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LECTRO 36VDC Technical Manual

Cpr series broadband power supply
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CPR
Series Broadband Power Supply
TM
36VDC and 48VDC Technical Manual
Effective: March, 2004
®

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Summary of Contents for LECTRO 36VDC

  • Page 1 Series Broadband Power Supply 36VDC and 48VDC Technical Manual Effective: March, 2004 ®...
  • Page 2 Power Alpha Technologies. Protecting The Power in Communications.
  • Page 3 Series Broadband Power Supply Technical Manual Effective: March, 2004 745-573-B0-001 REV. A — © 2004 Alpha Technologies NOTE: Photographs contained in this manual are for illustrative purposes only. These photographs may not exactly match your installation. NOTE: Review the drawings and illustrations contained in this manual before proceeding.

  • Page 4: Table Of Contents

    Preface Contents Important Safety Instructions ........................6 General Safety Precautions ........................7 Battery Safety Notes ..........................9 Battery Maintenance Guidelines ......................10 Recycling and Disposal Instructions ......................11 Electrical Safety ............................11 Mechanical Safety ............................ 12 1.0 Overview Introduction ............................. 13 Cabinet Nomenclature ........................
  • Page 5 Preface Figures & Tables 1.0 Overview Fig. 1-1, Ground Mount (Front View of 4 battery cabinet with ground skirt) ....14 Fig. 1-2, Pole Mount (Front View of 8 battery cabinet) ..........14 Fig. 1-3, Pole Mount (Rear View of cabinet) ............... 15 Fig.

  • Page 6: Important Safety Instructions

    Preface Important 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.

  • Page 7: General Safety Precautions

    Preface 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.
  • Page 8 • The Lectro CPR UPS is a 36 or 48Vdc system designed for use with either a single or dual string of three or four 12Vdc batteries. Please refer to Section 3 of this manual for more details on proper battery installation, maintenance, storage, and replacement procedures •...

  • Page 9: Battery Safety Notes

    Preface 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.

  • Page 10: Battery Maintenance Guidelines

    Preface Battery Safety Notes, continued Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have developed on your body. Never use uninsulated tools or other conductive materials when installing, maintaining, servicing or replacing batteries. Use special caution when connecting or adjusting battery cabling.

  • Page 11: Recycling And Disposal Instructions

    Preface Recycling and Disposal Instructions Spent or damaged batteries are considered environmentally unsafe. Always recycle used batteries or dispose of the batteries in accordance with all federal, state and local regulations. Electrical Safety Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical connection or conductor is not energized.

  • Page 12: Mechanical Safety

    Preface Mechanical Safety Keep hands and tools clear of fans. Fans are thermostatically controlled and will turn on automatically. Power supplies can reach extreme temperatures under load. Use caution around sheet metal components and sharp edges. 745-573-B0-001 REV. A...

  • Page 13: Overview

    This manual contains important instructions for the Lectro Uninterruptible Power Supply (UPS). These instructions should be followed during installation and maintenance of the power supply, batteries, cabinet, status monitor and any options and/or ancillary equipment.

  • Page 14: Cabinet Nomenclature

    1.0 Overview , Continued Cabinet Nomenclature EXTERNAL INDICATOR LAMPS PADLOCK HASP GROUND SKIRT Fig. 1-1, Ground Mount (Front View of 4 battery cabinet with ground skirt) EXTERNAL INDICATOR LAMPS Fig. 1-2, Pole Mount (Front View of 8 battery cabinet) 745-573-B0-001 REV. A...

  • Page 15: Fig. 1-3, Pole Mount (Rear View Of Cabinet)

    1.0 Overview , Continued Cabinet Nomenclature, continued OPTIONAL LOCATION FOR " " GROUND FEED THRU ADAPTOR AC INPUT CONDUIT CONNECTION POLE MOUNTING BRACKET Fig. 1-3, Pole Mount (Rear View of cabinet) DISCONNECT BREAKER BOX Fig. 1-4, Typical Placement of Disconnect Breaker on rear of Cabinet "...

  • Page 16: Pole Mounting

    A bucket truck and other suitable equipment, such as spikes and safety harness, should be used during installation or service of pole-mounted cabinets. To mount the Lectro UPS to a utility pole perform the following steps: INSTALLATION PROCEDURE 1. Install an appropriate disconnect box between the AC power source and the CPR cabinet mounting point.
  • Page 17 If attaching to a concrete pole additional mounting hardware will be required for the installation. Lectro does not provide the metal bands required to mount to a concrete pole. This hardware can be obtained from a cable TV hardware supplier.

  • Page 18: Ground Mounting

    2.0 Cabinet Installation, continued Ground Mounting Although ground mounting the CPR cabinet can be accomplished by several methods, the following procedure is recommended: INSTALLATION PROCEDURE 1. Select an appropriate site. Check with other local utilities for buried plant before site location is finalized.

