Alpha APP60S Operating instructions

Alpha APP60S Operating instructions
AM / AP SERIES
Standby Power Supplies
AM 660 Series
AM 960 Series
Technical Manual
©1996 Alpha Technologies
The AM / AP Series Standby Power Supply
IMPORTANT SAFETY INSTRUCTIONS
CONTAINED IN THIS MANUAL
CAUTION
RISK OF ELECTRICAL SHOCK
CAUTION:TO REDUCE THE RISK OF ELECTRICAL SHOCK,
AND ENSURE THE SAFE OPERATION OF THIS UNIT, THE
FOLLOWING SYMBOLS HAVE BEEN PLACED THROUGHOUT THE MANUAL. WHERE THESE SYMBOLS APPEAR,
SERVICING SHOULD BE PERFORMED ONLY BY QUALIFIED PERSONNEL.
DANGEROUS VOLTAGE
A DANGEROUS VOLTAGE EXISTS IN THIS AREA OF THE
POWER SUPPLY. USE EXTREME CAUTION.
ATTENTION
IMPORTANT OPERATING INSTRUCTIONS. THIS PROCEDURE SHOULD BE PERFORMED ONLY BY QUALIFIED SERVICE PERSONNEL.
SAVE THESE INSTRUCTIONS
The AM / AP Series Standby Power Supply
IMPORTANT TECHNICAL NOTE
CAUTION:
When operating the AP Series Standby Power Supply, a minimum
load of at least 1.5 Amperes (approximately 10% of the output
rating of the power supply) must be connected to the output. Failure
to do so could damage the load or the unit’s ferroresonant power
transformer.
Damage caused by this condition will not be covered under warranty.
For further information, contact AlphaTechnologies or your nearest
Alpha representative.
The AM / AP Series Standby Power Supply
IMPORTANT SAFETY PRECAUTIONS
THE POWER SUPPLY SHOULD BE SERVICED ONLY BY QUALIFIED PERSONNEL.
THE POWER SUPPLY CONTAINS MORE THAN ONE LIVE CIRCUIT. EVEN THOUGH AC IS NOT
PRESENT AT THE INPUT, IT MAY BE PRESENT AT THE OUTPUT.
WHEN USING AN EXTERNAL SERVICE DISCONNECT, VERIFY THAT IT IS EQUIPPED WITH A
HIGH MAGNETIC TRIP BREAKER PROPERLY RATED (AMPERAGE) FOR USE WITH THE
POWER SUPPLY.
THE USE OF IMMOBILIZED ELECTROLYTE-TYPE BATTERIES (SUCH AS GELLED OR OTHER
VRLA - VALVE REGULATED LEAD ACID - BATTERIES) IS STRONGLY RECOMMENDED OVER
LIQUID ELECTROLYTE-TYPES. WET CELL BATTERIES CAN LEAK OR SPILL, INCREASING
THE RISK OF EXPOSURE TO CORROSIVE LIQUID ELECTROLYTIC ACID.
WHEN IN STORAGE, BATTERIES SHOULD BE CHARGED AT LEAST ONCE EVERY THREE
MONTHS TO ENSURE OPTIMUM PERFORMANCE AND BATTERY LIFE.
WEAR EYE PROTECTION, SUCH AS SAFETY GLASSES OR A FACE SHIELD, WHENEVER
WORKING WITH BATTERIES.
USE GLOVES WHEN HANDLING BATTERIES. BATTERY ELECTROLYTE IS ACIDIC AND MAY
CAUSE BURNS.
NEVER SMOKE NEAR BATTERIES. SPARKS, FLAMES OR OTHER SOURCES OF IGNITION
MAY CAUSE A BATTERY EXPLOSION.
ALWAYS CARRY A SUPPLY OF WATER, SUCH AS A WATER JUG, TO WASH THE EYES OR SKIN
IN THE EVENT OF EXPOSURE TO BATTERY ELECTROLYTE.
USE PROPER LIFTING TECHNIQUES WHENEVER HANDLING THE ENCLOSURE, POWER
MODULE OR BATTERIES. GROUP 31 SIZE BATTERIES, USED IN THE MAJORITY OF CABLE
TELEVISION APPLICATIONS, CAN WEIGH AS MUCH AS 70 LBS.
USE A BUCKET TRUCK, OR SUITABLE SAFETY EQUIPMENT SUCH AS A SAFETY HARNESS
AND CLIMBING SPIKES, WHEN SERVICING POLE INSTALLATIONS.
ALWAYS SWITCH THE POWER SUPPLY’S BATTERY CIRCUIT BREAKER TO OFF BEFORE
DISCONNECTING BATTERY CABLES. THIS GREATLY REDUCES THE CHANCE OF SPARK AND
POSSIBLE BATTERY EXPLOSION.
DO NOT ALLOW LIVE BATTERY WIRES TO CONTACT THE ENCLOSURE OR POWER SUPPLY
CHASSIS. POSSIBLE EXPLOSION OR FIRE CAN OCCUR.
BEFORE PLACING A CURRENT LOAD ON THE BATTERIES, (SUCH AS WHEN SWITCHING THE
POWER SUPPLY TO STANDBY), USE THE ENCLOSURE DOOR AS A SHIELD IN THE EVENT OF
A BATTERY EXPLOSION.
INSPECT BATTERIES FOR SIGNS OF CRACKS, LEAKING OR SWELLING.
WHEN REPLACING BATTERIES, ALWAYS USE THOSE OF AN IDENTICAL TYPE. NEVER
INSTALL OLD OR UNTESTED BATTERIES.
CHECK THE BATTERY’S DATE CODE. BATTERIES OLDER THAN SEVERAL YEARS SHOULD
NOT BE USED.
AVOID THE USE OF UNINSULATED TOOLS OR OTHER CONDUCTIVE MATERIALS WHEN
HANDLING BATTERIES OR WORKING INSIDE THE ENCLOSURE.
SPENT OR DAMAGED BATTERIES ARE CONSIDERED ENVIRONMENTALLY UNSAFE.
ALWAYS RECYCLE USED BATTERIES.
The AM / AP Series Standby Power Supply
BATTERY CHARGING
ALWAYS REFER TO THE BATTERY MANUFACTURER’S RECOMMENDATION FOR
SELECTING CORRECT FLOAT AND EQUALIZE CHARGE VOLTAGES. FAILURE TO
DO SO COULD DAMAGE THE BATTERIES.
VERIFY THE POWER SUPPLY’S BATTERY CHARGER FLOAT AND EQUALIZE CHARGE
VOLTAGES. REFER TO THE POWER SUPPLY’S OPERATION MANUAL.
BATTERIES ARE TEMPERATURE SENSITIVE. DURING EXTREMELY COLD CONDITIONS, A BATTERY’S CHARGE ACCEPTANCE IS REDUCED AND REQUIRES A
HIGHER CHARGE VOLTAGE; DURING EXTREMELY HOT CONDITIONS, A BATTERY’S
CHARGE ACCEPTANCE IS INCREASED AND REQUIRES A LOWER CHARGE VOLTAGE.
TO COMPENSATE FOR CHANGES IN TEMPERATURE, THE BATTERY CHARGER
USED IN THE POWER SUPPLY IS TEMPERATURE COMPENSATING. FLOAT AND
EQUALIZE CHARGE VOLTAGES WILL VARY DEPENDING UPON AMBIENT AIR TEMPERATURE.
IF BATTERIES APPEAR TO BE OVER OR UNDER-CHARGED, FIRST CHECK FOR
DEFECTIVE BATTERIES AND THEN VERIFY CORRECT CHARGER VOLTAGE SETTINGS.
BATTERY PREVENTIVE MAINTENANCE
BATTERIES SHOULD BE INSPECTED EVERY THREE TO SIX MONTHS TO ENSURE
OPTIMUM PERFORMANCE.
VISUALLY INSPECT BATTERIES FOR SIGNS OF CRACKS, LEAKS OR SWELLING.
CHECK BATTERY TERMINALS AND CONNECTING WIRES. BATTERY TERMINAL
CONNECTORS SHOULD BE CLEANED PERIODICALLY AND RETIGHTENED TO APPROXIMATELY 50 INCH/LBS. SPRAY THE TERMINALS WITH AN APPROVED BATTERY TERMINAL COATING SUCH AS NCP-2.
CHECK BATTERY VOLTAGES UNDER LOAD. USE A LOAD TESTER IF AVAILABLE.
DIFFERENCES BETWEEN ANY BATTERY IN THE SET SHOULD NOT BE GREATER
THAN 0.3 VDC.
CHECK THE POWER SUPPLY’S BATTERY CHARGER VOLTAGES. REFER TO THE
BATTERY MANUFACTURER’S RECOMMENDATION FOR CORRECT CHARGE VOLTAGES AND THE POWER SUPPLY’S OPERATION MANUAL FOR CORRESPONDING
CHARGER SETTINGS.
NUMBER THE BATTERIES (1, 2, 3, ETC.) INSIDE OF THE ENCLOSURE FOR EASY
IDENTIFICATION.
ESTABLISH AND MAINTAIN A BATTERY MAINTENANCE LOG.
The AM / AP Series Standby Power Supply
Table of Contents
1.
INTRODUCTION
1.1
1.2
1.2.1
1.2.2
1.2.3
1.3
2.
AM SERIES FRONT PANEL
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3.
6
Ammeter
AC Output Fuse
Battery Circuit Breaker
"LINE ON" Lamp
"STANDBY" Lamp
Elapsed Time Meter (optional)
Test / EQ Reset Switch (optional)
AM SERIES SIDE PANEL
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
4.
1
The AM / AP Series Standby Power Supply
Theory of Operation
AC (LINE) Operation
Inverter (STANDBY) Operation
Charger Operation
Specifications
8
AC Power Cord
10-Pin Terminal Strip
Battery Connection
AC Output Connection
ACI (AC Indicator) Connection
LRI (Local / Remote Indicator) Connection
Remote Alarm Connection
STANDARD FEATURES
4.1
4.2
4.3
4.4
10
AP660 Standby Power Supply
AP660-E Standby Power Supply
AP960 Standby Power Supply
AP960-E Standby Power Supply
i
The AM / AP Series Standby Power Supply
Table of Contents, continued
5.
OPTIONAL FEATURES
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
5.25
5.26
6.
11
APM (Automatic Performance Monitor)
RPM (Remote Parallel Monitor)
LRI (Local and Remote Indicator)
ACI (AC Indicator)
ET (Elapsed Time Meter)
IC (Incident/Event Counter)
LA-P (Plug-in Lightning Arrester)
BCK - X (Battery Cable Kit)
BCK-FX (Fused Battery Cable Kit)
BMO (Battery Mat Option)
BTO (Battery Tray Option)
APX (Adaptor for Plug-in Type Enclosures)
MST (Module Slide Tray)
DSE (Delete Service Entrance)
ISE (Internal Service Entrance)
STH (Storm Hoods)
Additional Voltage Taps
APP60S (Service Power Supply)
Batteries
ABC-12 (Battery Charger)
RTS (Remote Temperature Sensor)
Enclosures
PS Series (Pedestal Supports)
AC Series (Amp Clamp)
Computer Aided Training (CD-ROM)
Instructional Videotapes
INSTALLATION
6.1
6.2
6.3
6.3.1
6.3.2
6.4
6.5
6.6
6.7
6.8
6.8.1
6.8.2
6.8.2.1
6.8.2.2
6.8.3
16
Unpacking and Inspection
Pole-mount Enclosure Installation (PME and PWE)
Ground-mount Enclosure Installation (UPE and UPE/M)
Pedestal Support Preparation
Concrete Pad Preparation
Connecting Utility Power
Connecting the SPI (Service Power Inserter)
Battery Installation and Wiring
Power Module Installation
Logic Card Installation, Removal and Operation
SCB (Standard Control Board)
APM (Automatic Performance Monitor)
APM Battery Charging Selection
APM Float and Equalize Chart
RPM (Remote Parallel Monitor)
ii
The AM / AP Series Standby Power Supply
Table of Contents, continued
7.
OPERATION
7.1
7.1.1
7.1.2
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.3
8.
PREVENTIVE MAINTENANCE
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.8.1
8.8.2
8.8.3
8.8.4
8.9
8.10
8.11
9.
33
Check Battery Terminals and Connecting Wires
Check Battery Open Circuit Voltage
Check Battery Voltage Under Load
Check Battery Charger (FLOAT) Voltage
Check Battery Charger (EQUALIZE) Voltage
Check Output Voltage
Check Output Current
APM Manual Self-Test
"Test" LED ON
"DC" LED ON
"AC" LED ON
"EQU" LED ON
Logic Card Maintenance
Internal Fuse Replacement
Additional Maintenance
TROUBLE-SHOOTING AND REPAIR
9.1
9.2
9.3
9.4
10.
29
Power Module Start-up and Testing
AC Line Operation (LINE)
Inverter Operation (STANDBY)
Identifying Modes of Operation
AC Line Operation
Inverter Operation
Self-test / Transfer Mode
Test Fail
Power Module Shutdown
37
Repair Instructions
Parts Ordering Instructions
Common Parts for AM / AP Series Standby Power Supplies
Trouble-shooting Guide
WARRANTY
44
iii
The AM / AP Series Standby Power Supply
Table of Contents, continued
ILLUSTRATIONS (contained in the manual)
AM Series Power Module Front Panel
AM Series Power Module Side Panel
PME and PWE Enclosures
UPE and UPE/M Enclosures
120 VAC and 220 or 240 VAC Input Circuit Breaker Assemblies
SPI (Service Power Inserter)
Module Installation and Wiring Diagram
Typical Battery Date Code Location and Identification
Battery Numbering and RTS Placement
APM Logic Card
RPM Configuration Diagrams
Indentifying Modes of Operation
APP60S (Service Power Supply)
DRAWINGS (located at the back of the manual)
PME Pole-mount Enclosure Installation and Wiring (UL / CSA)
PWE Pole-mount Enclosure Installation and Wiring (UL / CSA)
Pedestal Support for UPE Ground-mount Enclosures
Concrete Pad for UPE Ground-mount Enclosures
Pedestal Support for UPE/M Ground-mount Enclosures
Concrete Pad for UPE/M Ground-mount Enclosures
AM Series Power Module in PME Enclosure
AM Series Power Module in PWE Enclosure
AM Series Power Module in UPE Enclosure
AM Series Power Module in UPE/M Enclosure
PWE Enclosure with AP Module and Batteries
Battery Wiring with Remote Temperature Sensor Connection
ACI / LRI Options for PME and PWE Enclosures
AM Series Power Module 10-Pin Terminal Block
AM Series Power Module Block Diagram
Component Layouts
AM Series Power Module
Main Board
SCB Logic Card (Rev 8)
APM Logic Card (Rev 8)
Schematics
Main Board (60 Hz)
Main Board (50 Hz)
SCB Logic Card (Rev 8)
APM Logic Card (Rev 8)
iv
1. INTRODUCTION
INTRODUCTION
1.1
The AM / AP Series Standby Power Supply
Alpha AP Series standby power supplies are designed for powering signal processing
equipment in Cable Television and Broadband LAN distribution systems. The power supply,
which consists of an AM Series power module and a pole or ground-mount enclosure,
provides the critical load with current-limited, regulated AC power that is free from disturbances caused by spikes, surges, brownouts or blackouts. Backup power is achieved by a
set of rechargeable, gelled electrolyte (no maintenance) batteries.
