Alpha PME Series User Manual

PWE/PME Series

Pole and Ground-mount Enclosures

PWE/PME Series Technical Manual

Effective: April 2009

Alpha Technologies

®

Alpha Technologies

Power

®

PWE/PME

Technical Manual

031-161-B0-006, Rev. F

Effective Date: April 2009

Copyright© 2009

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 installed or operated in an unapproved manner, or improperly maintained. Alpha pole­mount enclosure systems are designed for static applications.

TM

To contact Alpha Technologies:

Visit www.alpha.com

or

For general product information and customer service (7 AM to 5 PM, Pacifi c T ime), 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 document, send an email to:

[e-mail]

3

List of Tables and Figures

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

1.0 Introduction .................................................................................................................9

1.1 PWE/PME Series Enclosures ........................................................................ 10

1.2 PWE Enclosure Diagram ................................................................................11

1.3 Optional Features .......................................................................................... 12

1.4 The Battery Integration Tray .......................................................................... 13

1.5 PWE Battery Tray Latch Operation (optional) ................................................14

1.6 PWE Lid Removal .......................................................................................... 15

1.7 PWE/PME Enclosure Specifi cations ..............................................................15

1.8 PWE Legacy Models...................................................................................... 15

2.0 Installation.................................................................................................................16

2.1 Pole-mounting ................................................................................................16

2.1.1 Wooden Pole ....................................................................................... 16

2.1.2 Concrete or Steel Pole ........................................................................18

2.1.3 Enclosure Grounding: Pole-mount ......................................................20

Ground-mount Installation, PWE-4, PWE-8, PWE-9, PWE-D36 .....................21

2.2

2.2.1 Pre-Installation .................................................................................... 21

2.2.2 Enclosure Grounding: Ground-mount ................................................. 23

2.2.3 Ground-mount Installation, PWE-3, PWE-9 and PWE-D36 ................24

2.2.4 PWE-4 and PWE-8 Ground-mount Installation ...................................26

2.3 Connecting Utility Power ................................................................................ 28

2.4 Connecting the Coaxial Cable ....................................................................... 35

2.4.1 Coaxial Cable Surge Protector Installation Instructions ......................35

2.4.2 Connecting the Service Power Inserter (SPI) ..................................... 36

2.5 Battery Installation ......................................................................................... 37

2.5.1 Battery Date Code Usage and Identifi cation ....................................... 37

2.5.2 Battery Installation Procedure ............................................................38

2.5.3 Connecting the Battery Integration Tray (PWE 3/6 Only)....................39

2.5.4 Battery Terminal Connections ............................................................. 40

2.5.5 Battery Wiring Diagrams ....................................................................42

2.6 Installing the XM Series 2 Power Supply .......................................................47

2.7 Cooling Fan Installation ................................................................................. 48

2.8 PWE-8 Solar Shield Installation .....................................................................49

2.9 Status Monitoring Transponder Bracket Installation Instructions ................... 50

3.0 Pole-mount Enclosure Maintenance ......................................................................... 51

031-161-B0-006, Rev. F4

List of Tables and Figures

Fig. 1-1, PWE-6 Enclosure ................................................................................................................................. 9

Fig. 1-2, PWE/PME Series Enclosures ............................................................................................................ 10

Fig. 1-3, PWE-3 Enclosure (confi gurations may vary).......................................................................................11

Fig. 1-4, Battery Integration Tray ...................................................................................................................... 13

Fig, 1-5, Opening the PWE Trays ..................................................................................................................... 14

Fig, 1-6, PWE Lid Removal .............................................................................................................................. 15

Fig. 2-1, PWE/PME Series Wooden Pole Mounting ......................................................................................... 17

Fig. 2-2, PWE/PME Series Steel or Concrete Pole Mounting .......................................................................... 19

Fig. 2-3, Enclosure Grounding for Pole-mount Confi guration........................................................................... 20

Fig. 2-4, Ground-mount Positioning and Safety ............................................................................................... 22

Fig. 2-5, Suggested Grounding Method ........................................................................................................... 23

Fig. 2-6, PWE-3, PWE-6, PWE-9, PWE-D36 Enclosure Pedestal ................................................................... 25

Fig. 2-7, Location of (4) Knockouts for Enclosure-to-Pedestal Mounting .........................................................25

Fig. 2-8, Access Holes for Front Bracket Mounting Locations .......................................................................... 26

Fig. 2-9, Ground Mounting Brackets, Installed ................................................................................................. 27

Fig. 2-10, Enclosure Ground-mount Footprint ................................................................................................. 27

Fig. 2-11, Enclosures Manufactured Before and After April 2002. .................................................................... 27

Fig. 2-12, Typical Service Entrance Wiring ....................................................................................................... 30

Fig. 2-13, Typical Receptacle Wiring ................................................................................................................ 30

