BLACKHAWK! 600-120-60-36 User Manual

INSTRUCTION MANUAL

BLACKHAWK SERIES

BROADBAND POWER SUPPLIES

Installation and Operation Manual

Manual Part No:

017-027-B0

Issue 01 (01/23/06)

Documented Power Supply Models

The following power supply models, with their part numbers, are documented by this instruction manual. For available options, refer to the OPTIONS section of this manual.

600 VA OUTPUT RATING

MODEL NUMBER PART NUMBER INPUTS

600-120/60-36 017-027-20 120VAC, 60Hz, 3-Battery 600-120/60-48 017-027-21 120VAC, 60 Hz, 4-Battery

600-240/60-36 017-027-22 240VAC, 60Hz, 3-Battery 600-240/60-48 017-027-23 240VAC, 60Hz, 4-Battery

600-100/50-36 017-031-23 100VAC, 50Hz, 3-Battery 600-100/50-48 017-031-21 100VAC, 50Hz, 4-Battery

600-200/50-36 017-034-20 200VAC, 50Hz, 3-Battery 600-200/50-48 017-034-21 200VAC, 50Hz, 4-Battery

900 VA OUTPUT RATING

MODEL NUMBER PART NUMBER INPUTS

900-120/60-36 017-028-20 120VAC, 60Hz, 3-Battery 900-120/60-48 017-028-21 120VAC, 60 Hz, 4-Battery

900-240/60-36 017-028-22 240VAC, 60Hz, 3-Battery 900-240/60-48 017-028-23 240VAC, 60Hz, 4-Battery

900-100/50-36 017-032-20 100VAC, 50Hz, 3-Battery 900-100/50-48 017-032-21 100VAC, 50Hz, 4-Battery

900-200/50-36 017-035-20 200VAC, 50Hz, 3-Battery 900-200/50-48 017-035-21 200VAC, 50Hz, 3-Battery

1350 VA OUTPUT RATING

MODEL NUMBER PART NUMBER INPUTS

1350-120/60-36 017-030-20 120VAC, 60Hz, 3-Battery 1350-120/60-48 017-030-21 120VAC, 60Hz, 4-Battery

1350-240/60-36 017-030-22 240VAC, 60Hz, 3-Battery 1350-240/60-48 017-030-23 240VAC, 60Hz, 4-Battery

1350-100/50-36 017-033-20 100VAC, 50Hz, 3-Battery 1350-100/50-48 017-033-21 100VAC, 50Hz, 4-Battery

1350-200/50-36 017-036-20 200VAC, 50Hz, 3-Battery 1350-200/50-48 017-036-21 200VAC, 50Hz, 3-Battery

Table of Contents

Blackhawk Series Broadband Power Supply

Section 1: Critical Safety Issues………………………………………….….5

Safety Admonishments

Emergency Shutdown Procedure General Safety Issues Safety Issues of Power Supply Installation and Use Enclosure Safety Issues Battery Safety Issues

Section 2: Introduction..................……………………….……...….....….....9

Blackhawk Series Product Overview Blackhawk Series Product Features Unpacking and Inspection Missing or Damaged Items Original Shipping Container Other Items

Section 3: Cabinet Installation.....................………………………..….….11

Pole Mount Application Ground Mount Application

Section 4: Front Panel Controls, Connections and Indicators………..14

Section 5: Installation and Setup............……………………………….....16

Preparation Placement in the Enclosure Wiring Battery Placement and Wiring Battery Installation Procedure

Section 6: Startup & Operation……………………………………………..20 Section 7: Power Supply Shutdown …….…………………………….….21 Section 8: Options ……………………………………………………………22

Cabinet Indicators Battery Cable Kits Remote Indicator Harness Output Cable Status Monitoring Battery Balance Manager

Section 9: Maintenance and Adjustments .......................…….….……23

Preventive Maintenance Output Voltage Reconfiguration Input Voltage Configuration Battery Test Time Reconfiguration Analog Adjustments Troubleshooting

Section 10: Specifications ………………………………………….……...29

EMI / RFI STATEMENT

This device has been designed and manufactured to comply with the limits for a Class A digital device pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when this equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed in accordance with this instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area may cause interference that the cable provider must correct at its own expense.

Section 1: Critical Safety Issues

SAFETY ADMONISHMENTS:

Three different levels of safety admonishments are used within this instruction manual; specifically DANGER, WARNING, and CAUTION.

The statement following the DANGER heading alerts the equipment user of a potentially life- or health-threatening situation unless precautions are taken against it. Admonishments of this nature usually entail the hazards of electrical shock or other such related hazards.

