22

4.7 Battery Connection Procedure ....................................................................... 23

4.8 Network Connections ..................................................................................... 23

5.0 Operation ..................................................................................................................24

5.1 Start-up .......................................................................................................... 24

5.2 Normal Operation........................................................................................... 24

5.3 Battery Backup Mode..................................................................................... 25

5.4 Charging Mode .............................................................................................. 25

6.0 Installing the Cold Weather Kit ................................................................................. 26

6.1 Installing the Battery Heater Mats .................................................................. 26

6.2 Installing the Insulated Battery Box................................................................ 27

7.0 Troubleshooting ........................................................................................................ 28

7.1 Troubleshooting Table .................................................................................... 28

7.2 Accessing the Local Craft Port....................................................................... 28

8.0 Maintenance ............................................................................................................. 29

8.1 Battery Replacement ..................................................................................... 29

8.2 Replacing the Power Module ......................................................................... 29

8.3 Battery Management...................................................................................... 30

4 021-514-B2-001, Rev. A

List of Figures and Tables

Fig. 1-1, MPS48-12M Overview ...........................................................................................11

Fig. 3-1, MPS48-12M Enclosure Dimensions...................................................................... 14

Fig. 4-1, AC Connections..................................................................................................... 19

Fig. 4-2, Input Voltage Select Switch ................................................................................... 19

Fig. 4-3, Streetlight AC Power Tap Cable, Stripped ............................................................. 21

Fig. 4-4, Streetlight AC Power Tap Cable, Installed ............................................................. 21

Fig. 4-5, Recommended Ground Wire Installation .............................................................. 22

Fig. 4-6, 3-hole Strain Relief Fitting ..................................................................................... 23

Fig. 4-7, Radio Cable Installed ............................................................................................ 23

Fig. 5-1, Status LEDs ..........................................................................................................25

Fig. 5-2, Battery Capacity Versus Temperature ................................................................... 26

Fig. 6-1, Battery Heater Mat Installation .............................................................................. 27

Fig. 6-2, Insulated Battery Box Installation .......................................................................... 28

Fig. 8-1, Battery Capacity Characteristics ........................................................................... 31

Table 5-1, Status LED Indications ....................................................................................... 25

Table 5-2, Recharge Times.................................................................................................. 26

5021-514-B2-001, Rev. A

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 this product, 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 provide 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!

WARNING presents safety information to PREVENT INJURY OR DEATH to the technician
or user.

6 021-514-B2-001, Rev. A

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,
which are electrically conductive and are 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.

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.

7021-514-B2-001, Rev. A

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.

8 021-514-B2-001, Rev. A

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 6 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.

• 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.

• 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 347Vac. 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

• Power supplies can reach extreme temperatures under load.

• Use caution around sheet metal components and sharp edges.

9021-514-B2-001, Rev. A

Grounding Connection Notes

In order to provide a ready, reliable source of backup power, it is necessary to establish a grounding system
that provides for the safety of service personnel responsible for operation and maintenance, and facilitates
the proper operation and protection of the equipment within the network. The grounding system must provide
protection with respect to operator safety, system communication, and equipment protection.

Safety Ground

The safety ground is a two-part system. The fi rst part is a return path for stray current back to the input
breaker, and the second is a return path from the Alpha enclosure to a second ground rod.

Typically, the safety, or utility ground, provides a return path to the input breaker or fuse panel by means
of a connection to an appropriate driven ground rod at the base of the power pole. This path must meet all
applicable codes to ensure the breaker will open, preventing unwanted current fl ow from posing a hazard to
service personnel.

The second part of the safety ground arrangement is the ground path between the Alpha enclosure and a
second ground rod located at least 6 feet away from the driven ground rod at the power pole. The second
ground rod and enclosure are connected via an AWG #6 solid copper wire buried at a depth of 8-12 inches.
The wire is connected to the cabinet by means of a ground lug on the back of the cabinet (for pole-mounted
enclosures), or to a ground lug inside the cabinet (for ground-mounted enclosures), and connected to the
ground rod by means of a listed grounding clamp suitable for direct burial, or exothermic weld. Normally it is
specifi ed that the impedance of this ground can be no greater than 25 ohms at 60Hz. If, however, dual ground
rods are installed approximately eight feet apart, it is not necessary to measure the impedance of the ground
rods to meet the maximum 25 ohms specifi cation—it is assumed that the impedance specifi cation is met.

Strike (Lightning) Ground

Lightning strikes, grid switching, or other aberrations on the power line have the potential to cause “fast rise­time currents" that can cause damage to the powering system. Without a low-impedance path to ground,
the current, while traveling through wires of varying impedance, can produce high voltages that can damage
the powering equipment. The most viable method available to protect the system from damage is to divert
unwanted fast rise-time currents along a low-impedance path to ground. A low-impedance path to ground
prevents these currents from reaching high voltage levels and posing a threat to equipment. The single­point grounding system provides a low-impedance path to ground, and the key to its success is the proper
bonding of the ground rods, so the components of the grounding system appear as a single point of uniform
impedance.

10 021-514-B2-001, Rev. A