Powernode Series Enclosures ® ® PN-6 and BD-8 Enclosure Installation Manual Effective: June, 2003 ®
Alpha PN-6 / BD-8 Powernode Enclosure Installation Manual Effective: June, 2003 031-032-C2-002, Rev.
PN-6/BD-8 Enclosure Installation Manual 031-032-C2-002, Rev. B Effective Date: June, 2003 Copyright© 2003 Alpha Technologies, Inc. NOTE: Alpha denies responsibility for any damage or injury involving its enclosures, power supplies, generators, batteries, or other hardware when used for an unintended purpose, installed or operated in an unapproved manner, or improperly maintained. NOTE: Photographs contained in this manual are for illustrative purposes only.
Preface Powernode Series Enclosures Table of Contents OVERVIEW 1.1 Introduction ....................................................................................................... 10 PRE-INSTALLATION 2.1 2.2 2.3 2.4 Site considerations ........................................................................................... 11 Concrete Pad Dimensions ................................................................................. 12 Site Cross Section ........................................
Preface Powernode Series Enclosures List of Figures OVERVIEW Fig. 1-1 PN-6 with BD-8 battery enclosure .............................................................. 10 PRE-INSTALLATION Fig. 2-1 Fig. 2-2 Fig. 2-3 PN-6, Single-wide Cabinet Pad dimensions ................................................ 12 Pad Fabrication .......................................................................................... 13 Enclosure Grounding ...................................................................
Product Safety Impor tant Safety Instructions Contained In This Manual Read This Manual Before Proceeding! Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference.
Product Safety General Safety Precautions A “Warning” identifies conditions and actions that pose a hazard to the user. A “Caution” identifies conditions and actions that may damage the power supply or associated equipment. Warnings NOTE: This enclosure and its associated hardware (power supply, batteries, cabling) may contain equipment, batteries or parts which have accessible hazardous voltage or currents.
Product Safety General Safety Precautions Cautions NOTE: Enclosure, equipment or parts may be damaged or cause damage if used or installed improperly. To avoid damage: • • • • • • • 8 Prior to installation, verify that the AC input voltage to the enclosure and its equipment match with respect to voltage and frequency. Prior to installation, verify that the output voltage from the enclosure or its equipment match the voltage requirements of the connected equipment (load).
Product Safety Battery Safety Notes Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery installation, maintenance, service and replacement must be performed by authorized personnel only. Chemical Hazards NOTE: Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contain dilute sulfuric acid, which is harmful to the skin and eyes. Emissions are electrolytic, which are electrically conductive and corrosive.
1. Overview 1.1 Introduction Alpha's PN Series Powernode enclosures offer complete flexibility and modular expandability for Cable TV powering applications. The PN-6 is designed for up to three XMS2 power supply and up to eight batteries. A 7.5 kW generator can be co-located for extended back-up power. For additional battery capacity, the BD-8 battery enclosure may be added. PN-6 BD-8 Fig. 1-1 PN-6 with BD-8 battery enclosure 10 031-032-C2-002 Rev.
2. Pre-Installation 2.1 Site considerations The site must be planned so that the enclosure will receive good air flow. If possible, in areas of extreme heat, it is best to position the enclosure so that it will be shaded from the afternoon sun. In areas of prevailing winds, it is best that the enclosure be located so that the sides of the cabinet face the winds instead of the doors. This will greatly reduce the buildup of sand or snow against the enclosure’s air vents.
2. Pre-Installation 2.2 Concrete Pad Dimensions 3.00 (Ref.) 64.00 (Ref.) 21.50 ENCLOSURE REAR 15.50 14.62 Meterbase Service Entrance 7.62 7.00 Enclosure Mating Surface Open area for coax and grounding sweeps Enclosure Mounting Bolts or Insets 36.0 (Ref.) From Battery Vault 0.00 Service Disconnect Entrance 2.38 4.62 8.50 54.00 48.00 44.00 15.00 0.00 5.75 4.00 10.00 14.50 29.00 ENCLOSURE FRONT Fig.
