EM CableUPS 12V, 24V Technical Manual - Betsis · and maintenance, but also facilitates the proper operation and protection of the equipment within the network. Such a Such a grounding

EM CableUPS® 12V, 24VTechnical Manual

Effective: June 2015

Safety NotesAlpha considers customer safety its most important priority. To reduce the risk of injury or death and to ensure continual safe operation of this product, certain information is presented differently in this manual. Alpha tries to adhere to ANSI Z535 and encourages special attention and care to information presented in the following manner:

The following sections contain important safety information that must be followed during the installation and maintenance of the equipment and batteries. Read all of the instructions before installing or operating the equipment, and save this manual for future reference.

There may be multiple warnings associated with the call out. Example:

ATTENTION provides specific regulatory/code requirements that may affect the placement of equipment and /or installation procedures.

ATTENTION:

NOTICE provides additional information to help complete a specific task or procedure. NOTICE:

ELECTRICAL HAZARD WARNING provides electrical safety information to PREVENT INJURY OR DEATH to the technician or user.

WARNING! ELECTRICAL HAZARD

FUMES HAZARD WARNING provides fumes safety information to PREVENT INJURY OR DEATH to the technician or user.

WARNING! FUMES HAZARD

FIRE HAZARD WARNING provides flammability safety information to PREVENT INJURY OR DEATH to the technician or user.

WARNING! FIRE HAZARD

This WARNING provides safety information for both Electrical AND Fire Hazards

WARNING! ELECTRICAL & FIRE HAZARD

CAUTION provides safety information intended to PREVENT DAMAGE to material or equipment.

CAUTION!

GENERAL HAZARD WARNING provides safety information to PREVENT INJURY OR DEATH to the technician or user.

WARNING! GENERAL HAZARD

3017-897-B0-001, Rev. A (06/2015)

EM CableUPS®

Technical Manual017-897-B0-001, Rev. A

Effective Date: June 2015© 2015 by Alpha Technologies, Inc.

DisclaimerImages contained in this manual are for illustrative purposes only. These images may not match your installation.

Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding. If there are questions regarding the safe operation of this powering system, please contact Alpha Technologies or your nearest Alpha representative.

Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators, batteries or other hardware if used or operated in any manner or subject to any condition not consistent with its intended purpose or is installed or operated in an unapproved manner or improperly maintained.

Contact InformationSales information and customer service in USA(7AM to 5PM, Pacific Time):

Complete technical support in USA(7AM to 5PM, Pacific Time or 24/7 emergency support):

Website:

1 800 863 3364

www.alpha.com

1 800 322 5742

4 017-897-B0-001, Rev. A (06/2015)

Table of ContentsEM Power Supply Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.0 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1.1 Alpha EM Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111.1.1 EM Power Supply Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.2.1 AC (Line) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.2.2 Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.2.3 Charger Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.1 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.1.1 Pre-installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.2 EM Power Supply Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.2.1 Parts and Connection Ports Overview . . . . . . . . . . . . . . . . . . . . . . . . . 202.2.2 Battery Installation Options and Wiring Diagram . . . . . . . . . . . . . . . . . . . . 212.2.3 Threaded Insert Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.2.4 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.3 EM Power Supply Web Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252.3.1 Local Web Interface Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4 EM Power Supply Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.4.1 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.4.2 Network Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292.4.3 System Configuration and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 292.4.4 EM Start-Up and Reboot Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.5 Network Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312.5.1 Provisioning the DHCP Server with the MAC Addresses . . . . . . . . . . . . . . . . 312.5.2 Network Configuration with atiem01.cfg file. . . . . . . . . . . . . . . . . . . . . . . 31

2.6 Setting Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322.7 SNMP Community Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332.8 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.8.1 Security Using the Secure Access List . . . . . . . . . . . . . . . . . . . . . . . . . 332.9 Configuring a Static IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.9.1 Recovering from an Incorrect Static IP Address . . . . . . . . . . . . . . . . . . . . 343.0 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.1 Start-Up and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.1.1 Self Test Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.2 Automatic Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.3 Providing Power via Portable Generator or Inverter . . . . . . . . . . . . . . . . . . . . . 36

3.3.1 AC Powering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.3.2 Using a Truck-Mounted Inverter or Generator . . . . . . . . . . . . . . . . . . . . . 37

3.4 Resumption of Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.5 Configuring the EM Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383.6 Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464.2 Required Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474.3 Power Supply System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.3.1 Preparing for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484.3.2 Periodic Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5017-897-B0-001, Rev. A (06/2015)