Fig. 2-14, Typical ISE (Internal Service Entrance) Receptacle Wiring ............................................................. 31

Fig. 2-15, Typical BQO (Breaker Quad Option) Receptacle Wiring .................................................................. 32

Fig. 2-16, PWE Pole-mount Confi guration ....................................................................................................... 33

Fig. 2-17, Meter Wiring ..................................................................................................................................... 34

Fig. 2-18, 240Vac CSA Service Entrance Wiring .............................................................................................. 34

Fig. 2-19, 240Vac UL Service Entrance Wiring ................................................................................................ 34

Fig. 2-20, SPI Locations ................................................................................................................................... 34

Fig. 2-21, SPI ................................................................................................................................................... 36

Fig. 2-22, SPI (side view) ................................................................................................................................ 36

Fig. 2-23, Battery Date Code ............................................................................................................................ 37

Fig. 2-24, Battery Integration Tray Connections ............................................................................................... 39

Fig. 2-25, Threaded Insert Battery Terminal Connections ................................................................................ 40

Fig. 2-26, Flag Battery Terminal Connections .................................................................................................. 41

Fig. 2-27, PWE-3 (without BIT) and PME Battery Wiring Diagram...................................................................42

Fig. 2-28, PWE-4 Battery Wiring Diagram ........................................................................................................ 42

Fig. 2-29, PWE-6 Battery Wiring Diagram ........................................................................................................ 43

Fig. 2-30, PWE-D36 Battery Wiring Diagram .................................................................................................. 44

Fig. 2-31, PWE-8 Battery Wiring Diagram ....................................................................................................... 45

Fig. 2-32, PWE-9 Battery Wiring Diagram ........................................................................................................ 46

Fig. 2-33, XM Series 2 Power Supply............................................................................................................... 47

Fig. 2-34, Cooling Fan Kit Installed .................................................................................................................. 48

Fig. 2-35, PWE-8 Solar Shield Installation ....................................................................................................... 49

Fig. 2-36, Status Monitoring Bracket Location in PWE Series Enclosure ........................................................50

Table 1-1, PME/PWE Enclosure Specifi cations................................................................................................ 15

Table 2-1, Service Entrance Circuit Breaker Requirements ............................................................................. 28

5031-161-B0-006, Rev. F

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.

031-161-B0-006, Rev. F6

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 240Vac. 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.

7031-161-B0-006, Rev. F

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 spills 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.

031-161-B0-006, Rev. F8

1.0 Introduction

PWE/PME Series enclosures support distributed powering architectures in pole and ground-mount
broadband applications. Ideal for use in all climates, each enclosure comes with a removable lockable
door and easy opening lid. Standard features include a high-magnetic circuit breaker, duplex AC
receptacle, and service power inserter.

Key Features:

• Engineered for broadband powering applications

• All aluminum welded construction and durable powdercoat fi nish

• Agency certifi ed to meet applicable industry standards

• Internal or external SUSE rated service entrance options

• Optional Battery Integration Tray (BIT) (PWE 3/6 only)

• Portable generator cabling access door

Fig. 1-1, PWE-6 Enclosure with BIT

9031-161-B0-006, Rev. F

1.0 Introduction, continued

1.1 PWE/PME Series Enclosures

PWE-3

PWE-6

PWE-4

PWE-8

PWE-9

PME

PWE-D36

Fig. 1-2, PWE/PME Series Enclosures

031-161-B0-006, Rev. F10

1.0 Introduction, continued

1.2 PWE Enclosure Diagram

Optional SPI

Front View

Rear View

Standard SPI

Location

Optional Duplex

Receptacle

Generator

Access Door

Power Supply Module Shelf

Optional Battery Integration Tray

Optional Battery

Slide Tray Assembly

Optional

Cooling Fan

ACI

LRI

Knockouts

for Status Monitoring

Optional SPI

Locations

Standard SPI

Location

External Ground Lug

Standard LRI Location

(optional knockout located on right side)

Optional ACI Location

(knockouts located on left and

right sides of enclosure)

Optional External Breaker Box

Fig. 1-3, PWE-3 Enclosure (confi gurations may vary)

11031-161-B0-006, Rev. F

1.0 Introduction, continued

1.3 Optional Features

Feature Description

AC Indicator (ACI) The ACI verifies voltage output with a green light. Located next to the LRI

Battery Heater Mat (BHM) The BHM is AC line operated and turns on at 40°F. It increases battery

Battery Mat Option (BMO) The battery mat option provides additional battery cooling properties.