2. Pre-Installation 2.3 Concrete Pad Installation 5 7 6 4 3 2 1 (Pour-in-place option shown) 1 2 Undisturbed Ground Compacted Gravel (approx. 12") 3 Concrete Pad (3" to 6" thick) 4 Open area for output power and ground 5 1/2" -13 mounting studs or threaded inserts 6 Open area for utility power sweeps 7 Open area for Generator Interface Kit Fig. 2-2 Site Cross Section 031-032-C2-002 Rev.
2. Pre-Installation 2.4 Enclosure Grounding NOTE: Alpha Technologies recommends using the grounding method illustrated below. The grounding method for a particular site will be dependant upon soil type, available space, local codes, NEC (National Electric Code), and other site- specific characteristics. Alpha Technologies recommends 5 ohms minimum ground resistance between enclosure and ground rods, in accordance with IEEE 1100-1999 Powering and Grounding Electronic Equipment.
3. Installation 3.1 Enclosure Protection Alpha Technologies, Inc. cannot anticipate all of the ways a vehicle may potentially threaten an installed system or the specific type of protection that is appropriate for a particular location. The determination of the threat to the equipment and the means of protection are the responsibility of the end user of the equipment and the authority having jurisdiction.
3. Installation 3.2 Transportation and Lifting The PN-6 cabinet as shipped, is extremely heavy. A safe means of transportation to the site and a safe procedure for unloading the enclosure is necessary. Do not transport or lift with a device that may not be able to bear the unit's weight, and do not place the unit upon a surface that will not be able to fully support it. Verify that the transport path is free of obstructions.
3. Installation 3.3 Enclosure Installation 3.3.1 Attaching Enclosure to the pad Tools Needed: Ratchet set with 6” extension. Vapor Barrier Utility Knife Procedure: NOTE: A 25+ year continuous vapor barrier must be used between the enclosure and pad to prevent moisture ingress and possible corrosion caused by metal to concrete contact. The vapor barrier material (such as 30 lb.
3. Installation 3.4 Utility Powering 3.4.1 Electrical Service Connection The XM2 Power Supplies are powered by either 120Vac or 240Vac (120/120 grounded neutral), attached to an external service entrance. The size of the service conductors must be based upon the actual size of the utility service and be in accordance with applicable electrical code requirements. The utility conduit may be placed in two locations, depending upon the utility service entrance requirements.
3. Installation 3.4 Utility Powering, continued 3.4.1 Electrical Service Connection, continued Tools Needed: No. 1 Flat Head Screwdriver Adjustable Pliers (Channel-Lock) Procedure: 1. Locate the service entrance panel on the enclosure (exterior). Remove the cover to access the circuit breaker assembly. If this service panel is to be used as the primary service entrance, neutral must be bonded to ground. 2.
3. Installation 3.4 Utility Powering, continued 3.4.1 Electrical Service Connection, continued 3. Connect the #6 green ground wire to the large terminal on the ground bar. 4. Notify the electrical inspector to approve the service entrance wiring. Once approved, contact the local power utility for electrical service. Fig. 3-4 System Grounding 20 031-032-C2-002 Rev.
3. Installation 3.5 Service Power Inserter 1. The SPI box(es) are mounted on a bracket behind the top power supply. 2. Remove the two screws on the face of the SPI and lift off the cover to gain access to the Seizure Screw Assembly. Loosen the Seizure Screw several turns so that the stinger will pass through the clamp (Fig. 3-5). Seizure Screw Assembly 3. Insert the Coaxial Termination into the output port on the bottom of the SPI. Verify the stinger goes through the Seizure Screw Assembly.
3. Installation 3.6 Battery Installation 3.6.1 Battery Safety Battery systems represent a risk of electrical shock and high short circuit currents. The following precautions must be observed when maintaining batteries: • Remove all personal metal objects (watches, rings, etc.). • Use insulated tools. • Wear eye protection, rubber gloves and protective vest. • Observe circuit polarities. • Do not make or break live circuits. • Do not lay metal tools and hardware on top of the batteries.