During LINE operation, AC power enters the module where it is converted to a "quasi" square
wave and regulated (at the required output voltage). It is then passed onto the load via the
SPI (Service Power Inserter) located inside the power supply enclosure. At the same time,
power is directed to the battery charger to maintain a float charge to the batteries.
When the incoming AC line voltage drops significantly, or a utility power outage occurs, the
AM Series power module automatically transfers to inverter (STANDBY) operation in order
to maintain power to the load. During the transfer, energy contained in the module's
ferroresonant transformer continues to supply power to the output. Depending upon the type
of batteries used, and the loading on the power supply, backup power can continue for several
hours. When utility line power returns, the AM Series power module waits momentarily for
the utility voltage and frequency to stabilize and then initiates a smooth, in-phase transfer
back to AC line power. Once the transfer is complete, the battery charger quickly recharges
the batteries in preparation for the next utility power outage.
The AP Series standby power supply contains an impressive list of features including a front
panel ammeter to measure the output current; an output fuse to protect against excessive
short circuit currents; a battery circuit breaker to protect the DC circuit; a "LINE" indicator to
verify AC input power from the utility; and a "STANDBY" indicator to show inverter operation,
along with test and alarm status on units equipped with APM (Automatic Performance
Monitor). Optional features can include an elapsed time meter to accumulate "total outage
time;" and a TEST / RESET switch to allow a technician to control the module from the front
panel. Serval varieties of interchangeable logic card upgrades facilitate power supply selftesting and status monitoring.
UL Listed and CSA Approved, the AP Series standby power supply is designed to be one of
the most rugged, reliable, and versatile power supplies available. Alpha Technologies,
recognized as an international market leader in the field of backup power, offers complete
technical support and prompt, reliable service to ensure that your power supply continues to
provide years of trouble-free operation.
1
1. INTRODUCTION
1.2
Theory of Operation
The AM Series power module contains a ferroresonant transformer, resonant capacitor,
dual-mode temperature-compensated battery charger, DC to AC converter (inverter),
transfer isolation relay, main power board, and removable logic card.
1.2.1 AC (LINE) Operation
During AC line operation, utility power is fed into the primary winding of ferroresonant
transformer and through the contacts of the transfer isolation relay. At the same time, power
is fed to the auxiliary transformer which provides power for the control circuitry. A charger
winding on transformer feeds the charger circuit which provides the charge voltages to the
batteries. An AC capacitor forms the resonant circuit of the ferroresonant transformer which
provides excellent noise and spike attenuation, short circuit current limiting, and output
voltage regulation. The ferroresonant transformer produces a "quasi" square wave output
which resembles a rounded square wave.
The logic circuit constantly monitors the incoming AC line. When there is a significant drop
or a complete interruption of AC input power, the logic circuit automatically initiates inverter
operation.
NOTE: WHEN MEASURING THE OUTPUT VOLTAGE OF FERRORESONANT TRANSFORMERS, USE ONLY A TRUE RMS AC VOLTMETER. NON-RMS READING METERS
ARE CALIBRATED TO RESPOND TO PURE SINE WAVES AND WILL NOT PROVIDE AN
ACCURATE READING WHEN MEASURING A "QUASI" SQUARE WAVE OUTPUT.
1.2.2 Inverter (STANDBY) Operation
When the incoming AC Line voltage drops significantly, or a complete power outage occurs,
the control logic’s line monitor activates STANDBY operation. The battery powered inverter
comes on-line (in-phase with the failing AC line) as the isolation relay switches to prevent AC
power from back-feeding to the utility. The transfer from utility to inverter operation takes
place in less than 16 milliseconds. During the transfer period, the energy contained in the
ferroresonant transformer continues to supply power to the load. The following changes
occur: The transfer / isolation relay opens to disconnect the AC line from the primary winding
of the ferroresonant transformer. The control logic drives the inverter transistors ON and OFF
at line frequency. This switching action converts the DC battery current into AC in the inverter
winding of the ferroresonant transformer which provides regulated power to the load. The
control logic, which includes a circuit to protect the inverter transistors from over-current
damage, monitors the condition of the batteries during inverter operation. Since a prolonged
AC line outage would severely discharge the batteries, resulting in permanent damage, the
control logic disables the inverter when the batteries drop to approximately 10.5 VDC / battery
(31.5 VDC / set).
When AC line voltage returns, the power module transfers back to LINE operation after
approximately 1 minute. This delay allows the AC line voltage and frequency to stabilize
before the control logic phase-locks the inverter’s output to the utility input. It then deenergizes the isolation relay, re-connects the AC line to the primary of the ferroresonant
transformer and disconnects the batteries from the inverter. This results in a smooth, inphase transfer back to utility power without interruption of service to the load. The battery
charging circuit is then activated to recharge the batteries in preparation for the next utility
power outage.
2
1. INTRODUCTION
1.2
Theory of Operation, continued
1.2.3 Charger Operation
The AP Series power supply uses a dual-mode, temperature-compensated battery charger.
During AC line operation, a charger winding on the ferroresonant transformer feeds the
charger circuit which provides "FLOAT" and "EQUALIZE" charge voltages to the batteries.
The circuit consists of a switching regulator, inductor and other associated components. The
charger winding of the transformer produces an AC voltage that is rectified by diodes and
filtered by an inductor. Regulation is provided by a PWM (Pulse Width Modulation) controller
on the logic card which switches the transistors ON at the appropriate duty cycle. This
produces a regulated DC battery charging voltage. The charge current passes through a
resistor to provide current-limit sensing for the charging circuit. A fuse protects the circuit in
the event of a charger malfunction or reversal of the battery leads. The charge current is
determined by the acceptance level of the batteries, but limited to 10 Amps maximum. As
the batteries approach full charge, the charger’s current tapers off to normal float levels.
On units equipped with the SCB (Standard Control Board), the charger provides a FLOAT
charge to the batteries for approximately 2 weeks. The voltage is then slightly increased to
EQUALIZE for approximately 2.5 hours before switching back to float. Both float and
equalize charge voltages are calculated according to the battery manufacturer's recommendations. A switch, located on top of the logic card, allows a technician to manually sequence
the charger through its dual charging modes. On units equipped with APM (Automatic
Performance Monitor), the module's front panel switch performs the same function. With the
optional APM or RPM logic upgrade installed, after the charger has completed 3 cycles of float
and equalize (similar to SCB), it automatically initiates a 30 minute self-test. This is done
approximately every 52 days to ensure that the inverter and batteries are capable of
supporting inverter operation. NOTE: APM and RPM cards released after 1989, provide
switch selectable float and equalize charge voltage settings, plus a remote battery temperature sensor.
LEDs located on top of the logic card display the charging modes. The standard control board
(SCB) contains one red LED. When the LED is OFF, the charger is in float mode; when it
is ON, the charger is in equalize mode. On units equipped with the optional APM logic
upgrade, lighted LEDs indicate: SELF-TEST (yellow), EQUALIZE (green), AC FAIL (red),
and DC FAIL (red). When the EQUALIZE LED is OFF, the charger is in float mode.
3
1. INTRODUCTION
1.3
SPECIFICATIONS
MODEL
CONFIGURATION
INPUT
Voltage (VAC)
Frequency (Hz)
Current Max. (A)1
Low AC Ref. (VAC)
AM660
J5
AM660
-
100
50
11.8
80
120
60
11
95
120
60
11
95
220
50
6.1
182
240
50
5.7
182
220
60
6.1
182
240
60
5.7
182
OUTPUT
Voltage (VAC)
Current Max. (A)
Power (VA)
60
12
720
60
12
720
60
14
840
60
12
720
60
12
720
60
12
720
60
12
720
BATTERIES
Number
Voltage (VDC)
Backup Time (Hrs)*
3
36
4.0
3
36
4.0
3
36
3.7
3
36
4.0
3
36
4.0
3
36
4.0
3
36
4.0
WEIGHTS
(lbs)
(kg)
62
28.0
62
28.0
62
28.0
62
28.0
62
28.0
62
28.0
62
28.0
AM960
J5
AM960
J6
AM960
-
AM960
E
AM960
E
AM960
P
AM960
P
100
50
12
80
100
60
12
80
120
60
12
95
220
50
6.5
182
240
50
6.0
182
220
60
6.5
182
240
60
6.0
182
OUTPUT
Voltage (VAC)
Current Max. (A)
Power (VA)
60
15
900
60
15
900
60
15
900
60
14
840
60
14
840
60
15
900
60
15
900
BATTERIES
Number
Voltage (VDC)
Backup Time (Hrs)*
3
36
3.1
3
36
3.1
3
36
3.1
3
36
3.7
3
36
3.7
3
36
3.1
3
36
3.1
WEIGHTS
(lbs)
(kg)
67
30.5
67
30.5
67
30.5
67
30.5
67
30.5
67
30.5
67
30.5
MODEL
CONFIGURATION
INPUT
Voltage (VAC)
Frequency (Hz)
Current Max. (A)1
Low AC Ref. (VAC)
AM660-14 AM660-14 AM660-14 AM660-14 AM660-14
E
E
P
P
1
At nominal line voltage.
*NOTE: Battery run times are subject to temperature, age and overall condition of batteries.
4
1. INTRODUCTION
1.3
SPECIFICATIONS, continued
Regulation
Input Voltage (VAC)
Input Frequency (Hz)
Output Voltage (VAC)
Output Frequency (Hz)
Inverter Frequency Stability
Output Current Limit
Transfer Time
Efficiency
+/- 15%
+/- 3%
+/- 5%
+/- 1%
+/-0.05%
150% of maximum output rating
less than 16 ms
90% typical @ rated load (LINE)
85% typical @ rated load (STANDBY)
Battery Type
Gelled electrolyte (or equiv) 12 VDC batteries
Battery Low Voltage Cutout
31.5 VDC (1.75 Volts per cell)
Battery Recharge Acceptance
37.5 VDC (typical)
Battery Float Charge Voltage
39.0 VDC to 44.4 VDC (selectable)*
(2.16 VDC to 2.31 VDC per cell)
Battery Equalize Charge Voltage 39.0 VDC to 44.1 VDC (selectable)*
(2.16 VDC to 2.46 VDC per cell)
Temperature Compensation
-0.05 Volts/0F (-0.09 Volts/0C)
Battery Charging Current
10 Amps maximum
Battery Recharge Time
12 hours typical (from low cutout) with 75 Ah batteries
Operating Temperature Range
Finish
Dimensions
Enclosures:
PME
PWE
UPE
UPE/M
Modules:
All AM Series
Weights
Enclosures:
PME
PWE
UPE
UPE/M
-400 to +1220 F (-400 to +500 C)
Gray, Powder Coat Paint
22" W x 24" H x 14" D (559mm x 610mm x 356mm)
24" W x 24" H x 14" D (610mm x 610mm x 356mm)
28" W x 35.3" H x 17" D (711mm x 889mm x 432mm)
28" W x 45" H x 21.3" D (711mm x 1143mm x 540mm)
14.5" W x 10.0" H x 12.0" D (368mm x 254mm x 305mm)
34 lbs. (15.4 kg)
47 lbs. (21.4 kg)
66 lbs. (30.0 kg)
124 lbs. (56.4 kg)
All specifications are at load @ 770 F (250 C)
* When using APM, charge voltages should be user selected according to specific battery manufacturer’s recommendations.
5
2. FRONT PANEL
THE AM SERIES FRONT PANEL
AM SERIES
2.1
2.6
2.7
2.2
2.3
2.4
2.5
2.1 - Ammeter
2.2 - AC Output Fuse
2.3 - Battery Circuit Breaker
2.4 - LINE ON Lamp
2.5 - STANDBY Lamp
2.6 - Elapsed Time Meter (optional)
2.7 - Test/EQ Reset Switch (optional)
6
2. FRONT PANEL
FRONT PANEL
2.1
Ammeter
The front panel ammeter displays output current flowing from the power module into the load.
It is extremely useful in determining the status of the power supply during maintenance and
trouble-shooting. When there is no load at the module's output, the ammeter reads zero.
When the meter reads above the rated output of the module, such as 18 or 20 Amps, an
overload or short circuit condition may exist in the load.
2.2
AC Output Fuse
The AC output fuse protects the load from excessive durations of short circuit current. If the
front panel ammeter reads zero, indicating no output to the load, this fuse should be checked
and replaced if necessary. ABC-15 Fuse: Alpha P/N (460-042-10) 15 Amp, 220 V Fast.
2.3
Battery Circuit Breaker
The front panel battery circuit breaker is used to disconnect the batteries from the module's
DC circuit. When the breaker is OFF, the module will not be able to transfer to standby mode.
The inverter is disabled and the battery charger is unable to charge the batteries. If a short
circuit occurs in the DC circuitry, the breaker will trip.
2.4
LINE ON Lamp (Green)
The LINE ON lamp indicates the presence of utility AC and that the power supply is in its
normal operating mode. For 60 Hz applications the lamp is green; for 50 Hz, amber.
2.5
STANDBY Lamp (Red)
The STANDBY lamp indicates that the power supply is operating on backup power from the
batteries. When a brownout or utility outage occurs, the LINE ON lamp goes out and the
STANDBY lamp lights to signal that the unit has transferred to inverter operation. On units
equipped with an APM or RPM logic upgrade, the STANDBY lamp flashes to indicate when
the power supply fails self-test and requires service. During the 30 minute self-test mode,
the STANDBY lamp will come ON as well the LINE ON lamp, indicating the availability of utility
AC (see section 7.2).
2.6
Elapsed Time Meter (optional)
The optional, Elapsed Time Meter is activated only during inverter operation. It is extremely
useful for tracking battery use and displays elapsed time in hours. The clock, accurate to 0.01
hours, accumulates the total amount of time that the power module has been in standby
mode.