4.3.3 Replacing the MOV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494.4 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.4.1 Battery Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504.4.2 Battery Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514.4.3 Battery Disposal, Recycling and Storage Instructions . . . . . . . . . . . . . . . . . 514.4.4 Battery Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.4.5 Preparing for Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 544.4.6 Periodic Battery Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . 554.4.7 Battery Refurbishment Plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.4.8 Battery Evaluation Procedures for AlphaCell Batteries . . . . . . . . . . . . . . . . . 59

5.0 Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616.0 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627.0 EM Power Supply Mounting Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648.0 Web Interface Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Table of Contents, Continued

6 017-897-B0-001, Rev. A (06/2015)

FiguresFig. 1-1, Alpha EM Power Supply (12V and 24V Models) . . . . . . . . . . . . . . . . . . . . . . .11Fig. 1-2, EM Power Supply Layout (24V Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Fig. 1-3, 3-Stage Charger Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Fig. 1-4, 4-Stage Charger Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Fig. 1-5, 4-Stage Charger Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Fig. 1-6, 5-Stage Charger Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Fig. 2-1, Overview of EM Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Fig. 2-2, 12-Volt Battery Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Fig. 2-3, 24-Volt Battery Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Fig. 2-4, Precision Temperature Sensor (PTS), p/n 746-331-20 . . . . . . . . . . . . . . . . . . . 22Fig. 2-5, Battery Terminal/Fuse Bolt Stack-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Fig. 2-6, Removal of the Terminal Block Cover (12V and 24V) . . . . . . . . . . . . . . . . . . . 24Fig. 2-7, Local EM Power Supply Web Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . 25Fig. 2-8, Windows 7 Local Area Connection Screen . . . . . . . . . . . . . . . . . . . . . . . . . 26Fig. 2-9, Windows 7 Internet Protocol (TCP/IPv4) Screen . . . . . . . . . . . . . . . . . . . . . . 26Fig. 2-10, Windows 8 Ethernet Properties Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 27Fig. 2-11, Windows 8 Internet Protocol (TCP/IPv4) Screen . . . . . . . . . . . . . . . . . . . . . 27Fig. 2-12, Representative System Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Fig. 2-13, Start-Up Routine: Order of Operations . . . . . . . . . . . . . . . . . . . . . . . . . . 30Fig. 2-14, MAC Address Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Fig. 3-1, Web Interface, Login Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Fig. 3-2, Web Interface, HOME Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Fig. 3-3, Web Interface, POWER Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Fig. 3-4, Web Interface, BATTERY Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Fig. 3-5, Web Interface, ALARM Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Fig. 3-6, Web Interface, COMMS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Fig. 3-7, Output and Alarm LEDs on the EM Power Supply . . . . . . . . . . . . . . . . . . . . . 43Fig. 4-1, Removing and Replacing the MOV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Fig. 4-2, Capacity vs. Storage Time for AlphaCell XTV . . . . . . . . . . . . . . . . . . . . . . . 52Fig. 4-3, Capacity vs. Storage Time for AlphaCell HP . . . . . . . . . . . . . . . . . . . . . . . . 52Fig. 4-4, Capacity vs. Storage Time for AlphaCell GXL . . . . . . . . . . . . . . . . . . . . . . . 52Fig. 4-5, Efficiency vs. Temperature AlphaCell XTV Series . . . . . . . . . . . . . . . . . . . . . 53Fig. 4-6, Efficiency vs. Temperature AlphaCell HP Series . . . . . . . . . . . . . . . . . . . . . . 53Fig. 4-7, Flow Chart for Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 55Fig. 4-8, Flow Chart for Battery Refurbishment Plan. . . . . . . . . . . . . . . . . . . . . . . . . 58Fig. 5-1, Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Fig. 7-1, Wall Mount Rack (12V Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Fig. 7-2, Wall Mount Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Fig. 7-3, NPS Cabinet for 2 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Fig. 7-4, LPE Cabinet for 1 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7017-897-B0-001, Rev. A (06/2015)

TablesTable 1-1, Low Battery Cutoff (EOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Table 1-2, Charger Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Table 2-1, Ethernet LEDs and Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Table 2-2, atiem01.cfg Download Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Table 2-3, Communications Module Communication Parameters . . . . . . . . . . . . . . . . . . 32Table 2-4, Community String Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Table 2-5, Secure Access Table Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Table 2-6, Static IP Address Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Table 3-1, AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Table 3-2, Main Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Table 3-3, POWER Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Table 3-4, BATTERY Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Table 4-1, On-Site Battery Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 57Table 4-2, AlphaCell Conductance Values, Healthy vs. Suspect Batteries. . . . . . . . . . . . . . 59Table 6-1, Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

8 017-897-B0-001, Rev. A (06/2015)

EM Power Supply Safety NotesSafety Precautions

Battery Safety Notes

• The Power Supply contains more than one live circuit! Even though AC voltage is not present at the input, voltage may still be present at the output.