3. Installation 3.6 Battery Installation, continued 3.6.3 Battery Terminal Connections The accompanying drawings are for illustrative purposes only. Various types of batteries with different mounting styles and hardware may be shipped with the system. Mounting hardware requirements may vary with battery manufacturers. Use only the hardware recommended by your particular battery manufacturer. The following illustration shows the typical terminal assembly for vertically mounted battery posts.
3. Installation 3.6 Battery Installation, continued 3.6.4 Battery Connection Tools Needed: Two 7/16” open end wrenches Procedure: Note: The BD-8 battery enclosure is an option, and may not be present. 1. Place batteries on the PN-6 battery trays, as shown in Fig. 3-10 or 3-11. 2. If the BD-8 enclosure is used, route the cables through the opening in the right front corner of the enclosures. 3. Connect the battery packs to the Battery Interface Unit at the top of the right side of the PN-6 enclosure.
3. Installation Battery Installation, continued 3.6 3.6.5 Battery Connection, Numbering for 36 Volt Battery Pack Pos Neg Pos Neg Pos Neg PN-6 Enclosure Pos Neg Battery Interface Unit Optional BD-8 Connection Upper Tray Pos Neg 1A 2A 3A 1B Lower Tray 2B 3B BD-8 Enclosure (Option) 1D 1C 2D 2C 3D 3C NOTE: Battery numering scheme in accordance with SCTE guidelines for battery status monitoring. Fig 3-10 Battery Power Distribution, 36 VDC 031-032-C2-002 Rev.
3. Installation 3.6 Battery Installation, continued 3.6.6 Battery Connection, Numbering for 48 Volt Battery Pack Pos Neg Pos Neg Pos Neg PN-6 Enclosure Pos Neg Battery Interface Unit Optional BD-8 or Generator Connection 1A From Generator Output Pos Neg Pos Neg 4A Upper Tray 2A 3A 1B 4B Lower Tray 2B 3B BD-8 Enclosure (Option) 4C 1D 2D 4D 3D 1C 3C 2C NOTE: Battery numering scheme in accordance with SCTE guidelines for battery status monitoring.
3. Installation 3.6 Battery Installation, continued 3.6.7 Battery Monitor Connection with optional Status Monitoring Module The BATT connection (8-pin Mini Mate-n-Lok), on an optional Status Monitoring Module is an interface which enables the measuring of two sets of 36V or 48V battery strings. Refer to the status monitor’s installation and operation manual for detailed instructions on wiring the battery packs. 031-032-C2-002 Rev.
3. Installation 3.7 Power Supply Installation 3.7.1 Power Supply Installation Tools Needed: None Procedure: 1. Place an XMS2 power supply on one of the trays inside the enclosure. 2. Verify the input AC breaker is in the OFF position. Plug the XMS2 into an available outlet on the left wall of the enclosure. 28 031-032-C2-002 Rev.
3. Installation 3.7 Power Supply Installation, continued 3.7.1 Power Supply Installation, continued 3. Verify that the Battery Circuit Breaker is in the OFF position. Connect the red and black battery cable to the BATTERY INPUT connection. 4. Connect the black and white wire from the SPI(s) to the OUTPUT connection on the front of the XMS2 power supply. 031-032-C2-002 Rev.
3. Installation 3.8 Battery Remote Temperature Sensor (RTS) Tools Needed: Adhesive Tape Procedure: 1. Attach the RTS Probe to the inner side of one of the batteries with adhesive tape. 2. For enclosures with multiple battery strings, the RTS must be located with the WARMEST battery string. This ensures proper operation of the battery charger’s temperature compensation circuit. Failure to locate the RTS with the warmest battery string could result in overcharging and premature battery failure. 3.
3. Installation 3.9 Lightning Arrester Option Alpha’s LA Series voltage suppressors provide reliable protection of power supplies and related equipment from the damaging powerline disturbances common to cable TV and broadband applications. The LA Series incorporates MOV’s that effectively limit voltage surges and absorb excessive energy levels. Housed in a durable polymer casings with standard electrical plugs, the LA Series plugs directly into any electrical outlet.
3. Installation 3.
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