2.7
Test/EQ Reset Switch (optional)
The front panel Test/EQ Reset switch is standard on all AM Series power modules equipped
with APM or RPM logic upgrades. It duplicates the switch located on the logic card and is
used to manually cycle the power module through charging modes (float and equalize), into
self-test mode, and to reset alarms. If a fault is detected during the APM self-test mode, the
Test/EQ Reset switch resets the module’s flashing STANDBY lamp and the enclosure’s
flashing LRI (Local / Remote Indicator).
7
3. SIDE PANEL
THE AM SERIES SIDE PANEL
10
9
3.2.5
8
7
6
3.2.4
5
4
3
+2
- 1
3.2
3.1
AC Power Cord
3.2
10-Pin Terminal Strip
3.2.3
3.2.2
3.2.1
3.1
3.2.1
Battery Connection (Pins 1 and 2)
3.2.2
AC Output Connection (Pins 3 and 4)
3.2.3
ACI (AC Indicator) Connection (Pins 3 and 4)
3.2.4
LRI (Local / Remote Indicator) Connection (Pins 6 and 7)
3.2.5
Remote Alarm Connection (Pins 8, 9 and 10)
8
3. SIDE PANEL
SIDE PANEL
3.1
AC Power Cord
The module’s AC power cord plugs directly into the enclosure’s convenience outlet. Since
the module does not have an ON/OFF switch, simply unplug the power cord or use the utility
circuit breaker as the main switch. In situations where the module is to be completely
powered down, first switch the battery breaker OFF, or remove the battery fuse. This will
prevent the unit from going into standby (inverter) operation when utility AC is removed.
3.2
10-Pin Terminal Strip
The 10-pin terminal strip provides all input and output connections to the power module. For
easy identification, polarity and pin locations are clearly marked. Screw terminals accommodate both straight blade and Phillips screwdrivers. In the majority of installations, the batteries
and the AC output (pins 1 - 4, respectively) are the only connections made to the terminal strip.
Pin 5, in most cases, is not used.
3.2.1 Battery Connection
The batteries connect to pins 1 and 2 on the module's 10-pin terminal strip. Always verify
proper polarity before connecting the battery cables to the module. Polarity is clearly marked
for easy identification. The blue cable connects to pin 1 (negative); the red cable connects
to pin 2 (positive). If, for some reason, the cables have been interchanged at the batteries,
the 10 Amp fuse located on the module's main board will open. NOTE: Whenever making
or breaking battery connections at the terminal strip, make sure that the battery breaker on
the module's front panel is first pulled out, or the fuse removed.
3.2.2 AC Output Connection
The SPI (Service Power Inserter) couples output power from the module to the cable plant
and connects to pins 3 and 4 on the10-pin terminal strip. The wiring configuration is clearly
marked for easy identification. The white wire connects to pin 3 (neutral); the black to pin 4
(hot).
3.2.3 ACI (AC Indicator) Connection
The optional, green AC Indicator, which is externally mounted on the enclosure, indicates the
presence of output power from the module. It co-connects to pins 3 and 4 (60 VAC) on the10pin terminal strip along with the Service Power Inserter. The yellow wire connects to pin 3
(neutral); the black to pin 4 (hot). The indicator remains ON as long as there is output power.
3.2.4 LRI (Local / Remote Indicator) Connection
The optional, red Local / Remote Indicator, used in conjunction with the APM and RPM logic
upgrades, connects to pins 6 and 7 (28 VDC) on the module's 10-pin terminal strip. The wiring
configuration is clearly marked for easy identification. The white wire connects to pin 6
(negative); the blue to pin 7 (positive).
3.2.5 Remote Alarm Connection
On units equipped with APM and RPM logic upgrades, dry “Form C” contacts are provided
to accommodate systems requiring remote alarms. Pin 8 is configured “normally open”
(contacts close when alarm is present). Pin 9 is configured as common. Pin 10 is configured
“normally closed” (contacts open when alarm is present).
9
4. STANDARD FEATURES
STANDARD FEATURES
AP Series Standby Power Supplies are available in the following packages:
AM 60V Series power module with standard control logic; Pole-mount enclosure (PME)
complete with galvanized mounting brackets, Service Power Inserter (SPI),
“High Magnetic” trip circuit breaker and duplex receptacle. Optional pole (PWE) and
ground-mount (UPE and UPE/M) enclosures are available. Batteries are separate.
4.1
AP660 Standby Power Supply
AM660 Module (120 VAC, 60 Hz Input)
-
(60 VAC, 14 Amp, 840 VA Output)
AM660 E Module (220 or 240 VAC, 50 Hz Input) - (60 VAC, 10 Amp, 600 VA Output)
4.2
AP960 Standby Power Supply
AM960 Module (120 VAC, 60 Hz Input)
-
(60 VAC, 15 Amp, 900 VA Output)
AM960 E Module (220 or 240 VAC, 50 Hz Input) - (60 VAC, 12 Amp, 720 VA Output)
NOTE: All models listed utilize a 36 VDC battery system.
10
5. OPTIONAL FEATURES
OPTIONAL FEATURES
The following options can be ordered factory installed or, in most instances, can be field
retrofitted by qualified service personnel.
5.1
APM (Automatic Performance Monitor) with RTS
The APM, with Remote Battery Temperature Sensing, is a field replaceable logic card that
plugs directly into the edge connector located behind the main power board. It contains the
circuitry that monitors the incoming utility AC, charges the batteries and controls the inverter.
The APM also contains a self-test feature that automatically tests the batteries and inverter
once every 52 days. If a problem is detected during self-test, LEDs on top of the card indicate
the circuit that failed the test. The APM uses a 24-pin connector located on the component
side of the board to accommodate RPM (Remote Parallel Monitor) plug-in logic cards.
5.2
RPM (Remote Parallel Monitor)
The RPM is a field replaceable logic upgrade that plugs directly into the existing APM (Rev
8 or higher) logic cards. The Remote Parallel Monitor allows the AM Series power module
to be configured for pre-existing status monitoring systems such as Scientific Atlanta “6585,”
Magnavox “6DSS,” Jerrold “RSM,” AM Communications “TMC-8061,” Texscan “Vital Signs,”
and C-COR “Quick Alert.”
5.3
LRI (Local / Remote Indicator)
A standard feature when used in conjunction with APM and RPM logic upgrades, the LRI lamp
(red) is located on the outside of pole-mounted enclosures and duplicates the function of the
power module’s front panel STANDBY lamp. During AC line operation, the lamp remains
OFF. During inverter operation, the lamp remains ON. When a fault condition occurs during
the APM self-test, an alarm circuit flashes the lamp to indicate that service is required. This
acts as a simple form of status monitoring by allowing the cable technician to check the status
of the power supply without having to climb the pole and open the enclosure.
5.4
ACI (AC Indicator)
The ACI lamp (green for 60 HZ / amber for 50 Hz) indicates AC output from the power module
during LINE and STANDBY operation. The lamp is located on the outside of pole-mounted
enclosures, next to the LRI. As long as power is present at the module’s output, the ACI lamp
remains ON. As with the LRI, this acts as a simple form of status monitoring by allowing a
technician to check the status of the power supply’s output without having to climb the pole
and open the enclosure.
5.5
ET (Elapsed Time Meter)
Used to record accumulated standby time, the ET is helpful for tracking battery use and
overall utility outage time. The counter, which displays elapsed time in hours, is activated only
during inverter operation. The Elapsed Time Meter must be specified at the time of order.
5.6
IC (Incident/Event Counter)
The Incident/Event Counter maintains an active record of standby events. Whenever the
module's inverter is brought on-line, the analog counter records the event, making it useful
for determining battery use and counting utility outages. The IC easily retrofits into existing
AM Series power modules.
5.7
LA-P (Lightning Arrestor)
The LA-P consists of a 350 Joule, Metal Oxide Varistor (MOV). It plugs directly into the
enclosure’s convenience outlet, eliminating the need for hard-wired MOVs. Enclosed in a
plastic housing, the LA-P is used to provide additional protection from voltage spikes caused
by lightning and other power disturbances. No wiring is necessary.
11
5. OPTIONAL FEATURES
5.8
BCK - X (Battery Cable Kit)
Battery Cable Kits are heavy-duty wiring assemblies used to connect (3) gelled electrolyte,
or equivalent batteries to the power module. All kits come with mounting hardware.
5.9
BCK-FX (Fused Battery Cable Kit)
Fused Battery Cable Kits are available for applications requiring additional battery circuit
protection. Cables can be ordered with fuse ratings of 30 A (AP660) or 40 A (AP960). Always
specify the application when ordering.
5.10
BMO (Battery Mat Option)
Used for a variety of applications, the rubber battery mat provides additional thermal isolation
and battery shelf protection in PME enclosures.
5.11
BTO (Battery Tray Option)
Used mainly with less common wet cell applications, the BTO is designed to contain and
prevent electrolyte from leaking onto the enclosure's shelf. It can also be used to provide
additional thermal isolation from the power module. Battery trays are constructed of PVC and
accommodate individual battery sizes up to Group 31. PME enclosures only.
5.12
APX (Adaptor for Plug-in Type Enclosures)
The APX contains a set of quick connects used to adapt AM power modules with spade
lugs to Alpha enclosures equipped with plug-in type connectors.
5.13
MST (Module Slide Tray)
The MST is designed for use on PME and PWE pole-mount enclosures only and is compatible
with all AM Series power modules. The MST's movable platform rides on a set of heavy-duty
ball bearing slides to promote access to the power module during servicing. It is available
factory installed or as a field retrofit kit.
5.14
DSE (Delete Service Entrance)
For installations requiring an externally-mounted service disconnect, the enclosure's internal
service entrance, if equipped, can be removed. The DSE option, which must be specified
at the time of order, eliminates the internal service entrance assembly. A Square D 15 Amp
"HM" high magnetic trip circuit breaker (for use with the external service disconnect) and
duplex outlet are included with this option. The DSE comes as standard equipment on most
U.S. enclosures.
5.15
ISE (Internal Service Entrance)
For applications requiring an internal service disconnect to be located inside the enclosure,
the ISE option features a Square D 15 Amp "HM" high magnetic trip circuit breaker, an agency
approved service disconnect box and duplex outlet. The ISE comes as standard equipment
on most Canadian enclosures.
5.16
STH (Storm Hoods)
Storm hoods are used on PME and PWE pole-mount enclosures to prevent snow from
entering the enclosure during blizzard conditions. Specify the type of enclosure when
ordering.
5.17
Additional Voltage Taps
AM Series power modules, with a nominal 60 VAC output, are available with 30 and 48 VAC
taps located on the power transformer. Custom taps are available as special order items.
Contact Alpha Technologies for further information and pricing.
12
5. OPTIONAL FEATURES
5.18
APP60S (Service Power Supply)
The APP60S is a portable, non-standby power supply used to provide conditioned AC power
to the load when the main power module is out of service. A front panel switch allows the
APP60S to be set for 30 VAC or 60 VAC applications. Used in conjunction with the “Jones”
connector and "ALT/ON" switch located on the enclosure's SPI (Service Power Inserter),
power can be transferred from the main module to the APP60S without interrupting the load.
5.19
Batteries
Sealed, gelled electrolyte (no maintenance) batteries are recommended for use with AP
Series standby power supplies. The majority of Cable Television and Broadband LAN
operators prefer this type of battery due to its exceptional performance, safety record and
service life. Batteries are available in ratings of 75Ah and 100Ah.
5.20
ABC-12 (Battery Charger)
The ABC-12 is designed for use with 12 volt specialty batteries such as gelled electrolyte
products used in communications, UPS and standby applications. Selectable float or
equalize charge modes optimize battery recharging. The charger is ideal for recharging
batteries that have been in lengthy storage, plus batteries can be re-balanced using a parallel
charge before use in series applications.
5.21
RTS (Remote Temperature Sensor)
The RTS connects the power module to the batteries to provide precise temperature
compensation information. Standard with all current APM logic cards, the RTS can easily
be retrofitted into existing Alpha power supplies equipped with SCB (Standard Control Board,
Rev 4 and higher) and APM-TC (Automatic Performance Monitor with Temperatue Compensation, Rev 5 and higher).
5.22
Enclosures
AM Series standby power modules can be used in either pole or ground-mount installations.
Pole-mount enclosures, PME (for cold climates) and PWE (for warm climates), are
constructed of heavy-duty aluminum and come with two, galvanized steel mounting brackets.
UPE and UPE/M ground-mount enclosures are constructed of heavy-duty aluminum and
come with Galvanized (UPE/M only) steel doors. Alpha enclosures are vented to promote
natural convection cooling and prolong battery life.
Alpha enclosures contain separate compartments for the batteries and power module.
The battery compartment accommodates (3) Group 31 gelled-electrolyte, no-maintenance
batteries and is equipped with a battery slide tray (except PME) for easy access. The module
compartment accommodates the power module, a 15 Amp "HM" circuit breaker assembly,
duplex receptacle and SPI (Service Power Inserter). The AC power connection to the breaker
assembly is made through a conduit knockout on the rear of the PWE enclosure or through
the base of the PME, UPE and UPE/M. The cable connection is made directly to the SPI’s
"VSF" coaxial fitting located on the rear of the PWE, or at the base of the PME, UPE and UPE/
M. There is adequate space in the module compartment to accommodate a variety of power
modules, indicator lamps, and components used for status monitoring.
13
5. OPTIONAL FEATURES
5.23
PS Series (Pedestal Supports)
Alpha pedestal supports provide a quick, one-step solution for ground-mount enclosure
installations. Constructed of pre-formed, high density polyethylene (HDPE), the pedestal
support eliminates the need for costly concrete work. The large body design provides
excellent "hand hole" working space, allowing room for cable bends, wire loops and grounding
connections. Pedestal supports are available for use with Alpha UPE, UPE/M, PWV/PED,
PED/M and PMD/PED ground-mount enclosures.
5.24
AC Series (Amp Clamp)
Alpha Technologies’ Amp Clamps are designed to protect active and passive equipment
(such as amplifiers and power inserters) from voltage surges and transients. Amp Clamps
can be ordered as retrofit kits, or factory installed in the desired host hardware. A Product/
Serial Number label is included with each kit so that retrofitted equipment can be easily
identified. The Amp Clamp circuit consists of two, rugged SCRs (silicon controlled rectifiers)
connected in an inverse parallel configuration with a steady state current rating of 35 Amps
and a one cycle (8 ms) pulse rating of 500 Amps. The SCRs are triggered into conduction
whenever the Amp Clamp’s bi-directional trigger diode senses the presence of voltage
transients exceeding its 190 - 265 Volt peak breakover voltage (instantaneous clamping).