  • Page 19: Fig. 2-2, Pad Dimensions

    2.0 Cabinet Installation, continued Ground Mounting, continued INSTALLATION PROCEDURE CONTINUED 8. Drill out the two holes in the template and insert two 5/8" X 4" (M16-2.0 x 100mm) bolts (not supplied). The heads of the bolts will be embedded into the concrete pad when installation is complete.

  • Page 20: Enclosure Grounding

    2.0 Cabinet Installation, continued 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”.

  • Page 21: Electrical Connections

    2.0 Cabinet Installation, continued Electrical Connections WARNING: Be sure the utility (mains) disconnect is off and that no conductors are energized before proceeding. CONNECTION PROCEDURE 1. Open the cabinet doors. 2. Install liquid tight conduit to the fitting on the cabinet rear panel and pull the AC primary into the cabinet housing.

  • Page 22: Power Supply Installation

    3.0 Power Supply, continued 3.1 CPR Module Installation and Connection NOTE: The CPR module weighs 56 lbs/25 kg. (65 lbs./30 kg for the 24 amp model), and the center of gravity is offset to the right. The unit may be lifted using both of the lifting handles on the front of the module.
  • Page 23 3.0 Power Supply, continued 3.1 CPR Module Installation and Connection, continued 5. If the batteries are not installed, install them at this time per the instructions in Section 3.2. Connect the battery sensing wire harness to the appropriate battery terminals as shown in Figure 3-7 or 3-8.

  • Page 24: Fig. 3-2, Connection Points For 60Hz, 15A Units

    3.0 Power Supply, continued 3.1 CPR Module Installation and Connection, continued A. AC output cable B. Output voltage select C. Battery power cable (Fig. 3-5, 3-6) D. AC input E. Temp. probe connector Fig. 3-2, Connection points for 60Hz, 15A units A.

  • Page 25: Battery Installation And Connection

    Batteries produce explosive gases. Keep away all sparks and flames. • Remove watches, rings or other metal objects • Use tools with insulated handles. • Wear rubber gloves and boots Tools required: 10mm (Lectro™) or 7/16” (AlphaCell™) socket Inch-pound torque wrench Multimeter 745-573-B0-001 REV. A...

  • Page 26: Battery Installation Procedure

    3.0 Power Supply, continued 3.2 Battery Installation and Connection, continued 3.2.1 48V Battery Installation Procedure 1. Confirm the CPR DC circuit breaker is off (down). 2. Place the batteries in the bottom of the cabinet, negative terminals (-) at the rear of the cabinet. 3.

  • Page 27: Battery Installation Procedure

    3.0 Power Supply, continued 3.2 battery Installation and Connection, continued 3.2.2 36V Battery Installation Procedure 1. Confirm the CPR DC circuit breaker is off (down). 2. Place the batteries in the bottom of the cabinet, negative terminals (-) at the rear of the cabinet. 3.

  • Page 28: Connecting An Additional 48V Battery String

    Connecting an Additional 48V Battery String NOTE: This procedure assumes that the additional battery string is being installed in a Lectro brand cabinet. 1. Confirm the CPR DC circuit breaker is off (down). 2. Place the batteries in the bottom of the cabinet with the negative terminals (-) at the rear of the cabinet.
  • Page 29 Connecting an Additional 36V Battery String NOTE: This procedure assumes that the additional battery string is being installed in a Lectro brand cabinet. 1. Confirm the CPR DC circuit breaker is off (down). 2. Place the batteries in the bottom of the cabinet with the negative terminals (-) at the rear of the cabinet.

  • Page 30: Removing Batteries

    3.0 Power Supply, continued Battery Installation and Connection, continued 3.2.5 Battery Removal Turn the DC circuit breaker off (down) and observe all precautions for the safe handling of batteries as previously outlined. Remove all batteries in the reverse order of installation. BATTERY SENSE INPUT For Level 3 wiring, refer to manual P/N 040-0080-1501 OPTIONAL XM STYLE...
  • Page 31 3.0 Power Supply, continued Battery Installation and Connection, continued BATTERY SENSE INPUT For Level 3 wiring, refer to manual P/N 040-0080-1501 Red and Black OPTIONAL XM STYLE Anderson TEMPERATURE PROBE Connector BLACK Negative (Black) UPPER SHELF Middle (Orange) TEMP PROBE INPUT LOWER SHELF Positive (Red) Middle, Longer...
  • Page 32 3.0 Power Supply, continued Battery Installation and Connection, continued BATTERY INPUT For Level 3 wiring, refer to manual P/N 040-0080-1501 OPTIONAL XM STYLE Gray Anderson TEMPERATURE PROBE Connector BLACK Negative (Black) UPPER SHELF Middle (Orange) CABINET FRONT TEMP PROBE INPUT Positive (Red) Middle Longer (Orange) If unused, tuck connector out of the way...

