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PN-4
User Manual
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User Manual
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Alpha PN-4 User Manual

Powernode System Enclosures
Powernode System Enclosures
®
© 2002
Site Preparation and Installation
PN-3 Models PN-4 Models
Effective: March, 2002
®
TM
PN-3 & PN-4
www.alpha.com
Protecting The Power in Communications.
031-103-B0-003 Rev. C
© 2002
TM
Powernode System Enclosures
PN-3, PN-4 Models
Site Preparation and Installation
031-103-B0-003 Rev. C — © 2002 Alpha Technologies
This manual covers the installation of the PN-3 and PN-4 Enclosure. Installation may involve connection to the electrical utility lines and fuel vapor (Natural Gas or Propane). Always work with the local utilities when connecting the enclosure to these utilities and observe all local and national laws which may be applicable for your area. Refer to Section 2, Pre­Installation, for siteplanning and preparation.
Photographs contained in this manual are for illustrative purposes only. These photographs may not exactlymatch your installation.
Review the drawings and illustrations contained in the manual before proceeding. If there are questions regarding the safe installation and operation of this enclosure or the Powering System, please contact Alpha Technologies or your nearest Alpha representative.
To contact Alpha Technologies:
For general product information and customer service
1-800-863-3930
(7:00 AM to 5:00 PM Pacific Time )
For complete technical support
1-800-863-3364
(7:00 AM to 5:00 PM Pacific Time, or 24/7 emergency support)
© 2002
TM
031-103-B0-003 Rev. C
PN-3 & PN-4
Product Safety ....................................................................................................................................6
1. Introduction.................................................................................................................................... 9
1.1 Introduction ........................................................................................................................9
1.2 PN-3 and PN-4 Powernode Enclosure................................................................................10
2. Pre-Installation............................................................................................................................. 11
2.1 Site Preparation ................................................................................................................11
2.2 Concrete Pad Preparation..................................................................................................12
2.3 Enclosure Grounding.........................................................................................................13
3. Installation.................................................................................................................................... 15
3.1 T ransportation and Lifting.................................................................................................15
3.2 Enclosure Mounting Procedure..........................................................................................15
3.3 Utility Powering.................................................................................................................16
3.4 Coaxial Cable to Service Power Inserter (SPI) Installation.................................................22
3.5 Battery Installation ...........................................................................................................24

Table of Contents

Important Notes About Installation .................................................................................................... 7
Product Information, Customer Service or Technical Support ............................................................ 8
3.3.1 Connection Procedure for the BBX-100A-8POS Service Disconnect: ................................ 17
3.3.2 Connection Procedure for the BBX-70A Service Disconnect: ............................................ 18
3.3.3 Sample Input Power Panels..............................................................................................19
3.4.1 SPI to Ground Bar Connection Procedure ......................................................................... 22
3.4.2 Conduit Placement ........................................................................................................... 23
3.5.1 Battery Safety Notes.........................................................................................................24
3.5.2 Battery Identification ....................................................................................................... 25
3.5.3 Battery Terminal Connections........................................................................................... 25
3.5.4 Battery Terminal Assembly Procedure............................................................................... 26
3.5.5 Battery Installation Procedure .........................................................................................26
3.5.6 Battery Installation Layout ............................................................................................... 27
3.5.7 Battery Temperature Sensor .............................................................................................32
4. PN Series Options ........................................................................................................................ 33
4.1 Star Lock Security Bolt ......................................................................................................33
4.2 Battery Interface Unit (BIU)...............................................................................................34
4.3 Service Disconnects ..........................................................................................................34
4.4 Input Power Panel (IPP) ....................................................................................................35
4.5 Cooling Fan Kit.................................................................................................................36
4.6 Lightning Arrester (LA-P+)................................................................................................37
5. Alpha Part Numbers..................................................................................................................... 38
5.1 PN Series Options .............................................................................................................38
5.2 Pre-Cast Concrete Pads.....................................................................................................39
031-103-B0-003 Rev. C
© 2002
TM
PN-3 & PN-4