The fast response trigger SIDACTOR gates the appropriate SCR ON in a nanosecond (or
less) to shunt the surge current to ground, effectively protecting sensitive equipment from
transient overvoltage conditions. The Amp Clamp is compatible with numerous host
hardware including: C-COR PS-550-C power inserter, PS-900-C power inserter and T500
amplifiers (6 & 8 port); G.I./Jerrold SSP-PI power inserter, SSP-3 two-way splitter and SSP(7, 9, 12, or 16 ) directional couplers; Lindsay LPI-100 and 1GHz LPI-100 power inserters;
Magnavox 4-LPI, 5-LPI, 8-LPI, 49-LPI and 59-LPI power inserters; RCA PI-1 power inserter;
RMS CA-5400 and UP-6400 power inserters, and CA-5402/RFI two-way splitter; Scientific
Atlanta SAIF-RFI power inserter; Regal RPI-60 (blue) power inserter; and Antronix RPI-60
(green) power inserter. If your equipment is not listed, contact Alpha Technologies for
availability.
5.25
Computer Aided Training (CD-ROM)
Computer Aided Training for power supply maintenance is available for either MAC® or IBM ®
(and compatible) formats on CD-ROM. Technicians can learn operation, installation and
maintenance skills at their own pace before leaving the office, thus reducing overall
maintenance time and standardizing maintenance practices. The program can be viewed
using PowerPoint Viewer® , included with the CD-ROM.
14
5. OPTIONAL FEATURES
5.26
Instructional Videotapes
Instructional videotapes are available for AP Series power supplies including Product
Overview, Theory of Operation, Installation, and Maintenance. Each tape is available in
either NTSC (VHS) or PAL formats and covers all aspects of the Alpha Standby Power
Supply. Transcripts of each tape are available upon request.
"Alpha Technologies: Market Leader in Standby Power" (P/N 048-082-00) is a 20 minute
presentation which highlights standby power products and ephasizes reliability, ease of
operation and customer service.
"The Alpha Standby Power Supply" (P/N 048-070-00) is a 10 minute conceptual overview
of the Alpha standby power supply. The tape covers the advantages and disadvantages of
forward and reverse transfer systems and compares them to Alpha's approach to standby
power.
"Installing the Alpha CATV Standby Power Supply" (P/N 026-006-B4) is a 20 minute,
step-by-step, description of the installation process. The tape includes ground and polemount applications, start-up procedures and testing the unit.
"Power Supply Maintenance for AP and AM Series Power Products" (P/N 026-006-B2
[108-3]) is a 30 minute presentation that covers all aspects of AP Series standby power
supply operation and recommended maintenance procedures.
15
6. INSTALLATION
INSTALLATION
To ensure operator safety:
1. Power supplies should be installed only by qualified personnel and in accordance
with applicable electrical codes.
2. Use eye protection whenever working with batteries.
3. Use only sealed, lead-acid type batteries (gelled-electrolyte or equiv., 55 Ah min.)
4. Use a bucket truck, or suitable climbing equipment such as a safety harness and
climbing spikes, whenever installing or servicing pole-mount installations.
6.1
Unpacking and Inspection
Carefully remove the power module and enclosure from their shipping containers. Make sure
that the following items have been included:
1. AM Series Power Module (including APX and BCK-X battery cable kits).
2. PME Pole-mount enclosure (with two, galvanized mounting brackets, SPI service
power inserter, 15 Amp "HM" trip circuit breaker assembly with duplex receptacle).
PWE, UPE and UPE/M are optional enclosures. Batteries are shipped separately.
3. Operator's Manual.
4. Any other ordered options.
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.
SAVE THE ORIGINAL SHIPPING CONTAINER.
In the event a unit needs to be returned for service, it should be packaged in its original
shipping container. If the original container is not available, make sure the unit is packed with
at least three inches of shock-absorbing material to prevent shipping damage. NOTE: Do
not use popcorn-type material. Alpha Technologies is not responsible for damage caused
by improper packaging on returned units.
READ THE OPERATOR'S MANUAL.
Become familiar with the power supply's front and side panel. Review the drawings and
illustrations contained in the manual before proceeding. If you have questions regarding the
safe installation or operation of this unit, contact Alpha Technologies or your nearest Alpha
representative.
Upper Mounting Bracket
5/8" Dia. "Through" Bolts
5/8" Dia. "Through" Bolts
Cable Power Out
PME
PWE
Nut & Washer
18"
Nut & Washer
Chassis
Ground
ACI /
LRI
Options
18"
ACI / LRI
Options
Chassis Ground
Utility Power In
Cable Power Out
Utility Power In
Lower Mounting Bracket
Lower Mounting Bracket
PME and PWE Pole-mount Enclosures (Wood Poles)
16
6. INSTALLATION
6.2
Pole-mount Enclosure Installation (PME and PWE)
PME and PWE enclosures are designed to be mounted on wooden poles; however, special
brackets are available for concrete pole applications. Mounting bolts should go completely
through the wooden pole and be secured from the back with a large washer and nut. The
two galvanized mounting brackets mount between the enclosure and pole. Most codes
require the base of the enclosure to be located a minimum height from the ground. Always
verify height restrictions before proceeding. (Refer to the pole-mount drawings located at the
back of the manual.)
NOTE: THE MAJORITY OF POLES ARE THE PROPERTY OF THE LOCAL UTILITY.
BEFORE INSTALLING AN ENCLOSURE, THE LOCATION AND THE METHOD OF
MOUNTING MUST BE APPROVED BY THE UTILITY.
Wood Pole Procedure: (see opposite page)
Materials required:
Two (2) 5/8" dia. machine bolts (UNC thread) SAE
(Grade 5 or better), length to suit pole;
Two (2) 5/8" dia. zinc-plated flat washers;
Two (2) 5/8" dia. hex nuts (UNC thread).
Tools required:
Auger or drill for boring 3/4" dia. holes
in the wooden pole;
Mallet or hammer;
Assorted sockets or wrenches.
1. Unpack the galvanized brackets and turn the enclosure face-down on a soft surface.
2. Slide one bracket up through the lower mounting strap on the rear of the enclosure. The bracket’s flanges
face away from the enclosure. Secure the lower mounting bracket using the 3/8" x 3/4" hex bolt (included).
3. Mark the position for the upper mounting bracket on the utility pole. Drill a 3/4" hole completely through the
pole. Secure the bracket with a 5/8" machine bolt, washer and nut. Do not fully tighten the bolt at this time.
4. Position the enclosure on the upper mounting bracket. It may be necessary to slightly rock the enclosure
and pull downward to properly seat it on the bracket. Center the enclosure on the pole.
5. Mark the hole for the lower mounting bracket. Lift the enclosure off of the top bracket and drill the lower
hole. Spacing between the holes should be 18.0" on center.
6. Slide the enclosure back into place over the top bracket. Align the lower bracket with the hole and secure it
with a 5/8" machine bolt, washer and nut. Tighten both brackets until the flanges seat into the wood.
7. The enclosure is now ready for the utility connection, power module and batteries.
Concrete / Steel Pole Procedure: (see below)
Materials required:
Two (2) Pole Straps (customer supplied) to fit pole.
(straps must be stainless, galvanized or better)
Tools required:
Assorted sockets or wrenches.
1. Unpack the galvanized brackets and turn the enclosure face-down on a soft surface.
2. Slide one bracket up through the enclosure's lower mounting strap. The bracket’s flanges should face away
from the enclosure. Secure the lower mounting bracket using the 3/8" x 3/4" hex bolt included.
3. Position the upper mounting bracket on the pole and secure using a pole strap. Lift the enclosure onto the
upper mounting bracket and pull downward to properly seat it. Center the enclosure on the pole.
4. Secure the lower mounting bracket on the pole using a pole strap.
5. The enclosure is now ready for the utility connection, power module and batteries.
Upper Mounting Bracket
Pole Straps
(Customer Supplied)
Pole Straps
(Customer Supplied)
PME
18"
Chassis
Ground
Cable Power Out
PWE
18"
ACI / LRI
Options
ACI /
LRI
Options
Chassis Ground
Utility Power In
Cable Power Out
Utility Power In
Lower Mounting Bracket
Lower Mounting Bracket
PME and PWE Pole-mount Enclosures (Concrete and Steel Poles)
17
6. INSTALLATION
6.3
Ground-mount Enclosure Installation (UPE and UPE/M)
UPE and UPE/M enclosures are designed to bolt directly to a Pedestal Support or concrete
pad. Four 1/2" holes are provided in the base of the enclosure to accommodate 3/8" Anchor
or J-bolts. Secure the enclosure using a flat washer, lock washer and 3/8" nut at each
mounting bolt. NOTE: Enclosures must be mounted flush with a smooth surface and not
over-torqued to prevent damage. (Refer to the ground-mount drawings located at the back
of the manual).
6.3.1 Pedestal Support Preparation
(Refer to the pedestal support drawings located at the back of the manual).
Pedestal supports, available from Alpha, provide a quick, one-step solution for ground-mount
enclosure installations. Constructed of pre-formed, high density polyethylene, the pedestal
support eliminates the need for costly concrete work. The large body design provides
excellent "hand hole" working space, allowing room for cable bends, wire loops and grounding
connections. Pedestal supports are available for use with Alpha UPE and UPE/M groundmount enclosures. Installation is as easy as digging a hole to the appropriate depth to
accommodate the base of the pedestal support and backfilling using a suitable material. See
1.3.2 below for recommended utility and cable TV conduit placements.
6.3.2 Concrete Pad Preparation
(Refer to the ground-mount drawings located at the back of the manual).
UPE - Four 3/8" J-bolts should be centered with the pad 24" (side to side) and 10"
(front to back). From the front of the pad, service conduits should be placed with the
utility entrance left of the center line; cable TV to the right. If required, an 8' dedicated ground rod should be placed near the utility conduit.
UPE/M - Four 3/8" J-bolts should be centered with the pad 24" (side to side) and 14"
(front to back). Service conduits should enter the pad between the rear mounting
studs and 6" to either side of the pad's center line. From the front of the pad, cable
TV conduit should be placed on the left; utility on the right. If required, an 8' dedicated ground rod should be placed near the utility conduit.
Utility Power Input
(Right Raceway)
Utility Meter
Compartment
Cable Power Output
(Left Raceway)
Cable
Power
Output
Utility
Power
Input
Pedestal Support
UPE
UPE/M
UPE and UPE/M Ground-mount Enclosures
18
6. INSTALLATION
6.4
Connecting Utility Power
CAUTION: THE FOLLOWING SHOULD BE PERFORMED ONLY BY QUALIFIED SERVICE PERSONNEL AND IN COMPLIANCE WITH LOCAL ELECTRICAL CODES. CONNECTION TO UTILITY POWER MUST BE APPROVED BY THE LOCAL UTILITY BEFORE
INSTALLING THE POWER SUPPLY.
NOTE: UL AND NEC REQUIRE THAT A SERVICE DISCONNECT SWITCH (UL LISTED)
BE PROVIDED BY THE INSTALLER AND BE CONNECTED BETWEEN THE POWER
SOURCE AND THE ALPHA POWER SUPPLY. CONNECTION TO THE POWER SUPPLY
MUST INCLUDE AN APPROPRIATE SERVICE ENTRANCE WEATHER HEAD.
WIRING THE ENCLOSURE’S UTILITY SERVICE
Utility power enters the enclosure through a 1 1/8" opening at the bottom of PME, UPE
and UPE/M, and the rear of PWE. The enclosure accepts a standard electrical fitting. The
UPE is equipped with a service entrance mounted in the small compartment at the bottom
of the enclosure. The PME and PWE are equipped with a circuit breaker assembly located
in the enclosure’s module compartment. UPE/M is equipped with a dedicated utility raceway.
IMPORTANT NOTE: A "high-magnetic" trip breaker must be used in order to
accommodate the high-inrush currents normally associated with the start-up of
ferroresonant transformers (400 Amp, no-trip, first-half cycle). Do not replace this
breaker with a conventional service entrance breaker. Alpha recommends Square D
breakers because of increased reliability in this powering application.
High-magnetic Square D circuit breakers are available from Alpha Technologies, as well
as a BBX option which is a UL Listed service entrance.
Description
High Magnetic Trip Breaker (15A)
Ext. Serv. Disconnect
Alpha Part No.
470-013-10
020-085-10
Square D
Q0115HM
Q02-4L70RB
AC Line (black) connects to the large terminal on the base of the breaker. Neutral (white)
and Utility Ground (green) connect to the neutral bus bar located inside the breaker box
assembly. An external grounding clamp is also provided on the outside of the enclosure to
accommodate a dedicated ground rod. In most cases, this configuration is deemed suitable
for service entrance use and usually does not require a separate, externally-located service
disconnect (unless otherwise specified by local codes.)
If an external service disconnect is required, it is placed between the utility power connection
and the standby power supply. It should be attached directly to the wooden utility pole using
1/4" x 2-1/4" steel wood screws. If a utility power meter is to be used, its mounting base should
be secured in the same manner. Use a suitable conduit to interconnect the meter base,
service disconnect, and power supply enclosure.
Utility
Ground
Neutral
(white)
AC Line (black)
AC Line (brown)
Breaker
Assembly
Breaker
Assembly
Neutral
Ground
Outlet
Ground (green)
Ground (green)
AC
Line
Utility Grounding Clamp
on underside of enclosure
Chassis Ground
AC Line (brown)
Utility Grounding Clamp
on underside of enclosure
120 VAC (60 HZ)
220 or 240 VAC (50 HZ)
Typical Circuit Breaker Assembly
19
Ground
Outlet
Ground (green)
AC Line (black)
Chassis Ground
Neutral
Neutral
(blue)
AC
Line
6. INSTALLATION
6.5
Connecting the SPI (Service Power Inserter)
Procedure: (Refer to SPI drawing located at the back of the manual)
1. Prepare the incoming coaxial cable.
2. Remove the two screws from the Service Power Inserter and lift off the cover.
3. Loosen the seizure screw on the PCB, (located inside the SPI), to accommodate the
center pin of the cable connector.
4. Screw the cable connector into the output port located on the rear panel of the PWE or
UPE/M (or lower compartment of the PME or UPE) enclosure. Make sure that the center
pin slides through the seizure screw assembly. Heat shrink the external connection.
5. Tighten the seizure screw on the SPI so that the center pin on the cable connector is firmly
clamped. If a connection is left loose, arcing could result and possible damage to the
connector or SPI could occur.
