Alpha Node Power Supply User Manual

Node Power Supply

Node Power Supply Enclosures

Installation Manual

Effective: April 2009

Alpha Technologies

Alpha Technologies

Power

®

Node Power Supply Enclosures

Installation Manual

031-295-B0-001, Rev. A

Effective Date: April, 2009

Copyright© 2009

Alpha Technologies, Inc.

NOTE:

Alpha denies responsibility for any damage or injury involving its enclosures, power supplies, generators,
batteries or other hardware, manufactured by Alpha or members of the Alpha Group, when used for an
unintended purpose, installed or operated in an unapproved manner, or improperly maintained.

NOTE:

Photographs and drawings contained in this manual are only for illustrative purposes. These photographs and
drawings my not exactly match your installation.

NOTE:

Review the written and illustrative information contained in this manual before proceeding. If there are
questions regarding the safe installation or operation of this product, please contact Alpha Technologies or
your nearest Alpha representative.

Contacting Alpha Technologies: www.alpha.com

For general product information and customer service (7 AM to 5 PM, Pacifi c Time), call

031-295-B0-001 Rev.A

OR

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

3

Table of Contents

Safety Information ................................................................................................................. 6

1.0 Introduction and Specifi cations ................................................................................. 10

1.1 Node Power Supply Enclosures .................................................................... 10

1.2 Node Power Supply Enclosures (NPS) Specifi cations ...................................11

1.3 Parts List ........................................................................................................ 12

2.0 Installation.................................................................................................................13

2.1 Pole-mounted version ....................................................................................13

2.1.1 Dimensions and features .................................................................... 13

2.1.2 Installation on wooden pole................................................................. 14

2.1.3 Installation on steel/concrete pole ....................................................... 16

2.1.4 Populating the Cabinet and Turn-Up ................................................... 18

2.2 Rack-mounted version ...................................................................................19

2.2.1 Dimensions and features .................................................................... 19

2.2.2 Installation ........................................................................................... 20

2.2.3 Populating the Cabinet and Turn-Up ................................................... 20

2.3 Wall-Mounted version .................................................................................... 21

2.3.1 Dimensions and features .................................................................... 21

2.3.2 Installation ........................................................................................... 22

2.3.3 Populating the Cabinet and Turn-Up ................................................... 22

2.4 Floor-Mounted version ...................................................................................23

2.4.1 Dimensions and features .................................................................... 23

2.4.2 Installation ........................................................................................... 24

2.4.3 Populating the Cabinet and Turn-Up ................................................... 24

2.5 Connecting Utility Power ................................................................................ 25

2.5.1 Service Power ..................................................................................... 26

2.6 Connecting the Coaxial Cable ....................................................................... 28

2.6.1 Coaxial Cable Surge Protector Installation ......................................... 28

2.6.2 Connecting the Service Power Inserter (SPI) ..................................... 29

2.6.3 Connecting the Service Power Inserter-RF (SPI) ............................... 30

2.7 Battery Installation ......................................................................................... 31

2.7.1 Installation Procedure ......................................................................... 32

2.7.2 Battery Wiring Diagram ....................................................................... 33

2.7.3 Battery Terminal Connections .............................................................34

2.8 Installing the XM Series 2 Power Supply .......................................................35

2.9 Cooling Fan Kit Installation ............................................................................ 36

2.10 Cooling Fan Kit Removal ............................................................................... 36

4

031-295-B0-001 Rev. A

Figures & Tables

Fig. 1-1 NPS Enclosures .................................................................................................. 10

Fig. 2-1 Dimensions, Pole-mounted NPS Enclosure ........................................................ 13

Fig. 2-2 Wooden Pole Installation ..................................................................................... 15

Fig. 2-3 Steel/Concrete Pole Installation .......................................................................... 17

Fig. 2-4 Dimensions, Rack-Mounted NPS Enclosure ....................................................... 19

Fig. 2-5 Dimensions, Wall-mounted NPS Enclosure ........................................................21

Fig. 2-6 Dimensions, Floor-mounted NPS Enclosure ....................................................... 23

Fig. 2-7 120Vac Service Entrance Wiring ......................................................................... 26

Fig. 2-8 Breaker Quad Option DSE-20 ............................................................................. 27