The statement following the WARNING heading alerts the equipment user of a condition or procedure that could result in interruption of service. While this condition may only be a nuisance in video-only services, it may prove to be more serious when telephony, VoIP or data transfer services are being provided.

The statement following the CAUTION heading alerts the equipment user of a condition that could result in damage to the subject equipment or ancillary equipment if care is not exercised during certain maintenance or operating procedures.

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

Emergency Shutdown Procedure

DANGER

Exercise extreme caution when performing the following procedure. Carry out the steps precisely in the order given to avoid the possibility of personal injury or equipment damage.

Perform the following procedure if the power supply must be shut down and disconnected on an emergency basis:

1. Switch the BATTERY CIRCUIT breaker to the OFF position.

2. Disconnect the AC power cord from the outlet in the cabinet.

3. Remove the BATTERY connector from its location at the power supply front panel.

4. Disconnect the output cable from the OUTPUT connector at the power supply front panel.

5. Within the service entrance box or branch circuit box, operate the AC input circuit breaker for the power supply to the OFF position.

General Safety Issues

The power supply documented in these instructions has been designed, tested and produced to ensure safe, trouble-free operation. Personnel using or installing this power supply should completely read and fully understand the following safety instructions. They are provided here as informational guidelines for your continued safety in usage of the product. These general safety issues should be observed in all phases of power supply installation and service.

This power supply uses two sources of electrical power: commercial AC and DC derived from a battery. Whenever performing maintenance on any of the internal components, you must disconnect both the battery cable and AC line cord.

Always use proper lifting techniques when handling the power supply or batteries. Both the power supply and a single 12-volt battery weigh approximately the same, about 65 pounds (30 Kg).

Personnel installing or servicing batteries must wear eye protection (goggles or full face shield) and protective clothing (apron and gloves) as mandated by standard operating procedures. Additionally, only fully insulated tools specifically designed for battery installation and service should be used for that purpose. Tools wrapped with vinyl or fabricbased electrical tape are NOT acceptable substitutes.

Safety Issues of Power Supply Installation and Use

The subject power supply has been designed and built to power CATV and broadband distribution equipment only. It is not intended for any other usage and provides output voltages suitable only for its intended application.

Power supplies documented in this instruction manual use more than one source of power. If any reason exists to open the power supply enclosure for maintenance or adjustments, first turn off the BATTERY CIRCUIT breaker on the front panel, disconnect the AC line cord from its outlet and remove the BATTERY connector from its receptacle on the front panel. Be certain that at least 5 minutes has elapsed before opening covers after disconnecting operational power.

DANGER

This power supply operates from either a 120 volt or 240 volt AC source and produces internal voltages in excess of 500 volts. DO NOT open any covers or panels or attempt to perform any service to the power supply without first removing and disconnecting all external AC and DC power sources. Only trained, qualified personnel should attempt service and repair work on the power supply.

Install only gelled electrolyte valve regulated lead acid (VRLA) or AGM type batteries as a standby DC source for this power supply. See the following Battery Safety Issues for further information.

The power supply must be installed within a cabinet suitable for accommodating CATV power supplies. If installed outdoors, the cabinet must have a 3R (rainproof) rating as a minimum requirement. See the following Enclosure Safety Issues for further information.

Enclosure Safety Issues

The cabinet and the power supply must be installed by qualified technicians or installers only. Whether using ground-mount or pole-mount option, appropriate mounting hardware meeting local codes and construction practices must be used. Failure of fasteners over the service life of the cabinet may result in hazardous conditions for the general public who may pass near the installation.

The outer cabinet housing the power supply must be of adequate strength to support the power supply and its associated batteries. Additionally, the cabinet must afford adequate ventilation for the power supply such that a minimum free air space of 2-inches remains around all sides and the top of the power supply. Air intake at the front of the inverter module must remain unobstructed.

Temperature of the air entering the inverter module and flowing around the power supply must not exceed 60 degrees Celsius. Air intake and exhaust openings within the outer cabinet must not be less than 40 square inches in area. If these limits are exceeded or

cannot be attained, a suitable forced-air cooling system may be required within the cabinet.

Battery Safety Issues

When installing batteries for the power supply, do not mix battery types (gelled electrolyte and AGM) in the same string or within the same cabinet. DO NOT use flooded type batteries with liquid electrolyte with the power supply under any circumstances. Such batteries are hazardous to use within broadband cabinets and can degrade or destroy equipment installed in the cabinet with them. Use only gelled electrolyte or AGM batteries of suitable size, voltage and capacity for use in a CATV system.

DANGER

Batteries can supply extremely large currents for a short period of time, sufficient to vaporize or melt metal objects. For this reason, installers must remove watches, rings and other jewelry before placing or connecting batteries in the the cabinet. Insulating gloves and protective clothing should be worn during

battery installation, consistent with local practices.