6. Replace the cover on the SPI. NOTE: Make sure that the screws securing the SPI's
internal PCB to its chassis are tight; otherwise, loss of power, arcing, or possible damage
can occur. During routine maintenance, the seizure screw assembly can be accessed
through the grommeted hole without removing the SPI’s cover.
7. Once the module has been installed in the enclosure, the SPI plugs into the APX cable
which connects to pins 3 and 4 on the module’s 10-pin terminal strip (See section 6.6).
8. Make sure that the "ALT/ON" switch, located on the Service Power Inserter, is in the "ON"
position. When the switch is in the "ALT" position, the input is transferred to the SPI's
"Jones" connector which is used with an alternative power source such as the Alpha
APP60S Service Power Supply during module maintenance or replacement.
Enclosure Output Port
(heatshrink connection)
SPI
(inside enclosure)
SPI
(inside enclosure)
Enclosure Output Port
(heatshrink connection)
PME Enclosure
PWE Enclosure
Cable Connection to SPI
Coax Cable
(to power supply output connector)
Grommeted Hole
(seizure screw access)
"ALT/ON" Switch
"Jones" Connector
Black and White connectors
plug into APX Cable which connects to
pins 3 and 4 on the AM module
SPI Service Power Inserter
(shown in PWE enclosure)
20
6. INSTALLATION
6.6
Battery Installation and Wiring
WHENEVER INSTALLING OR REPLACING BATTERIES, DO NOT ALLOW LIVE BATTERY WIRES TO CONTACT THE ENCLOSURE OR THE POWER MODULE CHASSIS.
Insulate any exposed wire ends with electrical tape. Shorting battery wires could result in a
fire or possible explosion. Make sure that the power module’s battery circuit is deactivated
by switching the battery breaker OFF, or removing the battery fuse.
WEAR EYE PROTECTION WHENEVER WORKING WITH BATTERIES.
MAKE SURE THAT ALL BATTERY TERMINAL CONNECTIONS ARE TIGHT. Terminal
connectors should be torqued to 75 inch-pounds at installation and then re-torqued to 50 inchpounds during routine maintenance. Loose connections will cause the unit to operate
improperly. Use an approved battery terminal coating such as NCP-2 to protect the
terminals. If custom battery cables are made, they should be #6 AWG or larger and as short
as practical. Battery terminals should be checked for corrosion and cleaned if necessary.
CHECK BATTERY POLARITY. Polarity identifications are clearly marked at the module's
battery connector. A single battery connected backwards may go unnoticed until it is required
to perform. In the event polarity becomes accidently reversed at the batteries, the battery
circuit breaker will trip to protect the module.
IN ADDITION TO VOLTAGE CHECKS, ALWAYS INSPECT BATTERIES FOR SIGNS OF
CRACKS, LEAKS OR SWELLING. If a battery has one or more defective (shorted or high
impedance) cells, erratic operation or failure to provide standby power will result.
ALWAYS USE NEW BATTERIES WHEN FIRST INSTALLING A POWER SUPPLY.
VERIFY THAT THEY ARE THE SAME TYPE OF BATTERY WITH AN IDENTICAL DATE
CODE.
NEVER INSTALL OLD OR UNTESTED BATTERIES.
Whenever batteries have been in storage for more than 3 months, they should be recharged
for (at least) 24 hours and checked under load prior to installation. Batteries with date codes
older than 2 years should not be used unless thoroughly recharged and tested.
BATTERY TYPE: "A"
("FLOAT" Service Battery
containing gelled electrolyte
acid.) Used for majority of
Cable TV applications due
to its exceptional service life.
MONTH: (OCT) 10
YEAR: 1998
8 1 0 A
Typical Battery Date Code Location and Identification
21
6. INSTALLATION
6.6
Battery Installation and Wiring, continued
Procedure: (Refer to the Battery Wiring drawing located at the back of the manual)
1. Place the batteries with the positive terminals forward on the enclosure’s shelf or slide
tray. Position the batteries with maximum ventilation space between them (+/- 1").
2. Interconnect the three batteries in series (negative to positive). The optional in-line fuse,
if included, should be connected to the positive terminal on the right-hand battery.
3. Route the lugged ends of the cable through the grommeted holes in the enclosure’s shelf
and into the battery compartment. Connect the red cable (+) to the positive terminal of
the left-hand battery. Connect the black cable (-) to the negative terminal of the right-hand
battery. Terminal connectors should be torqued to approximately 75 inch/pounds at
installation and then re-torqued to 50 inch/pounds during routine maintenance.
4. Use a voltmeter to verify polarity and DC voltage at the module's battery connector.
Caution: Whenever making or breaking battery connections, never allow live battery
cables to contact the chassis. If necessary, wrap the lugs with electrical tape to prevent
arcing and temporarily disconnect one of the leads from the center battery.
5. Number the batteries 1 - 3, left to right, using labels or masking tape. Record each battery’s
number and date code in the power supply's maintenance log.
6. Uncoil the Remote Battery Temperature Sensor (RTS) cable. Route the sensor end of
the cable into the battery compartment and attach it to the side of the center battery using
a high-strength adhesive tape (see previous page for exact placement). In the event the
sensor is disconnected, or fails, a secondary sensor located on the main board of the AM
module provides temperature compensation based upon ambient temperature inside the
enclosure.
Do not reset the battery breaker until the module is running on AC LINE power.
Battery terminal sizes
and shapes vary
depending upon battery
type and manufacturer.
Battery Numbering
and RTS Placement
Number the batteries
inside the enclosure,
1 - 3 (left to right), for
easy identification.
Attach the RTS Battery
Temperature Sensor to either
side of the center battery using
high- strength adhesive tape.
NOTE: The sensor should be
placed approximately mid-way
on the side of the center
battery, 2/3rds of the way up
from the base.
RTS Temperature Sensor Placement
22
6. INSTALLATION
6.7
Power Module Installation
AM Series power modules are placed in the lower-right compartment of PME enclosures; the
upper-right compartment of PWE, UPE and UPE/M enclosures. The enclosure's lid lifts and
the door(s) can be removed. (Refer to the Module and Battery Placement drawings located
at the back of the manual). NOTE: Enclosure components such as SPI and LRI accept plugin type connectors. An APX cable is provided to accommodate the AM module's screw-in
terminal block.
Procedure:
1. Slide the power module against the back wall of the enclosure (under the retaining
brackets).
2. Use a retaining screw to secure the power module to the enclosure. The screw goes
through the opening in the front lip of the module and into a hole in the enclosure’s shelf.
3. Connect the wires from the SPI (Service Power Inserter) to the power module’s 10-pin
terminal strip: White to pin 3 (neutral); Black to pin 4 (60 VAC).
4. If an optional ACI (AC Indicator) is included, it should also be wired to the module’s 10pin terminal strip, along with the SPI: Yellow to pin 3 (neutral); Black to pin 4 (60 VAC).
5. Switch the battery circuit breaker, located on the module's front panel, OFF (or remove
the battery fuse). This will prevent the inverter from starting when the batteries are first
connected to the power module.
6. Connect the battery cables to pins 1 and 2 on the module’s 10-pin terminal strip: Negative
(blue) to pin 1; Positive (red) to pin 2. Polarity is clearly marked for easy identification.
Route the cables through the grommeted hole in the enclosure's shelf and into the battery
compartment.
7. If an optional LRI (Local and Remote Indicator) is included, it should be wired to the
module’s 10-pin terminal strip: Negative (white) to pin 6; Positive (blue) to pin 7.
8. If remote alarms are included in the installation: Pin 8 is configured “normally open”
(contacts close when alarm is present); Pin 9 is configured as common; Pin 10 is
configured “normally closed” (contacts open when alarm is present).
PME Enclosure
PWE Enclosure
(same placement for UPE and UPE/M)
*RTS
....
*APM LEDs
AM SERIES
Ammeter
*Remote
Alarm
*LRI
OUTPUT (SPI)
BATTERIES
N/C
COM
N/0
POS
NEG
LINE
NEU
POS
NEG
10
9
8
7
6
5
4
3
2
1
*Elapsed
Time
Meter
Output Batteries
*Test/
Reset
Switch
Line On Standby
* Indicates Options
AM Series Power Module
23
6. INSTALLATION
6.8
Logic Cards - Installation, Removal and Operation
THE POWER MODULE MUST BE COMPLETELY POWERED DOWN WHENEVER
INSTALLING, REMOVING OR RESEATING A LOGIC CARD. IF NECESSARY, USE AN
APP60S SERVICE POWER SUPPLY TO AVOID INTERRUPTION OF POWER TO THE
LOAD.
Procedure:
1. Switch the module's front panel battery circuit breaker OFF, or remove the fuse.
2. Unplug the module’s power cord or switch the AC input circuit breaker OFF.
3. Wait several minutes for the power module's capacitors to completely discharge.
4. Use the card ejectors to remove the logic card from the card guide. Handle the card
only by the edges to avoid touching static sensitive parts.
5. Plug the new logic card into the card guide (component side facing away from the
module's front panel). Make sure the card is properly seated before restoring power.
NOTE: IF POWER IS RESTORED WITH THE LOGIC CARD REMOVED, THE MODULE
WILL CONTINUE TO OPERATE AS A NON-STANDBY POWER SUPPLY.
6.8.1 SCB (Standard Control Board)
AP Series power supplies come equipped with a field-replaceable, SCB standard control
board that contains the circuitry to monitor incoming AC, charge the batteries and control the
inverter. The board uses a dual-mode (float and equalize) temperature compensated battery
charger to maintain the batteries. It can be equipped with an optional, RTS (Remote
Temperature Sensor) which is attached to the side of the center battery to provide optimum
battery temperature measurements. Battery charging voltages are factory set and do not
require user recalibration unless the logic card has been repaired or has been tampered with.
Custom settings for unique battery types, (other than gelled-electrolyte), must be specified
at the time of order. The SCB can be manually sequenced through its two charging modes
by pressing switch (S1) located on top of the logic card. When lighted, the board's LED
indicates EQUalize charge. When the LED is OFF, the charger is providing a FLOAT charge
to the batteries.
6.8.2 APM (Automatic Performance Monitor)
The APM is field-replaceable and contains the circuitry to monitor incoming AC, charge the
batteries, control the inverter, and self-test the inverter and batteries. Unlike the SCB, the
APM's dual-mode temperature compensated battery charge voltages (float and equalize)
can be selected using rotory switches (S2) and (S3) which are located on top of the logic card.
NOTE: Selecting the correct charging voltage is critical. The APM is pre-set for gelled
electrolyte type batteries (switch S2 in position 5 to produce 40.5 volt float; switch S3 in
position 3 to produce a 41.4 volt equalize charge). Always verify the two switch settings with
the APM chart (section 6.8.2.2) when first installing a power supply, and again during routine
maintenance. Custom settings for unique battery types (other than gelled-electrolyte) or
special charging applications can be selected by changing the two rotory switch settings
according to the APM chart (section 6.8.2.2). Always consult the battery manufacturer's
recommendations before changing switch settings.
The APM can be manually sequenced through its various modes of operation by pressing the
module's front panel TEST/Reset switch, or switch (S1) located on top of the logic card.
When lighted, the APM's four LEDs (DS1 to DS4, respectively) indicate status and fault
conditions: TEST (yellow), EQUalize (green), AC FAIL (red) and DC FAIL (red). When all
four LEDs are OFF, the power supply is in its normal mode, providing a FLOAT charge to the
batteries. The RTS (Remote Temperature Sensor), standard on the APM, connects directly
to the top of the logic card and is routed to the battery compartment. The sensor is then
attached to the side of the center battery to provide optimum battery temperature information
(see illustration on page 22). In the event the RTS is disconnected or not used, a secondary
sensor, located on the APM card, provides temperature compensation based upon the
ambient temperature of the module compartment.
24
6. INSTALLATION
6.8.2.1 APM Battery Charging Selection
Rotary switches (S2) and (S3), located on top of the APM, are used to select FLOAT and
EQUalize charge voltages. The FLOAT switch (S2) sets the charge voltage in 0.3 volts
increments, starting at the calibration level 39.0 volts. The EQUalize switch (S3) adds 0.3
volts per setting above the value of the FLOAT switch setting.
The APM is preset for gelled electrolyte batteries (FLOAT 40.5 VDC; EQUALIZE 41.4
VDC). Always refer to the battery manufacturer's recommendations before selecting
FLOAT and EQUalize switch settings. Failure to do so could result in battery damage
or decreased service life.
Example:
Follow the chart below. In a typical 3-battery system (36 VDC), if the battery manufacturer
calls for a FLOAT of 40.5 volts and an EQUALIZE charge of 41.4 volts, set the FLOAT switch
(S2) to position 5 (40.5 volts) and the EQUALIZE switch (S3) to position 3 (0.9 volts).
NOTE: The EQUALIZE value is added to the FLOAT voltage (i.e, 0.9 volts + 40.5 volts =
41.4 volts) to give the required EQUALIZE voltage.
6.8.2.2 APM Float and Equalize Chart
Values given for 36 volt systems calculated at 77OF (25OC).
Switch
Setting
0
1
2
3
4
5
6
7
8
9
Calculated
volts/cell
FLOAT (S2)
volts/setting
2.167
2.183
2.200
2.217
2.233
2.250
2.267
2.283
2.300
2.317
EQUalize (S3)
volts/setting
39.0
39.3
39.6
39.9
40.2
40.5
40.8
41.1
41.4
41.7
0.0
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
Alpha Technologies does not assume responsibility for batteries damaged by
improper switch settings. Always consult the battery manufacturer for correct charging
levels. If batteries appear to be over or under-charged, first check for defective batteries and
then verify the correct charge voltage settings.
TEST (yellow) LED
EQUalize (green) LED
AC FAIL (red) LED
DC FAIL (red) LED
Remote Battery Temperature Sensor
TEST/Reset Switch (S1)
FLOAT Switch (S2)
EQUalize Switch (S3)
Plug-in Status Monitoring Board
(for RPM Option)
Secondary Temperature Sensor
APM Logic Card
25
6. INSTALLATION
6.8.3
RPM (Remote Parallel Monitor)
The optional, RPM status monitoring logic upgrade plugs directly into connector J2 located
on the component side of the APM logic card (Rev 8 or higher). NOTE: Power must first be
removed before adding the RPM board (Refer to section 7.3 Power Module Shutdown).
Status monitoring interfaces are listed below and identified according to their manufacturer,
along with the associated parts. For additional installation information, refer to the RPM
operator's manual.