Battery Retaining Bar (BRB) The BRB provides additional security against batteries falling out of the

External Coax Raceway (ECR) The ECR conceals and protects the coaxial cables outside the PWE-9

Enclosure Cooling Fan (ECF) The ECF is a thermostat-controlled cooling system for PWE Series

Lightning Arrester-P+ (LA-P+) The LA-P+ provides protection against voltage spikes caused by lightning

Local Remote Indicator (LRI) The LRI is a red lamp which indicates when the power supply is running in

Module Retaining Cable (MRC) The MRC attaches the XM Series 2 power supply to the PWE Series

15A and 25A Service Power

Inserters (SPI)

Solar Shield Kit

(SSK)

Storm Hood Kit

(SHK)

Tamper Switch

(TMPR SW)

Coax Surge Protector Provides surge suppression for power supply.

External Generator Connector Allows a permanent generator connection point.

Battery Slide Tray Option allows access to battery cabling without removing batteries.

PWE High Security Device

(PHSD)

Ladder Bracket The ladder bracket option (Alpha P/N 745-095-21) easily attaches to all

AlphaGEM The AlphaGEM Generator Expansion Module is temporarily installed to

BE-PWE The BE-PWE expands battery backup capacity for PWE-3 enclosures. See

lamp on the outside of PWE/PME Series enclosures, it is easily monitored
from the ground. Because of its longer life, Alpha recommends the ACI­LL (long life) LED over the incandescent light bulb design. 60V and 90V
models are available.

capacity in cold environments. Battery heater mats are available in 120Vac
and 240Vac versions.

enclosure.
and PWE-D36 when ground-mounted. It is used in conjunction with the

available pedestal mount, and is easily removed by unscrewing one wing­nut.

enclosures. Alpha recommends this option in extremely high-temperature
environments. The fan automatically turns on at 140°F/60°C and off at
110°F/43°C. Replace the fan fuse with a 1/4" X 1-1/4", 5A, 250V fuse only
(Alpha P/N 460-025-10).

and other power disturbances. It consists of three Metal Oxide Varistors
(MOV), and is plugged directly into the enclosure’s convenience outlet. The
LA-P+ eliminates the need for hard-wired MOVs. Use the LA-P+ 120 in
120Vac applications, and the LA-P+ 240 in 240Vac applications.

Standby Mode. A major alarm causes the lamp to flash, indicating service
is required. Located on the outside of PWE/PME Series enclosures, it is
easily monitored from the ground.

enclosure wall, preventing it from being knocked off of its shelf.
A Service Power Inserter is required in all enclosures. The primary function

of the SPI is to provide a connection point between the Alpha power supply
and the cable load. Additionally, the SPI can bypass the power supply
with a Service Power Supply. A 15A SPI is standard on PWE/PME Series
enclosures. The SPI-25 (25A) is for use with higher output current power
supplies.

The Solar Shield Kit maintains a cooler environment within the PWE-8
enclosure, prolonging the life of the batteries and the power supply. By
protecting the enclosure’s skin, the shield reduces the amount of solar
radiation absorbed by the enclosure (Note: For PWE-8 enclosure only).

The SHK offers protection against dirt and snow ingress. Alpha recom­mends the use of the ECF (Enclosure Cooling Fan) in enclosures equipped
with the SHK.

The Tamper Switch is a magnetic door switch that connects to status
monitoring equipment. Tamper Switches are available either as normally
open (NO) or normally closed (NC) and set off an alarm if triggered.

The PHSD is constructed of high grade stainless steel to provide physical
security , corrosion resistance, and a strong visible deterrence. The PHSD is
compatible with Alpha’s PWE enclosures including; PWE 3, 6, and 9.

Alpha PWE Series enclosures and does not require a pole attachment
point. The Ladder Bracket provides safe access for technicians servicing
power supplies and batteries without the use of a bucket truck.

provide backup power during extended outage periods. See the AlphaGEM
Installation Instructions, Alpha P/N 745-872-C0.

the BE-PWE Technical Manual, Alpha P/N 033-077-C0.

031-161-B0-006, Rev. F12

1.0 Introduction, continued

1.4 The Battery Integration Tray

The optional Battery Integration Tray (BIT) eliminates the need for battery slide trays, and
allows batteries to be individually installed or removed in PWE-3/6 enclosures. Each battery
is connected directly to the BIT using modular 50A connectors.

The BIT further improves wire management by pre-terminating connections for status
monitoring voltage sense leads and for the AlphaGuard battery balancer. This eliminates the
need to stack multiple wire terminations on each battery terminal, vastly simplifying battery
replacement. Battery preventative maintenance is virtually eliminated when the BIT is used
in conjunction with the new AlphaCell threaded-insert batteries, which do not have to be re­torqued.

Key Features:

• Improves enclosure wire management and reduces clutter

• Eliminates the need for sliding battery trays

• Reduces battery preventive maintenance costs

• Pre-wired for status monitoring and AlphaGuard, eliminating stacked leads

• Allows direct connection to the AlphaGen DC portable generator

• Factory installed option in PWE-3/6 enclosures

Fig. 1-4, Battery Integration Tray (BIT)

13031-161-B0-006, Rev. F

1.0 Introduction, continued

1.5 PWE Battery Tray Latch Operation (optional)

As an added safety precaution, the PWE series features a latch to hold the optional
battery slide trays securely in place, in both open and closed positions. The latch
automatically locks in place when the tray is pushed back in.