List of Figures

Figure 1-1; Enclosure as it Arrives from Alpha ...................................................................................................................... 9
Figure 1-2; Packing Label Location ........................................................................................................................................ 9
Figure 1-3; PN-3 Specifications ........................................................................................................................................... 10
Figure 1-4; PN-4 Specifications ........................................................................................................................................... 10
Figure 2-1; Suggested Site Selection, PN-3 and PN-4 ......................................................................................................... 11
Figure 2-2; Single-Wide Concrete Pad for PN-3 and PN-4 ................................................................................................... 12
Figure 2-3; Suggested Grounding, PN-3 and PN-4 .............................................................................................................. 13
Figure 2-4; Alternate Grounding, PN-3 and PN-4 ................................................................................................................ 14
Figure 3-1; PN-3 Mounted to the Prepared Pad ................................................................................................................... 15
Figure 3-2; BBX-100A-8POS Service Disconnect.................................................................................................................. 17
Figure 3-3; BBX-70A Service Disconnect.............................................................................................................................. 18
Figure 3-4; Schematic: Primary Service BBX-100A-8POS with IPP-240-3 ........................................................................... 19
Figure 3-5; Schematic: Primary Service BBX-100A-8POS with IPP-120-3 ........................................................................... 19
Figure 3-6; Schematic: Secondary Service BBX-100A-8POS with IPP-120-2 ....................................................................... 20
Figure 3-7; Schematic: Secondary Service BBX-100A-8POS with IPP-240-2 ....................................................................... 20
Figure 3-8; Schematic: Secondary Service BBX-70A with IPP-120-1 ................................................................................... 21
Figure 3-9; Schematic: Primary Service BBX-70A with IPP-240-1 ....................................................................................... 21
Figure 3-10; Connector Fitting in Rear of Equipment Tray.................................................................................................... 22
Figure 3-11; Location of SPI in Equipment Tray .................................................................................................................... 22
Figure 3-12; SPI Ground Wire Connected to Enclosure Ground Bar ..................................................................................... 22
Figure 3-13; Conduit Location.............................................................................................................................................. 23
Figure 3-14; Coaxial Connectors .......................................................................................................................................... 23
Figure 3-15; Alpha Cell Battery Date Code .......................................................................................................................... 25
Figure 3-16; In-Line Fuse Link Mounting.............................................................................................................................. 25
Figure 3-17; Vertically Mounted Battery Post...................................................................................................................... 26
Figure 3-18; Battery Installation Arrangement.................................................................................................................... 27
Figure 3-19; Wiring Diagram for two 36V Battery Strings — PN3 Enclosure...................................................................... 28
Figure 3-20; Wiring Diagram for two 48V Battery Strings — PN3 Enclosure...................................................................... 29
Figure 3-21; Wiring Diagram for three 36V Battery Strings — PN4 Enclosure................................................................... 30
Figure 3-22; Wiring Diagram for three 48V Battery Strings — PN4 Enclosure................................................................... 31
Figure 3-23; Battery Temperature Sensor Mounting Location............................................................................................. 32
Figure 4-1; Security Bolt Location ........................................................................................................................................ 33
Figure 4-2; Black Clip in Place............................................................................................................................................. 33
Figure 4-3; Retaining Washer .............................................................................................................................................. 33
Figure 4-4; Security Key (Part Number 647-089-10)............................................................................................................ 33
Figure 4-5; Battery Interface Unit........................................................................................................................................ 34
Figure 4-6; BBX 70A (BBX-FI2)............................................................................................................................................ 34
Figure 4-7; BBX 100A (BBX-FI8).......................................................................................................................................... 34
Figure 4-8; MTS (Showing100A and 60A boxes) ................................................................................................................... 35