RPM-T (Texscan Vital Signs "TDM-1A" and "RTDM-1A")
Designed for systems utilizing Texscan TDM-1A transponders. Transponders are internally mounted in Alpha power
supply enclosures.
Contact Alpha Technologies or your
nearest Alpha representative to order an
RPM kit according to your specific
enclosure. Please state enclosure type:
PWE, PME, UPE, UPE/M or other.
POWER SUPPL Y ENCL OSURE
RF In /O u t
T DM - 1A
D a ta
T amp e r S w it ch
T ru n k O u t
S PI
RPM
USM-T
D C- 1 6
R F +A C
Al p h a P ow e r
M od u le
6 0 V AC O ut
T ru n k I n
120VAC In
Batteries
36 VDC
RPM-AM (AM Communications "LANguard")
Designed for systems utilizing AM Communications TMC 8061 transponders. Transponders are internally mounted
in Alpha power supply enclosures.
Contact Alpha Technologies or your
nearest Alpha representative to order an
RPM kit according to your specific
enclosure. Please state enclosure type:
PWE, PME, UPE, UPE/M or other.
PO WER S UPPLY ENCLO S URE
RF In/O ut
TM C 80 6 1
D a ta
Ta mp e r Sw itc h
US
M -A M
RPM
To C abl e T elevisio n
S ystem
Alp ha Po wer
Mod ule
120 VAC In
Batt er ies
36 VDC
RPM-C (C-COR "Quick Alert")
Designed for systems utilizing C-COR “Quick Alert” transponders. The transponder is externally mounted in its own
enclosure.
Contact Alpha Technologies or your
nearest Alpha representative to order an
RPM kit according to your specific
enclosure. Please state enclosure type:
PWE, PME, UPE, UPE/M or other.
PO WER S UPPLY ENCLOS URE
T am p e r Sw itc h
To C -C OR " Qu ick A ler t"
Tr an spo nde r
To C abl e T el evisio n
S ystem
RF In/ O ut
60V A C O ut
RPM
USM-C
A lp ha P ow er
M o d ule
Order from C-COR:
5' data cable
172960-01
10' data cable
172960-02
20' data cable
172960-03
40' data cable
172960-04
120 VAC In
Batter ies
36 VDC
Configurations subject to change without notice.
26
6. INSTALLATION
6.8.3
RPM (Remote Parallel Monitor), continued
RPM-J (Jerrold "RSM")
Designed for systems utilizing Jerrold model “RSM” transponders. Transponders are internally mounted in Alpha
power supply enclosures.
Contact Alpha Technologies or your
nearest Alpha representative to order an
RPM kit according to your specific
enclosure. Please state enclosure type:
PWE, PME, UPE, UPE/M or other.
PO WER SUPPLY ENCLOS URE
Jerro ld R SM
RF Ou t
RF I n/O ut
T ru n k
Out
T a m pe r S w i t ch
Dat a and
DC Pow er
RF I n
IC K- J2
US M-J
RPM
36 V DC
Al p ha P ow e r
M od u le
Also order from Alpha:
ICK-J2
740-080-20-RPM
120 VAC In
6 0 V AC O u t
D C-1 6
RF + AC
Ba t t eri es
36 V DC
T ru n k
In
RPM-M (Magnavox "6-DSS")
Designed for systems utilizing the Magnavox 6-DSS Digital Sentry System. The transponder is externally mounted
in its own enclosure.
Contact Alpha Technologies or your
nearest Alpha representative to order an
RPM kit according to your specific
enclosure. Please state enclosure type:
PWE, PME, UPE, UPE/M or other.
POWER SUPPLY ENCL OS URE
T o M a gna vox
"C O NKIT" a nd
RI/D SS
D a ta t o 6 D SST r a nsponde r
T amp e r S w it ch
US
RPM
M -M
60 VA C Ou t
A lp ha Po wer
M od ule
Order from Magnavox:
CONKIT and RI/DSS
Data cable from USM to 6DSS
1 20 V AC In
Batter ies
36 V DC
RPM-SA (Scientific Atlanta "6585")
Designed for systems utilizing Scientific Atlanta, Model 6585 transponders. The transponder is externally mounted
in its own enclosure.
Da ta C a bl e to S /A
6585 Tr a n sp o nd e r
Contact Alpha Technologies or your
nearest Alpha representative to order an
RPM kit according to your specific
enclosure. Please state enclosure type:
PWE, PME, UPE, UPE/M or other.
POWER SUPPLY ENCLOSURE
Ta mp e r Sw itc h
IC K-X Da ta C a ble
USM
-SA
RPM
Amp h e no l
We a th e r p r o o f
C o nne ct o r s
60 V A C O u t
A lph a Pow er
M odul e
Also order from Alpha:
ICK-X
740-050-20
120 VAC In
Order from Scientific Atlanta:
6585 data cable
Batte ries
36 VDC
Configurations subject to change without notice.
27
6. INSTALLATION
6.8.3
RPM (Remote Parallel Monitor), continued
RPM-LL (Magnavox "Lifeline")
Designed for systems utilizing the Magnavox Lifeline Status Monitoring System. The transponder is externally
mounted in its own enclosure.
Contact Alpha Technologies or your
nearest Alpha representative to order an
RPM kit according to your specific
enclosure. Please state enclosure type:
PWE, PME, UPE, UPE/M or other.
POWER SUPPLY ENCLOSURE
RF In/Ou t
T M C 80 61
D ata
T a m p e r S w it c h
URPM
S M -L L
Alp ha Po wer
M odule
To C able T elevision
S ystem
Order from Magnavox:
CONKIT and RI/DSS
Data cable from USM to Lifeline
120 VAC In
Batteries
36 VDC
RPM-SEG (Superior Electronics "Cheetah")
Designed for systems utilizing Superior Electronics SEG transponders. The transponder is externally mounted
in its own enclosure.
Contact Alpha Technologies or your
nearest Alpha representative to order an
RPM kit according to your specific
enclosure. Please state enclosure type:
PWE, PME, UPE, UPE/M or other.
POWER SUPPLY ENCLOS URE
RF In/ Out
CM M- 3 RF
Tr ansponder
D a ta
T a m p e r S w itc h
USM-SEG
RPM
To C able T elevision
S ystem
D a ta
Alpha Power
Mod ule
120 VA C In
Batter ies
36 VDC
Configurations subject to change without notice and may not be applicable under certain conditions.
28
7. OPERATION
OPERATION
7.1
Power Module Start-up and Testing
Once connections have been made to the power module, it should be tested for AC LINE and
STANDBY operation before placing it into service. NOTE: The power module should always
be started from utility AC (not batteries). This is because high inrush currents, associated
with the start-up of ferroresonant transformers, could place unnecessary stress on the
batteries.
7.1.1 AC Line Operation (LINE ON)
1. Plug the module’s power cord into the enclosure's AC convenience outlet and switch the
AC circuit breaker ON. The module’s LINE ON lamp will light to indicate AC LINE
operation: (Green for 60 Hz applications; Amber for 50 Hz applications).
2. Wait at least 1 minute and then reset the battery breaker on the front panel (or re-insert
the fuse). If the red STANDBY lamp flashes, press the TEST/EQ RESET switch, located
on top of the logic card (or the front panel, if equipped), once.
3. Use a true RMS voltmeter to verify AC output at pins 3 and 4 on the module's 10-pin
terminal strip. If a non-RMS voltmeter is used, the output reading can vary by as much
as 10% due to the "quasi" square wave output of the ferroresonant transformer.
4. Check the module's front panel ammeter to verify output current.
5. If the power module is equipped with an APM logic card, press the TEST/EQ RESET
switch, located on the front panel, several times until the "TEST" LED lights. This will
activate the self-test mode. If the logic card detects a problem in the battery or inverter
circuit, it will flash the module's red STANDBY lamp. It will also light a LED (located on
top of the logic card) to indicate the circuit ("DC" or "AC") that has failed self-test: DC
indicates a battery-related problem; AC indicates an inverter-related problem.
6. Press the TEST/EQ RESET switch on the front panel once to cancel self-test and
return the module to AC LINE operation. NOTE: The logic card contains an identical
TEST/EQ RESET switch, located on top of the card, that performs the same function.
7.1.2 Inverter Operation (STANDBY)
1. With the power module operating from AC LINE power, indicated by the LINE ON lamp,
unplug the module’s AC power cord or switch the AC circuit breaker OFF. The LINE ON
lamp will go OFF, indicating the loss of utility AC, and the STANDBY lamp will come ON
to signal inverter operation.
2. Use a true RMS voltmeter to verify AC output at pins 3 and 4 on the module's 10-pin
terminal strip.
3. Return the unit to AC LINE operation by plugging the AC power cord back into the
receptacle, or switch the AC circuit breaker ON. It takes approximately 1 minute for the
power module to complete its transfer back to utility power. This delay allows the
utility voltage and frequency to stabilize for approximately 30 seconds before the module’s
phase-lock circuitry is activated. It then takes up to 30 seconds for the module to
syncronize the inverter’s waveform to the utility’s. This ensures a smooth, inphase transfer back to utility power. The LINE ON lamp will come ON to indicate that utility
power is again available. During the transfer period, both the LINE ON and STANDBY
lamps will remain ON. When the transfer is complete, the red STANDBY lamp will turn
OFF.
29
7. OPERATION
7.2
Identifying Modes of Operation
It is extremely important to be able to recognize the modes of operation indicated by the power
module's front panel lamps: LINE ON (Green for 60 Hz applications; Amber for 50 Hz
applications) and STANDBY (Red).
This is especially important when performing maintenance or trouble-shooting the power
supply, Both lamps should be checked periodically for normal operation and replaced if
necessary.
7.2.1 AC LINE OPERATION - Green Lamp ON (Red Lamp OFF):
Indicates AC LINE operation with the power module running on utility power.
AM SERIES
LINE ON STANDBY
AC LINE OPERATION
(Green Lamp ON)
7.2.2 INVERTER OPERATION - Red Lamp ON (Green Lamp OFF):
Indicates inverter (STANDBY) operation using the battery backup. AC from the utility is
unacceptably low or not available.
AM SERIES
LINE ON STANDBY
INVERTER (STANDBY) OPERATION
(Red Lamp ON)
30
7. OPERATION
7.2
Identifying Modes of Operation, continued
7.2.3 SELF-TEST / TRANSFER MODE - Green Lamp ON (Red Lamp ON):
Indicates that the power supply is in either self-test or transfer mode. If the module is
equipped with APM, check the LED on the logic card marked TEST. If the LED is ON, the
module is in its 30 minute self-test mode. If the LED is OFF, or if the unit is equipped with
an SCB logic card, the power module is preparing to transfer back to utility power after
standby operation. The complete re-transfer takes approximately 1 minute to ensure that the
utility voltage and frequency have stabilized, and to allow the power module to syncronize
wave forms with the utility before transferring.
AM SERIES
LINE ON STANDBY
SELF-TEST (APM) or TRANSFER MODE
(Green and Red Lamps ON)
7.2.4 TEST FAIL - Green Lamp ON (Red Lamp FLASHING):
Indicates that the logic card has detected a problem with either the inverter or the batteries
during self-test mode (only on units equipped with APM logic upgrade). Under this condition,
maintenance is required. If an optional, external LRI lamp is installed on the enclosure, it will
flash as well. As long as power is available from the utility, indicated by the LINE ON lamp,
power will continue being supplied to the output; however, if the utility fails, the power supply
will be unable to support inverter operation.
AM SERIES
LINE ON STANDBY
TEST FAIL (APM)
(Green Lamp ON with Red Lamp Flashing)
31
7. OPERATION
7.3
Power Module Shutdown
When a power module needs to be removed from service, an Alpha APP60-S Service Power
Supply is recommended as an alternate non-standby power source to prevent interruption
to the cable plant. NOTE: When powering down a module, always switch the battery breaker
OFF before removing AC, otherwise the module will transfer into inverter operation.
Procedure
1. Plug the APP60-S "Jones" connector into the SPI (Service Power Inserter).
2. Plug the APP60-S power cord into the enclosure's convenience outlet. Switch the
APP60-S ON. NOTE: Verify that the 30 / 60 VAC selector is in the desired position.
3. Toggle the switch on the SPI from "ON" to "ALT".
4. Switch the battery breaker on the front panel of the AM Series module OFF, or remove
the fuse.
5. Unplug the AM Series module's power cord from the enclosure's convenience outlet.
6. Wait approximately 1 minute for the module's capacitors to fully discharge.
7. Disconnect the wires from the module's 10-pin terminal strip. Do not let the exposed
battery cables come in contact with the chassis or enclosure.
8. Remove the hold-down screw and carefully slide the module out of the enclosure.
CAUTION: The ferroresonant transformer generates heat and may cause burns if
handled with bare hands.
9. Reverse this procedure, when re-installing a module. Always test the power module
before toggling the switch on the SPI back from "ALT" to "ON".
AC Output Fuse
30 VAC / 60 VAC
Selector Switch
AC Input Fuse
ON/OFF Switch
"Jones" connector to enclosure's
SPI (Service Power Inserter)
AC Line cord to enclosure's
convenience outlet
APP60-S Service Power Supply
32
8. PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
Maintenance should be performed every three months. If the power module fails to perform
a specific function, refer to the troubleshooting chart. By establishing a routine maintenance
program and following the guidelines contained in this manual, the AP Series power supply
will continue to provide years of trouble-free operation.
Care of the batteries should be the first step in any power supply maintenance program. In
addition to voltage checks, visually inspect the batteries for signs of cracks, leaks or swelling.
To aid in quick identification and tracing of voltages in the maintenance log, number the
batteries inside the enclosure using labels or masking tape, etc. Because of a battery’s
chemical composition, it is temperature sensitive and susceptible to over and undercharging. Since batteries behave differently in the winter than they do in the summer, Alpha
logic cards automatically compensate for changes in temperature by adjusting float and
equalize charge voltages.
SAFETY PRECAUTIONS
THE POWER SUPPLY SHOULD BE SERVICED ONLY BY QUALIFIED PERSONNEL.
USE A BUCKET TRUCK, OR SUITABLE SAFETY EQUIPMENT (SAFETY HARNESS AND
CLIMBING SPIKES), WHEN SERVICING POLE-MOUNT INSTALLATIONS.
USE HEAVY GLOVES WHEN HANDLING A POWER MODULE THAT HAS JUST BEEN
TAKEN OUT OF SERVICE. THE FERRORESONANT TRANSFORMER GENERATES
HEAT AND MAY CAUSE BURNS IF HANDLED WITH BARE HANDS.