• The battery string, which provides backup power, contains dangerous voltages. Only qualified personnel should inspect or replace batteries.

• In the event of a short-circuit, batteries present a risk of electrical shock and burns from high current. Observe proper safety precautions.


• Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can result in a fire or possible explosion.

• If replacing the internal auto style fuses, use only the same type and rating of fuse:• F1, F2, F3 Rated Littelfuse Type 0287025.PXCN IR rated 32V, 25A rated 1000A or equivalent

WARNING! ELECTRICAL & FIRE HAZARD

This power supply has been inspected by regulatory authorities for use in various Alpha enclosures. If you are using a non-Alpha enclosure, it is your responsibility to ensure your combination conforms to your local regulatory requirements and the Power Supply remains within its environmental specifications.

ATTENTION:

• Only qualified personnel should service the Power Supply.• Verify the voltage requirements of the equipment to be protected (load), the AC input voltage to the Power

Supply (line) and the output voltage of the system prior to installation.• Equip the utility service panel with a properly rated circuit breaker for use with this Power Supply.• When connecting the load, DO NOT exceed the output rating of the Power Supply.• Always use proper lifting techniques whenever handling units, modules or batteries.

CAUTION!

• Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contains diluted sulfuric acid, which is harmful to the skin and eyes. Emissions are electrolytic and are electrically conductive and corrosive.

• If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your company’s approved chemical exposure procedures.

• Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with a solution of one pound bicarbonate of soda to one gallon of water. Report a chemical spill using your company’s spill reporting structure and seek medical attention if necessary.

• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by authorized personnel using a battery of identical type and rating.


9017-897-B0-001, Rev. A (06/2015)

Battery Maintenance Guidelines

Grounding and Earth Connection Notes

In order to provide a ready, reliable source of backup power, it is necessary to connect the Power Supply to an effective grounding and earthing system. This not only provides for the safety of the service personnel responsible for its operation and maintenance, but also facilitates the proper operation and protection of the equipment within the network. Such a grounding system provides protection with respect to operator safety, system communication and equipment protection.

• Always wear eye protection, rubber gloves and a protective vest when working near batteries. To avoid electrical shock, remove all metallic objects (such as rings or watches) from your person.

• Use tools with insulated handles. Do not rest any tools on top of batteries.• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have

developed on your body.• Use special caution when connecting or adjusting battery cabling. An improperly or unconnected battery

cable can make contact with an unintended surface that can result in arcing, fire, or a possible explosion.


Batteries produce explosive gases. Keep all open flames and sparks away from batteries.

WARNING! FIRE HAZARD

• During maintenance visits, inspect batteries for the following:• Signs of battery cracking, leaking or swelling: The battery should be replaced immediately by

authorized personnel using a battery of the identical type and rating.• Signs of battery cable damage: Battery cable should be replaced immediately by authorized personnel

using replacement parts specified by vendor.• Loose battery connection hardware: Refer to documentation for the correct torque and connection

hardware for the application.• Always replace batteries with those of an identical type and rating. Match conductance, voltage and date

codes.• Do not attempt to remove the vents (valves) from the AlphaCell broadband battery or add water. This is a

safety hazard and voids the warranty.• Apply NO-OX grease on all exposed connections.• Follow approved storage instructions.• Always replace batteries with those of an identical type and rating. Never install untested batteries.• Do not charge batteries in a sealed container. Each individual battery should have at least 13mm of space

between it and all surrounding surfaces to allow for convection cooling.• All battery compartments must have adequate ventilation to prevent an accumulation of potentially

dangerous gas. Never place batteries in a sealed enclosure. Extreme caution should be used when maintaining and collecting data on the battery system. Ensure all enclosure vents and filters are clean and free of debris.

CAUTION!

• When necessary, clean up any spilled electrolyte in accordance with all federal, state, and local regulations or codes.

• Spent or damaged batteries are environmentally unsafe. Always recycle used batteries. Refer to local codes for proper disposal of batteries.

ATTENTION:

10 017-897-B0-001, Rev. A (06/2015)

Low impedance grounding is mandatory for personnel safety and critical for the proper operation of the cable system.