Figure 4-9; FBX-60A............................................................................................................................................................. 35
Figure 4-10; IPP for Three Power Supplies............................................................................................................................ 35
Figure 4-11; IPP for Two Power Supplies............................................................................................................................... 35
Figure 4-12; IPP for One Power Supply ................................................................................................................................. 35
Figure 4-13; Breaker Duplex Option (BDO) for One Power Supply......................................................................................... 35
Figure 4-14; Cooling Fan Panel............................................................................................................................................ 36
Figure 4-15; Panel is Installed in Top Rear of Enclosure...................................................................................................... 36
Figure 4-16; Cooling Fan Plugged into Power Supply and SPI.............................................................................................. 36
Figure 4-17; LA-P+ Installed in BDO ................................................................................................................................... 37
Figure 4-18; Location of LED on LA-P+. ............................................................................................................................... 37
Figure 5-1; Single-Wide Pad, for CE8/9 or PN 3/4 ............................................................................................................... 39
Figure 5-2; Double-Wide Pad, for CE8/9 or PN 3/4 .............................................................................................................. 40
Figure 5-3; Double-Wide Pad, for CE 3x2/9x2 and CE8/9 or PN 3/4 .................................................................................... 41
© 2002
TM
031-103-B0-003 Rev. C
Product Safety
Important Safety Instructions Used Throughout this Manual
To reduce the risk of injury or death caused by electrical shock, explosion of fuel or moving parts; and to ensure the continued safe operation of this product, the following symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.
CAUTION
HAZARDOUS CONDITION
Dangerous Voltage
This symbol indicates a “dangerous voltage” may exist in this area of the product. Use caution whenever working in the area to prevent electrical shock.
Inhalation Hazard - Don't Breathe Vapors
This symbol indicates an “inhalation hazard” may exist in this area of the product. Use caution whenever working in the area to prevent possible inhalation of harmful (fuel or exhaust) vapors.
No Matches or Open Flames
This symbol indicates a “fire or explosive hazard” may exist in this area of the product. Use caution whenever working in the area to prevent possible combustion of fuel vapors.
Mechanical or Moving Parts Hazard
This symbol indicates an “mechanical or moving parts hazard” may exist in this area of the product. Use caution whenever working in the area to prevent possible injury to the operator or service personnel.
Leak Hazard
This symbol indicates a “leak hazard” may exist in this area of the product. Use caution whenever working in this area to prevent and correct any leaks detected.
Attention
This symbol indicates important installation, operation or maintenance instructions. Always follow these instructions closely.
031-103-B0-003 Rev. C
Save these instructions for future reference.
NOTE: Alpha Technologies’ products are subject to change through continual improvement
processes. Therefore, specifications and/or design layouts may vary slightly from descriptions included in this manual. Updates to the manual will be issued when changes affect form, fit or function.
© 2002
TM
Product Safety
Important Notes About Installation
• The system must be installed only by qualified service personnel.
• Always consult local codes for mounting pad requirements.
• Consult local utility codes for additional cabinet grounding and utility requirements.
• Consult the local gas company for correct meter type and riser location.
• Whenever possible, it is best that the enclosure be installed above flood zones .
• Precast Mounting Pads may either be purchased from Alpha or poured in place. The pad must be capable of holding 1,000 lbs (minimum). Rebar may be placed in a crosshatch pattern for pad reinforcement, as needed.
• If the pad is to be located in an area with a deep frost line or unstable soil, concrete pylon footings (4" diameter X 4' deep, or 1' deeper than the regional frost line) can be placed below the concrete pad, in front of and below the (4) mounting features.
• The top of the pad must be above grade to reduce the buildup of debris around the base of the cabinet.
• Adequate space must be allowed for Cable TV input/output conduit; plant grounding electrode conductor(s); RF cable entrance via (1) 4", (2) 3" or (3) 2 1/2" rigid conduit sweep(s) with 2' bend radius (minimum); and fiber optic cable entrance (refer to fiber manufacturer's specification for minimum bend radius requirements).
• Prior to pouring concrete, any wire running through the pad must have a thermal expansion jacket (i.e., PVC) to prevent cracking of the concrete during lightning strikes.
• Alpha Technologies is not responsible for broken welds or other damage to the cabinet caused by improper installation.
• A 25+ year vapor barrier must be used between the concrete pad and the base of the enclosure to further inhibit the ingress of moisture. Alpha Technologies is not responsible for water damage or moisture damage resulting from improper installation.
• Concrete filled, 6" diameter steel posts (or equivalent) can be placed at the corners of the pad to reduce exposure to accidental traffic damage.
• All dimensions are given in inches.
• For further information regarding this installation, contact Alpha Technologies or your nearest Alpha representative.
© 2002
TM
031-103-B0-003 Rev. C
Contacting Alpha Technologies