NEVER ATTEMPT TO RECALIBRATE A LOGIC CARD IN THE FIELD, OTHER THAN
SETTING APM (REV. 8 OR HIGHER) BATTERY CHARGER VOLTAGE SWITCHES
(SECTION 6.8.2.1).
ALPHA TECHNOLOGIES IS NOT RESPONSIBLE FOR BATTERY DAMAGE DUE TO
IMPROPER CHARGER SETTINGS. REFER TO SECTION 6.8 AND CONSULT THE
BATTERY MANUFACTURER FOR CORRECT CHARGE VOLTAGE REQUIREMENTS.
WEAR EYE PROTECTION WHENEVER WORKING WITH BATTERIES.
ALWAYS SWITCH THE MODULE’S BATTERY BREAKER OFF, OR REMOVE THE FUSE,
BEFORE DISCONNECTING BATTERY CABLES.
Procedure:
8.1
Check Battery Terminals and Connecting Wires
Check each battery terminal and connection. Make sure the posts are clean and the crimped
connectors are tight. One major battery manufacturer suggests that terminal connectors be
torqued to 75 inch/pounds at installation and then re-torqued to 50 inch/pounds during routine
maintenance. If there is an “in-line” fuse in the battery cable, check the fuse holder and fuse.
Make sure the terminals are properly greased with an approved battery terminal corrosion
inhibitor such as NCP-2.
8.2
Check Battery Open Circuit Voltage
Switch the power module's front panel battery breaker to OFF, or remove the fuse.
Disconnect the negative (blue) battery cable from pin 1 on the module's 10-pin terminal strip.
CAUTION: Do not let the exposed end of the battery cable contact the chassis or the
enclosure. Measure the individual voltages across each battery. Differences greater than
0.3 VDC between any of the batteries may indicate a defective or marginal battery. Always
use an identical type of battery for replacement.
33
8. PREVENTIVE MAINTENANCE
8.3
Check Battery Voltage Under Load
If the batteries appear functional, reconnect the negative battery cable to pin 1 and switch
the module's battery breaker ON, or re-install the fuse. Caution: Weak or severely
discharged batteries can explode when put under load. As an added safety
precaution, place the enclosure's door between the technician and batteries before
attempting inverter operation. Turn off the AC circuit breaker, or pull the power cord, to
initiate inverter operation. Measure individual battery voltages under load. There may be a
rapid drop in voltage when the inverter first comes on, but it should stabilize within several
minutes. The difference between any of the batteries should not be greater than 0.3 VDC.
Replace defective or marginal batteries with an identical type of battery.
8.4
Check Battery Charger (FLOAT) Voltage
Reconnect the AC input and wait approximately 1 minute to allow the power module to return
to AC LINE operation. The LINE ON indicator will be ON and the LED on top of the SCB logic
card will be OFF. If the unit is equipped with an APM logic card, the four LEDs will be OFF.
Switch the battery breaker on the front of the power module OFF, or remove the battery fuse.
NOTE: If a LED is ON, press the TEST/EQ RESET switch, located on top of the logic card
(or on the power module's front panel), once. Disconnect the negative (blue) battery cable
from pin 1 on the module's 10-pin terminal strip. CAUTION: Do not let the exposed end of
the cable contact the chassis or the enclosure. Switch the battery breaker ON, or re-install
the fuse. Measure the DC voltage across pins 1 and 2 of the module's 10-pin terminal strip.
Since the battery charger is temperature compensating, the charge voltage will vary
depending upon the temperature measured at the batteries or inside the enclosure. The
normal float charge for three gelled electrolyte batteries is approximately 40.5 VDC at 770 F
(250 C). On hot days, the charge voltage will be several volts lower; On cold days, it will be
higher. Record the float voltage in the power supply's maintenance log. If calibration is
required, replace the logic card (SCB) and refer to section 6.8.
8.5
Check Battery Charger (EQUALIZE) Voltage
Press the TEST/EQ RESET switch, located on top of the logic card (or on the power module's
front panel), once. On SCB logic cards, the single LED will light to indicate that the battery
charger is in equalize mode. If the unit is equipped with an APM logic card, the green
EQUalize LED will come ON. Measure the voltage across pins 1 and 2 of the module's 10pin terminal strip. SCB and earlier APM versions will be approximately 1 VDC higher than
the float voltage. For APM logic cards (Rev. 8 and higher), the equalize voltage will be in
increments of 0.3 VDC (per switch setting) higher than float. Record the equalize voltage in
the power supply’s maintenance log. Switch the battery breaker OFF, or remove the fuse,
and reconnect the negative battery cable to pin 1. Switch the battery breaker ON, or re-install
the fuse. Always refer to the battery manufacturer for correct charging voltages. If calibration
is required, replace the logic card and refer to section 6.8.
8.6
Check Output Voltage
Measure the AC output voltage across pins 3 and 4 on the module's 10-pin terminal strip. Use
a true RMS digital voltmeter when taking voltages. The output voltage reading should fall
between +/- 5% of the module's nameplate value (i.e., 57.0 VAC to 63.0 VAC for 60 VAC
systems at nominal 120 VAC line input.) Record the voltage in the maintenance log.
8.7
Check Output Current
Check the module's output current. The front panel ammeter can be useful in determining the
status of the output load. If there is no reading on the meter, check the AC output at pins 3
and 4; If no output voltage is present, check the AC output fuse on the front panel. Also make
sure that the "ALT/ON" switch on the SPI (Service Power Inserter) is in the ON position. If
the meter is pegged to the right, a short circuit or overload condition may exist in the plant.
34
8. PREVENTIVE MAINTENANCE
8.8
APM Manual Self-test
On units equipped with APM logic cards (Automatic Performance Monitor), self-test can be
manually activated to trouble-shoot the batteries and inverter. If a failure occurs during the
test mode, either the “DC” or “AC” LED on the card will be activated to indicate the circuit that
has failed (see below). The red STANDBY lamp on the front panel of the power module and
external LRI option will flash to signal that maintenance is required. The APM self-test feature
can be activated by pressing the TEST/EQ RESET switch on the front of the module (or on
top of the card) several times until the “TEST” LED lights. To manually exit self-test and return
the power module to normal operation, press the TEST/EQ RESET switch once.
8.8.1 “TEST” LED ON
The “TEST” LED indicates that the module is in its 30 minute self-test mode.
8.8.2 “DC” LED ON
If the “DC” LED is ON, it indicates that one or more of the batteries are unable to carry the
load or that a connection in the battery circuit is malfunctioning. Check the battery breaker
on the front of the power module to make sure that it is not tripped. Check the battery
terminals and crimped connectors on the battery cable kit. Measure individual battery
voltages and replace the suspect battery if necessary. Reactivate the self-test mode to verify
that the problem has been corrected.
8.8.3 “AC” LED ON
If the “AC” LED is ON, it indicates that the inverter has failed to produce AC at the output.
Verify AC output at pins 3 and 4 on the module's 10-pin terminal strip. If no voltage is present,
check the AC output fuse on the front of the power module and replace it if necessary. If
voltage is present, turn the power module OFF and reseat or replace the logic card.
Reactivate the self-test mode to verify that the problem has been corrected. If the unit
continues to fail self-test, the module needs to be serviced.
8.8.4 “EQU” LED ON
When the “EQU” LED is ON, it indicates that the battery charger is in its equalize mode. This
increases the charge voltage to the batteries by approximately 1 volt. For APM logic cards
(Rev. 8 and higher), the increase is determined by the EQUalize switch setting on top of the
logic card. The equalize mode is activated once every two weeks and lasts approximately
2.5 hours. To manually exit this mode, press the TEST/EQ RESET switch once.
8.9
Logic Card Maintenance
CAUTION: NEVER ATTEMPT TO REMOVE OR RESEAT A LOGIC CARD WHILE THE
POWER MODULE IS OPERATING. DAMAGE TO THE LOGIC CARD, INVERTER
CIRCUITRY, OR CARD CONNECTORS MAY RESULT.
LOGIC CARD SERVICE AND CALIBRATION SHOULD BE PERFORMED ONLY BY A
QUALIFIED TECHNICIAN OR AN ALPHA SERVICE CENTER.
Procedure:
1. Power down the module and remove the logic card. (Refer to section 6.8)
2. Inspect the card for signs of dust or corrosion. If necessary, clean with a soft, non-metallic
brush or damp rag and allow the card to completely dry. Logic cards are static-sensitive
and should be handled with care.
3. Clean the card edge connector with an alcohol-based cleaner (such as greaseless TV
tuner cleaner). Also check the mating card edge connector inside the module and clean
if necessary.
4. Carefully tighten any screws used for mounting components to the heatsink. Make sure
that plug-in attachments such as APM and RPM options are firmly seated. Do not overtighten semiconductor mounting hardware.
5. Re-install the logic card. Power up the module and test it for proper operation.
35
8. PREVENTIVE MAINTENANCE
8.10
Internal Fuse Replacement
CAUTION: WHENEVER CHECKING OR REPLACING A FUSE ON THE MAIN POWER
BOARD, MAKE SURE THAT THE POWER MODULE IS COMPLETELY POWERED
DOWN BY SWITCHING THE BATTERY BREAKER OFF (OR REMOVING THE BATTERY
FUSE) AND UNPLUGGING THE AC POWER CORD.
The AM Series Power Module contains two internal fuses (one 1 Amp and one 10 Amp). The
fuses are clearly marked and located on top of the main power board, directly behind the
ammeter.
1 Amp Fuse The 1 Amp fuse protects the DC circuit that powers the red STANDBY lamp on the module’s
front panel and the optionally-mounted, LRI lamp. If a short occurs in the lamp circuit, the
fuse will open. This will not affect the overall operation of the power supply. The fuse should
be replaced with an identical type fuse (1A 250V AGC1).
10 Amp Fuse The 10 Amp fuse, which is to the right of the 1 Amp fuse, protects the DC charger circuit and
opens if battery polarity is reversed at pins 1 and 2 on the 10-pin terminal strip. Check this
fuse if there is no charger voltage present at pins 1 and 2. An open fuse may also indicate
a charger problem. The fuse should be replaced with an identical type fuse (10A 250V
ABC10).
8.11
Additional Maintenance
In addition to normal preventive maintenance, enclosures and power modules should be
cleaned periodically and checked for signs of battery acid corrosion, or buildups of dirt.
Procedure:
1. Power down the module by disconnecting the batteries and unplugging the AC power
cord. Carefully remove the power module from the enclosure. Remove the batteries
from the battery compartment.
2. Clean the module with a strong soapy solution using a brush to get into hard-to-reach
areas. Use a soft rag to dry the module.
3. Clean the enclosure. Replace or re-fasten torn or loose bug screens. If there has been
any leakage from the batteries, spray the battery compartment with an anti-corrosion
agent, or apply a liberal sprinkling of baking soda to help neutralize the acid.
4. Tighten the mounting bolts that secure the enclosure to the pole.
5. Re-install the power module and batteries. Check all connections for tightness and test
the unit for proper operation.
36
9. TROUBLE-SHOOTING AND REPAIR
TROUBLE-SHOOTING AND REPAIR
The trouble-shooting guide is designed to display typical symptoms, causes and solutions,
starting with the most obvious and working systematically through the unit. Alpha Technologies recommends that the power supply’s maintenance log accompany units brought in for
bench service to aid the technician in trouble-shooting the problem.
9.1
Repair Instructions
On units returned to Alpha Technologies for repair, a Return Material Authorization (RMA)
should first be obtained from Alpha's Customer Service Department. The RMA should be
clearly marked on the unit’s original shipping container. If the original container is no longer
available, the unit should be packed with at least 3 inches of shock-absorbent material.
NOTE: Do not use popcorn type packing material. Returns should be prepaid and insured
(COD and freight collect can not be accepted without prior approval). NOTE: It is
recommended that any information pertaining to the nature of the power supply failure or
problem, along with a copy of power supply's maintenance log, be included with the returned
unit.
9.2
Parts Ordering Instructions
When ordering parts from Alpha Technologies, contact the Customer Service Department
directly at (360) 647-2360; or (604) 430-1476 (Canada and International).
9.3
Common Parts for AP Series Standby Power Supplies
Alpha Part Number
Description
ASSEMBLIES
020-019-20
020-019-21
020-019-22
740-018-20
740-041-20
740-048-20
740-083-20
740-091-20
740-105-20
740-115-20
740-120-20
740-120-22
740-120-30
740-120-31
740-120-32
740-168-20
870-100-10
Output Filter Assembly (SPI)
Output Filter Assembly (SPI) for PWV/PED (60")
Output Filter Assembly (SPI) for PWV (20")
AC Pilot Lamp Retrofit Kit for AM660
Remote Temperature Sensor (for APM rev 8)
12-12 RPM Cable (ICK)
LRI Lamp Socket w/ wires, lamp & lens
Bleeder Resistor w/ terminals
PWE-PME Power Box w/o LA
ACI, Complete Assembly (new)
Tamper Switch, PME (old style)
Tamper Switch and Harness, PWE (old style)
Jerrold Tamper Switch, PME (old style)
Jerrold Tamper Switch, UPE (old style)
Jerrold Tamper Switch, PWE (old style)
Surge Guard Kit
RPM Current Sense Cable
BATTERY CABLE KITS
870-174-20
870-174-21
870-174-22
870-174-30
870-174-31
870-174-32
BCK Battery Cable Kit
BCK-F with 30A Fuse
BCK-F with 40A Fuse
BCK-FD Battery Cable Kit with Fast Disconnect
BCK-F/FD Battery Cable Kit with Fast Disconnect, 30A Fuse
BCK-F/FD Battery Cable Kit with Fast Disconnect, 40A Fuse
BREAKERS
470-008-10
470-010-10
470-013-10
470-017-10
470-024-10
470-027-11
470-150-10
523-002-10
Klixon CA-12.5 Auto Reset Circuit Breaker, 12.5A
Klixon CA-15 Auto Reset Circuit Breaker, 15A
QO-115HM "High Magnetic" AC Circuit Breaker
QO-120HM "High Magnetic" AC Circuit Breaker
30A Circuit Breaker (Battery: All AM / AP Series)
40A Circuit Breaker (Battery: All AM / AP Series)
50A Circuit Breaker (Battery: All AM / AP Series)
Square D Breaker Mounting Bracket
37
9. TROUBLE-SHOOTING AND REPAIR
9.3
Common Parts for AP Series Standby Power Supplies, continued
Alpha Part Number
Description
CAPACITORS
190-013-10
190-015-10
194-005-10
200-012-10
200-019-10
200-043-10
201-007-10
210-010-10
210-011-10
0.001uF 500V Ceramic Disc Capacitor
0.01uF 500V Ceramic Disc Capacitor
0.1uF 100V Poly Film Capacitor
10uF 100V Electrolytic Capacitor
220uF 25V Electrolytic Capacitor
10,000uF 75V Electrolytic Capacitor
15uF 25V Tantalum Capacitor
18uF 660VAC “Oil” Capacitor (660)
20uF 660VAC “Oil” Capacitor (660-14 & 960)
CHASSIS PARTS
590-271-P1
590-272-P1
590-278-A1
Left Side Panel (AM / AP Series)
Right Side Panel (AM / AP Series)
Card Guide Spacer (AM / AP Series)
CIRCUIT BOARDS
700-020-20
700-028-20
700-027-20
700-034-20
700-035-20
700-131-20
AP661 Main Power Board, complete (specify model)
SCB Logic Card
APM Logic Card
Extender Card for Logic Board (Used for bench re-calibration)
PCB for Output Filter (SPI, w/o wires)
RPM Upgrade Plug-in Logic Card (specify amplifier mfg.)