Fig. 2-9 520-R Receptacle Wiring .................................................................................... 27

Fig. 2-10 Surge Protector Mounting Locations ................................................................... 28

Fig. 2-11 SPI (Standard version) Mounting Locations ........................................................ 29

Fig. 2-12 SPI Cover Removal ............................................................................................. 29

Fig. 2-13 Coaxial Cable Connection ...................................................................................29

Fig. 2-14 SPI Mounting Locations ......................................................................................30

Fig. 2-15 Battery Identifi cation Label .................................................................................. 31

Fig. 2-16 Battery Wiring Diagram ....................................................................................... 33

Fig. 2-17 NPS Battery Wiring Diagram with HPL115 FT battery string ..............................33

Fig. 2-18 Hardware Stackup Threaded Battery Insert ........................................................ 34

Fig. 2-19 Hardware Stackup Threaded Battery Insert with Optional Inline Fuse ................ 34

Fig. 2-20 XM Series 2 Power Supply.................................................................................. 35

Fig. 2-21 Cooling Fan Installation Confi guration ................................................................ 36

Table 1-1 Specifi cations .......................................................................................................11

Table 1-2 Parts List ..............................................................................................................12

Table 2-1 Service Entrance Circuit Breaker Requirements ................................................. 25

031-295-B0-001 Rev.A

5

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!

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

6

031-295-B0-001 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 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 V AC. 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.

031-295-B0-001 Rev.A

7

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.

• 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.

8

031-295-B0-001 Rev. A

1.0 Introduction

Grounding Connection Notes

In order to provide a ready, reliable source of backup power it is necessary to connect the power supply to an
effective grounding and Earthing system that not only provides for the safety of the service personnel responsible for
its operation and maintenance, but also facilitates the proper operation and protection of the equipment within the
network. Such a grounding system provides protection with respect to operator safety, system communication, and
equipment protection.

Safety Ground

The safety ground is a two-part system, comprised of the utility service and the Alpha system.

1. First, utility service;

As a minimum requirement for the protection of Alpha equipment, the local utility service must provide a low­impedance path for fault current return to Earth. This must meet or exceed the requirements of the US National
Electrical Code. The connection between the Alpha Power Supply and the utility must also meet or exceed the
requirements of the US National Electrical Code.

2. Second, the Alpha grounding system,

The Alpha grounding system consists of a low-impedance connection between the enclosure and an Earth Ground
(located at least 6’ away from the Utility Earth connection).
This impedance between the enclosure and Earth must be 25 Ohms or less at 60 Hertz.
Local soil conditions will determine the complexity of the grounding system required to meet the 25 Ohm (maximum)
resistance specifi ed above.
For example, a single 8’ ground rod may be suffi cient to meet the requirement. In some cases, a more elaborate
system may be required such as multiple ground rods connected by a #6AWG solid copper cable buried 8-12” below
the surface. Where this is not possible, contact a local grounding system expert for alternate methods that will meet
the 25 Ohm (maximum) specifi cation.

NOTE:

All ground rod connections must be made by means of a listed grounding clamp suitable for direct burial or
exothermically welded.

Signal Ground

For proper operation, the Service Power Inserter (SPI) must be securely grounded to the enclosure chassis. This is of
particular importance in systems using an external status monitoring transponder. The transponder chassis is grounded
via a separate ground wire to the SPI case. For systems using an embedded transponder, the ground connection is
made either through a separate chassis ground block, or by means of the internal mounting hardware which grounds
the transponder through the XM2/XM2HP power supply. Please refer to the appropriate Communications product
manual for installation procedures.

Strike (Lightning) Ground

Lightning strikes, grid switching, or other aberrations on the power line and/or communications cable have the
potential to cause high-energy transients which can damage the powering or communitations systems. Without a low­impedance path to ground, the current, when traveling through wires of varying impedance, produce damaging high
voltage. The most viable method available to protect the system from damage is to divert these unwanted high-energy
transients 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 single-point grounding system provides a low­impedance 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. Alpha recommends the use of a surge arresting
device electrically bonded to the Alpha Ground System.

WARNING!

Low impedance grounding is mandatory for personnel safety and critical for the proper
operation of the cable system .