  • Page 33: Operation

    3.0 Power Supply, continued Operation UPS STARTUP AND INVERTER TEST PROCEDURE 1. Verify that all connections to the CPR have been made correctly as described in Section 3.1. 2. Verify that the desired output voltage has been selected (48V, 60V, 75V, or 87V) via the connection at the left side of the CPR module.
  • Page 34 3.0 Power Supply, continued Operation, continued 7. Verify the external LEDs on the CPR outdoor cabinet are functioning. In normal operation, the green external LED will be ON solid, (not flashing). The green LED flashes when the CPR system is on battery, and the red LED flashes when there is a system alarm or failure. 8.

  • Page 35: Maintenance

    3.0 Power Supply, continued Maintenance 3.4.1 Routine Maintenance Checks NOTE: It is important that secure mechanical and electrical connections be maintained on this equipment. Secure connections will help prevent outages and equipment damage. Refer to the following page for a sample of a maintenance log sheet. 1.

  • Page 36: Cpr Power Supply Maintenance Log Sheet

    3.0 Power Supply, continued Maintenance, continued 3.4.2 CPR Power Supply Maintenance Log Sheet Use this form in conjunction with the maintenance procedures in the previous section. Cable Company:___________________________________________________ Inspection Date:________________ Location:_________________________ Technician:____________________ Model/Serial#:____________________ Visual Problem and Fix:__________________________________ Inspection Comments:_______________________________________ Battery Weak LEDs: String 1: ON / OFF String 2: ON / OFF LED Display: Mark the illuminated LEDs on the diagram below:...

  • Page 37: Battery Storage

    Always store batteries in a cool, dry location. Optimum temperature is 25°C (77°F). Always monitor battery, open-circuit voltage at least once every 12 months. If not using a Lectro CPR battery, refer to the manufacturer’s guidelines for storage. Always provide a refreshing charge if the open circuit voltage drops below 12.2 volts.

  • Page 38: Troubleshooting

    4.0 Troubleshooting, Continued Troubleshooting Guide Part 1 Because it is impossible to account for every possible symptom and solution in a CATV Network, the following troubleshooting suggestions should be used as a general guideline. SYMPTOM PROBABLE CAUSE ACTION No AC output to coax Utility failure Notify local Power Co..

  • Page 39: Troubleshooting Guide Part 2

    4.0 Troubleshooting , Continued Troubleshooting Guide Part 2 SYMPTOM PROBABLE CAUSE ACTION AC input "High" red LED AC input voltage is above 156 (or 299 for Measure the AC input voltage with a true RMS is lit. 230V nominal units, or 276 for 240V voltmeter.

  • Page 40: Installation

    5.0 Status Monitor , Continued Installation The communication module installs in the same basic manner for all three levels of status monitoring. The external connections will be different as defined in Section 4.3. 1. Turn off the CPR Unit, and remove AC Power. 2.

  • Page 41: Operation

    The data available is in RS-232 format. The popular “Palm Pilot” PDA device may also be connected to this port using a Palm Pilot application and instructions available from Lectro. A telephony modem may also be connected to the RS-232 port. Be sure to disable “hardware handshaking” for proper operation of the modem in this application.

  • Page 42: Maintenance

    5.0 Status Monitor , Continued Operation, continued LEVEL THREE Allows for remote status monitoring similar to Level One and Two with the DB-9 connector replaced by a F-81 style, 75-ohm, RF connector. This level is proprietary or HMS, and directly compatible with CheetahNet.

  • Page 43: Specifications

    6. Specifications , Continued Electrical, Mechanical Specifications M O D E L P A R A M E T E R 1 2 0 V E x t d R a n g e 2 2 0 V I n t e r n a t io n a l 2 3 0 V I n t e r n a t io n a l 2 3 0 V E u r o ( C E ) 2 4 0 V ( 2 4 A )
  • Page 44 6. Specifications, Continued Electrical, Mechanical Specifications, Continued M O D E L 1 2 0 V 3 6 V E x t d 2 3 0 V 3 6 V E u r o P A R A M E T E R R a n g e ( C E ) N o m in a l I n p u t V o lt a g e...
  • Page 46 Power www.alpha.com Protecting The Power in Communications. Alpha Technologies 3767 Alpha Way Bellingham, WA 98226 Tel: (360) 647-2360 Fax: (360) 671-4936 Web: www.alpha.com Alpha Technologies Ltd. 4084 McConnell Court Burnaby, BC, V5A 3N7 CANADA Tel: (604) 430-1476 Fax: (604) 430-8908 Alpha Technologies Europe Ltd.

This manual is also suitable for:

48vdc

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