CONNECTORS
545-070-10
22-Pin PCB Socket
CRYSTALS
410-004-10
410-007-10
CX Crystal, 30.750 KHz (Statek CX-1H)
4.91 MHz Crystal
DIODES
301-001-10
301-003-10
301-006-10
302-002-10
310-001-10
313-002-10
1N4005 General Purpose Rectifier
MR752 General Purpose Rectifier
MR1122R General Purpose Rectifier
1N3890A Fast Recovery Rectifier
1N4148 General Purpose Switching Diode
1N4735A Zener Diode 6.2V 1W
FUSES
460-008-10
460-037-10
460-039-10
460-041-10
460-042-10
460-053-10
460-054-10
1.0A Fuse (AGC-1)
10A Fuse (AGC-10)
12A Fuse (ABC-12)
15A Fuse (MDL-15)
15A Fuse (ABC-15)
30A Fuse (BAF-30)
40A Fuse (SC-40)
FUSE HOLDERS
520-004-10
520-010-10
Fuse Holder, HKP (for ABC-15 fuse)
Fuse Holder, HPD (for FNW/BAF-30 fuse)
HARDWARE
189-004-10
640-017-10
641-019-10
643-003-10
647-008-10
651-007-10
651-008-10
652-002-10
653-015-10
654-003-10
654-004-10
654-005-10
654-006-10
654-019-10
655-001-10
655-002-10
Battery Carrying Handles
Nylon Spacer (for MJ transistors)
Rubber Transformer Feet
Module Handles
Key for UPE Enclosure
Latching Clip, Small-UPE
Latching Clip, Large-PME
Plastic Card Guide (new type, 4.5 inches)
Rubber Boot for “Oil” Capacitors
Green Lens (AM Modules - Line)
Green Lens (ACI Option)
Red Lens (AM Modules - Standby)
Red Lens (LRI Option)
Green Lens, Lexan (New ACI Option)
Cover for Potter/Blumfield 491-013-10 Relay
Cover for 491-014-10 Guardian Relay
38
9. TROUBLE-SHOOTING AND REPAIR
9.3
Common Parts for AP Series Standby Power Supplies, continued
Alpha Part Number
Description
IC SOCKETS
521-004-10
521-006-10
14-Pin IC Socket
16-Pin IC Socket
INTEGRATED CIRCUITS
360-002-10
360-201-10
361-006-10
361-202-10
361-203-10
366-001-10
366-003-10
366-004-10
366-006-10
366-007-10
366-010-10
366-012-10
366-016-10
367-201-10
367-202-10
368-001-10
385-003-10
7805 Voltage Regulator
TL494 Pulse Width Modulator
LM2904 Dual Op/Amp
LM2903 Dual Op/Amp
LM339N/LM239N Quad Comparator
4001B Quad 2-Input NOR Gate
4002B Dual 4-Input NOR Gate
4011B Quad 2-Input NAND Gate
4013 Dual Type D Flip Flop
4020B 14-Stage Ripple Carry Binary Counter
4043 NOR R/S Latch Quad Flip Flop
4049 Hex Inverting Buffer
4060B 14-Stage R.C. Counter, Divider, Oscillator
Programmed 8748 Microprocessor RPM Version
Programmed 8748 Microprocessor RSM Version
6402 UART
4N30 Optical Coupler
INDICATORS
390-002-10
390-004-10
390-006-10
390-007-10
390-008-10
392-002-10
392-004-10
392-005-10
392-007-10
28VDC Lamp #PSB28 (AM Series - Standby)
36 VDC Lamp #1822 (LRI Option)
60V Lamp (New ACI Option)
60V Lamp #60A (ACI Option)
120VAC Lamp #PSB120 (AM Series - Line)
LED, Green (APM-8 Logic Card)
LED, MV55 (SCB Logic Card)
LED, Red (APM-8 Logic Card)
LED, Yellow (APM-8 Logic Card)
INSULATORS
561-027-10
561-028-10
Insulator, Sil-Pad, TO-3 (for MJ transistors)
Insulator, Sil-Pad, DO-4 (for stud-mount diodes)
LAMP HOLDERS
522-001-10
522-002-10
522-003-10
522-005-10
Lamp Holder (PSB Series)
Lamp Holder (ACI Option, Socket only)
Lamp Holder (LRI Option, Socket only)
Lamp Holder (New LRI Option)
LIGHTNING ARRESTOR
020-049-20
350 Joule Plug-in MOV
MAGNETICS
240-034-10
240-036-10
242-027-10
247-051-10
Ferroresonant Transformer (660)
Ferroresonant Transformer (960)
Control Transformer PCB Mount (All Models)
2.5mh 10A Choke
METERS
400-007-10
405-401-10
0-20A AC Ammeter
Hourmeter, ET (meter only)
39
9. TROUBLE-SHOOTING AND REPAIR
9.3
Common Parts for AP Series Standby Power Supplies, continued
Alpha Part Number
Description
RELAYS
491-001-10
491-013-10
491-014-10
Relay, LRI
4PDT Contactor 24VDC, P&B
4PDT Contactor 24VDC, Guardian
RESISTORS
114-001-10
114-011-10
114-015-10
115-003-10
121-512-10
1 ohm 1W 5% FP Resistor
68 ohm 1W 5% FP Resistor
220 ohm 1W 5% FP Resistor
15 ohm 2W 5% FP Resistor
180 ohm 5W 5% Resistor
SURGE DEVICES
160-002-10
170-002-10
740-092-20
Varistor, V130LA10A (38 Joules)
Thermistor, SG100
Varistor Assembly (includes 160-002-10)
SWITCHES
421-005-10
424-003-10
Toggle Switch, SPI
Push Switch (front panel AP Series, w/o wire)
TERMINAL BLOCKS
535-039-10
Terminal Block, 10-Pin (AP Series)
TRANSISTORS
320-002-10
320-005-10
321-002-10
321-004-10
321-011-10
322-003-10
322-008-10
323-003-10
2N4401 NPN Transistor
2N5550 NPN Transistor
TIP112 NPN Power Transistor
TIP31C NPN Power Transistor
MJ11032 NPN Power Transistor
2N3906 PNP Transistor
2N5400 PNP Transistor
TIP117 PNP Power Transistor
40
9. TROUBLE-SHOOTING AND REPAIR
9.4
TROUBLE-SHOOTING GUIDE
SYMPTOM
No output to cable;
No AC line power;
Green “LINE ON” indicator OFF;
Red “STANDBY” indicator OFF.
SYMPTOM
No output to cable;
AC line power available;
Green “LINE ON” indicator ON;
Red “STANDBY” indicator OFF.
SYMPTOM
No output to cable;
No AC line power;
Green “LINE ON” indicator OFF;
Red “STANDBY” indicator ON.
SYMPTOM
Incorrect output voltage.
PROBABLE CAUSE
Utility power outage.
REMEDY
Use voltmeter to verify
120 VAC at receptacle.
AC power cord unplugged.
Plug in AC power cord.
AC input circuit breaker
tripped.
Reset AC circuit breaker.
Battery breaker tripped
or fuse open.
Reset battery breaker
or replace fuse.
In-line fuse open (BCK-F)
Replace fuse.
Battery cable disconnected.
Connect battery cable.
Battery voltage below
Low Voltage Cutout threshold
from extended power outage.
Batteries have been
disconnected by logic card
to prevent over-discharging.
If alternative power is
available, plug module
in and allow it to recharge
the batteries.
Marginal battery capacity or
faulty batteries.
Check batteries and
replace if necessary.
PROBABLE CAUSE
AC output fuse open.
REMEDY
Replace fuse.
SPI "ALT/ON" switch
in wrong position.
Move switch to
ON position.
Loose seizure screw inside SPI.
Tighten screw.
SPI not connected
to module's terminal strip.
Check connection at
pins 3 and 4 on module's
side panel.
PROBABLE CAUSE
AC output fuse open.
REMEDY
Replace output fuse.
SPI "ALT/ON" switch
in wrong position.
Move switch
to the "ON" position.
Loose seizure screw inside SPI.
Tighten screw.
SPI not connected
to module's terminal strip.
Check connection at
pins 3 and 4 on module's
side panel.
PROBABLE CAUSE
Wrong type of voltmeter used.
REMEDY
Use true RMS meter.
Under-loaded output
(less than 1 Amp).
Connect load.
Over-loaded output.
Reduce load.
Faulty resonant capacitor
(will appear swollen or
distorted; may leak oil).
Replace capacitor.
41
9. TROUBLE-SHOOTING AND REPAIR
9.4
TROUBLE-SHOOTING GUIDE, continued
SYMPTOM
Low output voltage when
unit is in STANDBY mode.
PROBABLE CAUSE
Defective inverter
transistors.
REMEDY
Replace power
board assembly.
SYMPTOM
No output voltage when attempting
to transfer from AC LINE to
STANDBY mode - “clicking” sound
from contactor.
PROBABLE CAUSE
Battery breaker OFF.
REMEDY
Switch battery breaker ON.
Battery voltage below
recharge acceptance
level.
Check battery voltages; check
terminal connections; charge or
replace battery(s) if necessary.
High resistance at
battery connection.
Check battery open circuit
voltages; clean and tighten
each connection; replace
faulty battery.
Logic card incorrectly seated
in card-edge connector.
Remove, clean and reseat
assembly.
Faulty logic.
Replace logic card.
Inverter transistors damaged.
Replace power board.
Faulty contactor.
Replace contactor.
PROBABLE CAUSE
Low AC line voltage.
REMEDY
Use voltmeter to verify
120 VAC at receptacle.
High impedance AC line.
Check all connections.
Check for correct wire gauges;
Shorten cables to AC utility.
Faulty logic.
Replace logic card.
PROBABLE CAUSE
Battery breaker OFF,
or battery fuse open.
REMEDY
Switch battery breaker ON,
or replace battery fuse.
Faulty batteries.
Check open circuit voltage;
Check voltage under load;
Check terminals and connecting
wires. Replace faulty battery(s).
Charger fuse open.
(on power board)
Replace 10 Amp fuse.
Faulty charger circuit.
Replace logic card.
Charger transistors damaged.
Replace power board.
SYMPTOM
Power module does not transfer
from STANDBY to AC LINE mode
when input power is restored;
contactor “clicks” periodically.
SYMPTOM
Batteries will not charge.
42
9. TROUBLE-SHOOTING AND REPAIR
9.4
TROUBLE-SHOOTING GUIDE, continued
SYMPTOM
Incorrect or, no float or
equalize charge voltages.
SYMPTOM
Battery breaker trips when
attempting to transfer from
AC LINE to STANDBY mode.
SYMPTOM
Open 10 Amp charger
fuse on power board.
SYMPTOM
MOV inside SPI darkened
or destroyed.
PROBABLE CAUSE
Battery breaker OFF,
or battery fuse open.
REMEDY
Switch battery breaker ON,
or replace battery fuse.
SCB charge voltages
out of calibration.
Replace logic card.
(See section 6.8).
APM charge voltages
incorrectly set.
Adjust switch settings.
(See section 6.8).
Charger fuse open
(on main power board).
Replace 10 Amp fuse.
Faulty logic.
Replace logic card.
Charger transistors damaged.
Replace power board.
PROBABLE CAUSE
Inverter transistors
damaged.
REMEDY
Replace power board.
Faulty logic.
Replace logic card.
PROBABLE CAUSE
Faulty fuse.
REMEDY
Replace fuse.
Faulty charger.
Replace power board.
Defective charger transistors.
Replace power board.
PROBABLE CAUSE
Lightning or other transient
damage on the output.
REMEDY
Replace MOV in SPI.
43
10. WARRANTY
WARRANTY.
Alpha Technologies, Inc., provides a LIMITED WARRANTY covering the
performance of its Broadband products. The terms and conditions of the
LIMITED WARRANTY STATEMENT are contained in a separate written LIMITED WARRANTY STATEMENT included with the Operator’s manual provided
with this product. If there are any warranty claims, the purchaser (or
purchaser’s representative) must follow the LIMITED WARRANTY guidelines,
described in the applicable LIMITED WARRANTY STATEMENT.
44
Investigate the
of Alpha @www.alpha.com
USA
ASIA PACIFIC
LATIN AMERICA
Alpha Technologies
3767 Alpha Way
Bellingham, WA 98226
Tel: (360) 647-2360
Fax: (360) 671-4936
Web: www.alpha.com
CANADA
Alpha Technologies
7033 Antrim Ave.
Burnaby, B.C. V5J 4M5
Tel: (604) 430-1476
Fax: (604) 430-8908
UNITED KINGDOM
Alpha Technologies
Cartel Business Estate
Edinburgh Way
Harlow, Essex CM20 2DU
Tel: +44-1279-422110
Fax: +44-1279-423355
GERMANY
Alpha Technologies
Hansastrasse 8
D-91126 Schwabach
Tel: +49-9122-997303
Fax: +49-9122-997321
Due to continuing product
improvements, Alpha reserves the right
to change specifications without notice.
Copyright © 1998
Alpha Technologies Inc.
All rights reserved.
MIDDLE EAST
Alphatec
P.O. Box 6468
3307 Limassol, Cyprus
Tel: +357-5-375675
Fax: +357-5-359595
AUSTRALIA
Alpha Technologies
8 Anella Ave., Unit 6
Castle Hill, NSW 2154
Tel: +61 (0)2 9894-7866
Fax: +61 (0)2 9894-0234
Printed in the USA
026-006-B0-002 8/98
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