Batteries contain sulphuric acid in gelled or semi-liquid form. Direct contact with any spilled electrolyte from a damaged battery may result in skin irritation or chemical burns. For this reason, handle batteries carefully to avoid puncturing the case and releasing any of the electrolyte. In case of contact with the electrolyte, thoroughly wash any contaminated areas of the skin with soap and water. In case of contact with the eyes, immediately flush with copius amounts of water and seek medical attention. Minor surface spills can be neutralized with an appropriate neutralizing agent such as bicarbonate of soda (baking soda).

Always use proper lifting techniques when handling batteries. Each 12-volt battery weighs approximately 65 pounds (30 Kg).

Personnel installing or servicing batteries must wear eye protection (goggles or full face shield) and protective clothing (apron and gloves) if necessary, according to local practices. Additionally, only fully insulated tools specifically designed for battery installation and service should be used for that purpose. Tools wrapped with vinyl or fabric-based electrical tape are NOT acceptable substitutes.

The BATTERY CIRCUIT breaker on the front panel of the power supply must be operated to the OFF position before installing, changing and connecting batteries.

Verify correct battery polarity and voltage at the DC input connector of the power supply before closing the BATTERY CIRCUIT breaker. Applying DC input of improper polarity or voltage can seriously damage or entirely destroy the power supply. Replace any battery that is found to have a swollen or cracked case. Always recycle used batteries to reclaim lead and other materials that can pose environmental hazards if disposed of improperly.

Section 2: lntroduction

Blackhawk Series Product Overview

The MultiPower Blackhawk Series power supplies provide filtered and regulated AC output power of proper voltage and current values to operate amplifiers, nodes and other active devices in CATV and broadband networks. These supplies are designed to normally power the network from the commercial AC line while maintaining an emergency battery in a state of full charge. If the commercial AC line fails for any reason or if line voltage exceeds preset low or high limits, the low voltage inverter within the power supply immediately begins providing power to the network load while drawing its operating power from the battery. After commercial AC line power has been restored, the power supply will revert to its normal operating mode supplying power to the network load while drawing operational power from the commercial AC line. Simultaneously, the internal battery charger within the power supply will recharge the battery. The power supply will continue providing filtered and regulated AC to the network load.

All Blackhawk Series power supplies operate as standby units, transferring between power sources (AC line and inverter) in less than one cycle of power. Inverter transfer from line mode to battery mode and from battery mode to line mode is synchronous resulting in minimum load power anomolies. Refer to Fig. 2-1 for a typical output power wave-form during transfer from commercial line to inverter power.

Fig. 2-1 Typical Output Transfer Waveform: Nominal 90 Volt Output, 80% Load

As shown in Fig. 2-1, output voltage never decreases below 90% of full output rating during the source transfer. Output voltage recovers to full rated output within 2 cycles following transfer. Under the test conditions in which the waveform was recorded, output voltage was measured to be 86.30 volts RMS with 80% of full rated load applied.

Video-only services using equipment powered by standby power supplies should exhibit little if any disturbance within the customers’ homes during a source transfer. On the other hand, critical services such as VoIP, telephony grade communications and data transfer may experience undesired disturbances from source transfers between commercial AC line and inverter power. Such services may be highly intolerant of any power anomolies, even minor disturbances that would never be noticed on video-only services. For mission-critical services requiring an exceptionally high degree of power integrity, system operators are advised to consider using one of the MP Plus Series true-UPS power supplies offered by Multilink Broadband. Contact you local Multilink sales representative for further information.

The power supplies documented in this instruction manual have been designed to support optional HMS status monitoring. The HMS protocol supports communication between the power supply and the monitoring device via an RS-485 serial port in an external modem. HMS status monitoring may be installed either at the factory or in the field as an added option.

Blackhawk Series Product Features:

o 60/75/90 VAC output operation; easily user selectable. o Serial status monitoring available, compatible with HMS-022 protocol. o High efficiency for economical line operation and longer standby run time. o Ferroresonant output: filters and regulates load power. o Status at a glance display. o High input power factor, typically 0.9 or better (line mode). o Temperature compensated charger with battery temperature sensor. o Robust inverter circuits with compact forced-air cooling. o PM (pole-mount) and GM (ground-mount) enclosure options.

Unpacking and Inspection Before installing this equipment, inspect the power supply for shipping damage or missing

components. If the power supply or other items were damaged in shipment, file a damage claim with the shipping company and contact your Multilink Broadband representative immediately. Be sure to retain the original shipping carton and all packing material for the power supply until you are certain that warranty return will not be required.

All Blackhawk Series power supplies include: Power supply, ready for installation in cabinet

Battery temperature sensor cable Installation and operating instructions

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