Product Information, Customer Service or Technical Support

For general product information and customer service 7:00 AM to 5:00 PM
Pacific Time, call:
1-800-863-3930
To obtain complete technical support 7:00 AM to 5:00 PM Pacific Time, or for
after-hours emergency support, call:
1-800-863-3364
(7 days per week, 24 hours a day)
Product Returns
Returns for Repair
In the event of a need for repair, Alpha products may be returned by either method listed below:
Download the necessary forms directly from Alpha's Web site, under "Support":
www.alpha.com/support/
OR
Call (800) 322-5742 for assistance.
Returns for Credit
Credit return requests must be initiated with a phone call. Call: (800) 322-5742.
031-103-B0-003 Rev. C
© 2002
TM

1.1 Introduction

To ensure operator safety:
• Enclosures must be installed only by qualified personnel and in accordance with all applicable electrical
codes.
• Use eye protection whenever working with batteries.
• Use only sealed, lead-acid type batteries (gelled-electrolyte or equivalent, 65 Ah min.)
Unpacking and Inspection:
Carefully remove the enclosure from the shipping container. Verify that:
• The correct unit was shipped (either Alpha PN-3 or PN-4 enclosure).
• Ordered options have been included. (Refer to packing label details located on wooden pallet. See
figure 1-2)
NOTE: Batteries are shipped separately.
1. Introduction

Figure 1-1; Enclosure as it Arrives from Alpha

Figure 1-2; Packing Label Location

Inspect the contents. If items are damaged or missing, contact Alpha Technologies and the shipping company immediately . Most shipping companies have only a short claim period.
© 2002
TM
031-103-B0-003 Rev. C
1. Introduction

1.2 PN-3 and PN-4 Powernode Enclosure

Alpha's PN Series Power Module enclosures offer complete flexibility and modular expendability for Cable TV powering applications. The Modular Tray system simplifies installation while allowing for future expansion or reconfiguration. The PN Series is designed to accommodate current system power requirements while allowing the cost-effective addition of power capacity, as well as enhanced reliability options, when new services are integrated. Excellent for either distributed or centralized powering architectures, PN Series enclosures are available to accommodate multiple power supplies, battery strings and/or natural gas or propane generators
Power Supply Capacity: Up to three power supplies (6kW)
Weight: 100-170 lbs ( depending on options)

Figure 1-3; PN-3 Specifications

Dimensions: 26" W x 44" H x 24" D
Material: Aluminum, .080-.125 inches
Power Supply Capacity: Up to three power supplies (6kW)
031-103-B0-003 Rev. C

Figure 1-4; PN-4 Specifications

Dimensions: 26" W x 52" H x 24" D
Weight: 110-180 lbs ( depending on options)
Material: Aluminum, .080-.125 inches
10
© 2002
TM
2. Pre-Installation

2.1 Site Preparation

The site must be planned so that the enclosure will receive good air flow. If possible, in areas of extreme heat, it is best to position the enclosure so that it will be shaded from the afternoon sun. In areas of prevailing winds, it is best that the enclosure be located so that the sides of the cabinet face the winds instead of the doors. This will greatly reduce the buildup of sand or snow against the enclosure’s air vents.
In areas of potential flooding, the geographical site and concrete pad must be located above the flood plain. Pedestals are available to raise the Power Node enclosures above expected snow and water levels.
The enclosure must be placed where it will be free of obstructions, allowing easy access to the doors for service or equipment access. For ventilation and maintenance, allow a minimum space of 36 inches in the front and 36 inches in the rear, between the enclosure and other solid structures.
Place the enclosure well away from ground level sources of forced water, such as underground sprinkler systems and direct roadway splash.
The concrete pad drawing is provided in the Pre-Installation Section of this manual contains all of the required mounting details, including electrical service and cable plant entrances.
The vapor barrier material (such as 30 lb. felt, neoprene pond liner, or heavy grade tar paper) must initially extend at least 6" in all directions around the perimeter of the enclosure and be trimmed closer to the enclosure, using the appropriate utility knife or cutting tool.
WARNING:
Never transport the unit with batteries installed. Batteries must ONL Y be installed after the
unit is transported to the site and secured to the pad. Transporting the unit with batteries installed may cause a short circuit, fire, explosion, and/or damage to the battery pack, enclosure and installed equipment. Damage caused by improper shipping or transporting a unit with batteries installed is not covered under warranty.
House
50 feet
PN-3/4
House
© 2002
25 feet
House