031-295-B0-001 Rev.A

9

1.0 Introduction

1.1 Node Power Supply (NPS) Enclosures

The NPS enclosures are equipped with AC service entrances, AC distribution and are supported with
a wide range of accessories, including Alpha’s XM Series 2 Model 906 power supply, AlphaCellTM
85GXL batteries and HPL-FT front terminal batteries providing extended standby runtime and life. An
optional Fan Kit is available for the NPS enclosure (see Section 2.9, Cooling Fan Kit Installation).

The NPS is specifi cally designed for indoor or outdoor installations requiring lower power, a smaller
footprint and embedded DOCSIS

®

or proprietary status monitoring capability. The NPS is available
in pole-, rack-, wall- or fl oor-mount confi gurations. The NPS is an ideal solution for back-up power
where traditional equipment is too large and bulky.

10

Fig. 1-1, Node Power Supply Enclosures, pole-mount, rack-mount, and wall-mount confi gurations

031-295-B0-001 Rev. A

1.2 Node Power Supply (NPS) Specifi cations

Models NPS-R NPS-W1 NPS-W2 NPS-F NPS-P

Confi gurations

Installation Indoor Indoor Outdoor Indoor Outdoor
Description 19" and 23" Rack Mount Wall mount Wall mount Floor mount Pole Mount

Mechanical

Dimensions
H x W x D (in/mm)

Weight (lb/kg) 39 / 17.7 39 / 17.7 39 / 17.7 39 / 17.7 39 / 17.7

Specifi cations

Material: Exterior powder-coated aluminum

Vent Screen:

Door and Lid Seal: Poron gasketing
Hardware: Stainless steel
Color: Gray (Custom colors available)
Tamper Switch: Optional
Battery Slide Tray: Optional
Safety Ground: Adjacent to AC outlets

Lid: Removable
Door: Hinged removable

Pole:

24.85 x 17 x 14.1 /
631 x 432 x 358

24.85 x 17 x 14.1 /
631 x 432 x 358

Stainless mesh (required for outdoor applications; optional for indoor
confi gurations) with .005" x .005" / .12mm x .12mm opening size to
minimize snow, water and dust ingress

(Optional stainless steel ground stud)

Galvanized steel brackets for wood, and concrete pole mount
and wall mount

24.85 x 17 x 14.1 /
631 x 432 x 358

24.85 x 17 x 14.1 /
631 x 432 x 358

24.85 x 17 x 14.1 /
631 x 432 x 358

1.0 Introduction

Estimated Load (Amps)

85 GXL, 60V Runtime (hr)
85 GXL, 90V Runtime (hr)

115 HPL, 60V Runtime (hr)
115 HPL, 90V Runtime (hr)

*Note: Battery temperature = 77˚F/25˚C

Load PF = 0.92
Accuracy = 0.25 hour

12345678

15.8 9.6 7.4 5.7 4.4 3.7 3.1 2.7

10.0 6.1 4.6 3.6 2.8 2.3 N/A N/A

20.0 12.6 9.7 7.6 5.9 5.0 4.2 3.7

12.7 8.1 6.1 4.8 3.7 3.1 N/A N/A

Table 1-1, NPS Confi gurations, Specifi cations and Runtimes

031-295-B0-001 Rev.A

11

1.0 Introduction

1.3 Parts List

Enclosure Components

Description Part Number
Enclosure Assembly, NPS 031-295-20

Installation Components

Description Part Number
Pole Mount Kit, Wooden Pole 746-032-20
Pole Mount Brackets, Wooden poles 744-670-20
Pole Mount Kit, Steel/Concrete poles 746-032-20
Brackets, pole mount, concrete/steel poles 591-557-20
Kit, Wall installation 746-034-20
Kit, Rack mounting 746-033-20
Kit, Indoor cover 746-036-20
Kit, Battery Cable, 36Vdc 746-038-20

Optional Components

Description Part Number
LA-P+ 120V 020-098-24
LA-P-SM 021-077-20
Surge Protector, 75 Ohm FF w/ground 162-028-10
Line Cord (Indoor version only) 874-540-38
Kit, optional Inline Fuse 746-039-20
Sliding tray, Battery (85GXL Batteries only) 746-030-20
AlphaGuard CMT-3SC 36V 012-306-20

12

Table 1-2, Parts List

031-295-B0-001 Rev. A