CAUTION!
The maxiumum weight of the battery slide tray is indicated by the color of the cap on the latch:

Black: max. 72lbs (32.7kg) (legacy enclosures); red: max. 82lbs (37.2kg) (standard for future enclosures).

Opening the PWE Battery Slide Tray:

2. Pull Out

PWE Tray Latch Location

Opening the PWE-4 and PWE-8 Trays:

1. Press In

Closing the Tray on all PWE models:

1. Push Up

To open, push latch up and pull tray
out. Tray automatically locks into “open”
position.

To open, press tray latch in and pull
tray out. Tray automatically locks in
the “open” position.

2. Pull Out

To unlock and close tray, press lock
in toward tray and push tray closed.

Press In

When returned to the “closed”
position, tray automatically locks
back into place.

Fig, 1-5, Opening the PWE Battery Slide Trays

031-161-B0-006, Rev. F14

1.0 Introduction, continued

1.6 PWE Lid Removal

1. Pull Out

2. Pull Up

Fig, 1-6, PWE Lid Removal

1.7 PWE/PME Enclosure Specifi cations

Model

PWE-3

PWE-4

PWE-6

PWE-8

PWE-9

PWE-D36

PME

Dimensions

(W x H x D) (in/mm)

24.25 x 24.5 x 14/
616 x 622 x 356

30.25 x 24.75 x 16/
768 x 629 x 406

24.25 x 36.75 x 14
616 x 933 x 356

30.25 x 36.88 x 16
768 x 937 x 406

24.25 x 47 x 14

616 x 1194 x 356

24.25 x 47 x 14

616 x 1194 x 356

22.25 x 24.5 x 14
565 x 622 x 356

Shipping

Weight (lb/kg)

38/17.2 3 349/158.3

59/26.8 4 445/201.8

56/25.4 6 594/269.4

90/40.8 8 780/353.8

70/31.8 9 750/340.2

65/29.5 6 600/272.2

34/15.4 3 344/156

Battery Capacity

The lid can be completely

removed by disconnecting

retention strap

Approx. Full System

Weight (lb/kg)

Table 1-1, PME/PWE Enclosure Specifi cations

1.8 PWE Legacy Models

New PWE (Since April, 2002) Type II PWE Type I PWE

15031-161-B0-006, Rev. F

2.0 Installation

CAUTION!

• Never transport the unit with installed batteries. Doing so can cause injury or damage to the
enclosure and installed equipment. Install the batteries after you transport the unit to the site
and secure it to the pole.

• Alpha recommends that you position the enclosure on the opposite side of the pole from traffi c.
This reduces the danger of falling equipment in the event that a pole is struck by an automobile.

• Mounting bolts must completely penetrate the wooden pole. Secure the bolts from the back with
a large washer and nut.

• System installation at >10º angle in not recommended.

ATTENTION:

The majority of poles belong to the local utility. Before you install an enclosure have both the location and
mounting method approved by the utility. Because most codes require the enclosure to be located at a
minimum height from the ground, always verify local height restrictions before you proceed.

2.1 Pole-mounting

2.1.1 Wooden Pole

Tools and Materials Required (customer supplied):

• Two (three for PWE-8, 9, D36) 5/8" (15.9mm) diameter machine bolts, length to
suit pole

• Two 5/8" (15.9mm) diameter zinc plated fl at washers

• Two 5/8" (15.9mm) diameter hex nuts (UNC thread)

• Auger or drill for boring 11/16" (17.5mm) diameter holes in the wooden pole

• Mallet or hammer

• Assorted sockets

• Tape measure

• Three-foot level

Procedure:

1. Unpack the enclosure and galvanized brackets.

2. Mark the position for the upper bracket on the utility pole. From the installation

side of the pole, and using a three-foot level to verify level, drill a 11/16"
(17.5mm) hole completely through the pole.

3. Mark the location of the hole(s) for the lower bracket(s). For three-bracket

enclosures, use the one-piece, 3-point bracket as a template. Spacing between
the holes is as follows:

Enclosure Distance (on center) (in/mm)

PWE-3 and PME 18"/457.2
PWE-4 15"/381
PWE-6 30"/762
PWE-8, PWE-9,
PWE-D36 (three holes)

4. Using the three-foot level to verify drill angle, drill the 11/16" (17.5mm) hole or

holes for the lower bracket or brackets from the installation side of the pole.

NOTE:

Drill all holes from the enclosure side of the pole to ensure proper spacing.

15" (30" total)/
381 (762 total)

031-161-B0-006, Rev. F16