Figure 2-1; Suggested Site Selection, PN-3 and PN-4

TM
11
House
031-103-B0-003 Rev. C
2. Pre-Installation

2.2 Concrete Pad Preparation

Pads can either be poured on site, or precast by Alpha Technologies. A vailable concrete pad configurations and part numbers can be found in section 5, "Alpha Part Numbers".
5
1
4
7
2
8
6
7

Figure 2-2; Single-Wide Concrete Pad for PN-3 and PN-4

All dimensions shown in inches. Mounting holes and sweeps indexed from this position.
Indicates PN-3 and PN-4 pedestal enclosure mating surface.
3
031-103-B0-003 Rev. C
Alpha standard; recommended distance (6" minimum) between edge of pad and cabinet. Four inch diameter hole for AC power IN (non-metered installation). Four inch diameter opening for DC Output cable and Status Monitoring harness. All mounting hardware must be stainless, galvanized, or better to prevent corrosion. 5" x 8" rectangular cutout (2 places), open area for all internal connections including: generator power
and/or coax cable conduit sweeps. A 25+ year continuous vapor barrier must be used between the enclosure and the pad to prevent
moisture ingress and possible corrosion caused by metal to concrete contact. The vapor barrier material (such as 30 lb felt, neoprene pond liner, or heavy grade tar paper) must be initially extended at least 6" in all directions around the perimeter of the enclosure. After the enclosure is secured to the pad, the material can be cut closer to the enclosure, using the appropriate knife or cutting tool.
12
© 2002
TM

2.3 Enclosure Grounding

&
211(&7,210$'(:,7+
%
851'<&211(&725
31<*+5&:
(48,9$/(17
#6 AWG
25
2. Pre-Installation
2 feet
min)
Enclosure Footprint
Opening for
Sweeps
Opening for
Sweeps
Opening for
Sweeps
(
#2 AWG
TWO (2) 8’ GROUND
PLACED A MINIMUM
RODS
6’ APART
OF

Figure 2-3; Suggested Grounding, PN-3 and PN-4

Lightning Protection (Optional)
1/2" x 8' copper ground rod, four places, driven about 2 feet (typical) from the corners of the pad.
#2 bare copper wire loop terminated to each ground rod and buried below grade 2 to 12 inches.
Corrosion-proof connections (25+ year life-span) and hardware suitable for direct burial MUST be used #2 bare copper wire from loop to the enclosure
&
211(&7,210$'(:,7+
%
851'<&211( &7 25
31<*+3&:71
25(48,9$/(17
© 2002
When the electrical supply is a primary service (not a secondary or feeder service) a #2 bare copper wire
must be bond the lightning protection loop to the Grounding Electrode Conductor where they are closest.
Service Grounding (required)
#6 bare copper wire from Service Neutral / Ground Bar with 2 ground rods located 6' apart.
TM
13
031-103-B0-003 Rev. C
2. Pre-Installation
2.3 Enclosure Grounding,
Side view
UFER Ground
30 inches
SE
conduit &
wires
separation
is required.
GEC
#2 bare copper
No
wire
20 feet (minimum)
#2 AWG
continued
&
211(&7,210$'(:,7+
%
31<*+5&:
#2 AWG
851'<&211(&725
(48,9$/(17
Opening for
Sweeps
Opening for
Sweeps
25
Enclosure Footprint
Opening for
Sweeps
t
e
e
f
n)
i
2
(m
&
211(&7,210$'(:,7+
%
31<*+3&:71

Figure 2-4; Alternate Grounding, PN-3 and PN-4

Lightning Protection (Optional)
1/2" x 8' copper ground rod, four places, driven about 2 feet (typical) from the corners of the pad.
#2 bare copper wire loop terminated to each ground rod and buried below grade 2 to 12 inches.
Corrosion-proof connections (25+ year life-span) and hardware suitable for direct burial MUST be used. #2 bare copper wire from loop to the enclosure
When the electrical supply is a primary service (not a secondary or feeder service) a #2 bare copper wire
must be bonded to the lightning protection loop to the Grounding Electrode Conductor where they are closest.
Service Grounding (required)
851'<&211(&725
25(48,9$/(17
031-103-B0-003 Rev. C
#2 bare copper wire from Service Neutral / Ground Bar down 30 inches and out 20 feet beyond the pad edge. This is often called a UFER ground (Ground Ring in the NEC).
14
© 2002
TM
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