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.
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 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.
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.
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.
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.
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 Op
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
9. TROUBLE-SHOOTING AND REPAIR 9.
9. TROUBLE-SHOOTING AND REPAIR 9.
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.
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.
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.
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 Operators manual provided with this product. If there are any warranty claims, the purchaser (or purchasers representative) must follow the LIMITED WARRANTY guidelines, described in the applicable LIMITED WARRANTY STATEMENT.
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