Lightning strikes, grid switching or other aberrations on the power line and/or communications cable have the potential to cause high-energy transients that can damage the powering or communications systems. The most viable method available to protect the system from damage is to divert these unwanted high-energy transients along a low-impedance path to earth. A low-impedance path to earth prevents these currents from reaching high voltage levels and posing a threat to equipment.

The key to the success of lightning protection is single-point grounding so the components of the grounding system appear as a single point of uniform impedance. Two places recommended by Alpha for single-point grounding are connections in the enclosure and connections to earth. Single-point grounding in the enclosure is achieved by bonding all electrical connections to the enclosure, including the connection to earth, as close together on the enclosure as possible. Single-point grounding for the connection to earth is achieved, for example by the proper bonding of the ground rods.

Safety Ground and Earth Connection

The safety ground and earth is a two-part system, comprised of the utility service and the Alpha system.

The utility service:

• As a minimum requirement for the protection of Alpha equipment, the local utility service must provide a low-impedance path for fault current return. In addition, there must be a low impedance bonded path between the Power Supply ground pin and the enclosure.

The Alpha grounding system:

• The Alpha grounding system consists of a low-impedance connection between the enclosure and an Earth Ground (located at least 1.82m away from the Utility Earth connection).

• This impedance between the enclosure and Earth must be 25 Ohms or less at 60 Hertz as measured by AMPROBE Model DGC-1000 or equivalent. The measurement should be made on the wire or ground rod after it exits the enclosure.

• Local soil conditions will determine the complexity of the grounding system required to meet the 25 Ohm (maximum) resistance specified above. For example, a single 2.44m ground rod may be sufficient to meet the requirement. In some cases, a more elaborate system may be required such as multiple ground rods connected by a #6AWG solid copper cable buried .2-.3m below the surface. Where this is not possible, contact a local grounding system expert for alternate methods that will meet the 25 Ohm (maximum) specification.

• All ground rod connections must be made by means of a listed grounding clamp suitable for direct burial or exothermic welding.

Power Output Return

The output return must be securely grounded or bonded to the enclosure.

Communications Grounding

For systems using a transponder, the grounding connection is typically made either through a separate chassis ground block bonded to the enclosure. Please refer to the appropriate communications product manual for installation procedures.

For communication cables, Alpha strongly recommends the use of a surge arresting device electrically bonded to the Alpha Enclosure.

11017-897-B0-001, Rev. A (06/2015)

1.0 Introduction1.1 Alpha EM Power Supply

Fig. 1-1, Alpha EM Power Supply (12V and 24V Models)

The Alpha EM Power Supply features include:• Inverter• Manual Test Button• Wide Input Voltage Range• Embedded Ethernet Communications• Precision Battery Temperature Sensor• Removable MOV• Tamper Port• LRI Port• Auxiliary Output Port• Voltage Select: 48V, 60V, 87V (24V Model Only)

The EM Power Supply powers signal processing equipment in cable television and broadband LAN distribution systems. It provides a critical load with current-limited regulated AC power that is free of spikes, surges, sags and noise.

During AC line operation, the power supply converts AC power into a quasi square wave and regulates it via a ferroresonant transformer at the required output voltage. The output terminal blocks connect the regulated voltage to the load. The power supply also maintains a float charge on the battery string(s).

The inverter switches to standby operation and maintains power to the load when the incoming AC line voltage significantly deviates from normal. During the switch to standby operation, energy in the ferroresonant transformer continues to supply power to the load. In standby mode, the power supply powers the load until the battery voltage reaches a low-battery cutoff point.

The EM Power Supply initiates a smooth, in phase transfer back to utility power after it returns and the frequency stabilizes. This occurs after 10 to 20 seconds. It then begins recharging the battery string.

OUTPUT

ALARM

TEST

ETH

BATTERY TEMP

BATTERY INPUT 12V

LRI

TPR

NOUTPUT

~

AUX230V/30WN

~

OUTPUT

ALARM

TEST

ETH

BATTERY TEMP

BATTERY INPUT 24V

LRI

TPR

V SEL

48 V

60 V

87 V

NOUTPUT 2

~

NOUTPUT 1

~

AUX230V/30WN

~

12 017-897-B0-001, Rev. A (06/2015)

1.0 Introduction, continued

1.1.1 EM Power Supply Layout

Fig. 1-2, EM Power Supply Layout (24V Model)

• AC In: The connection for the AC power cord.• LED Indicators:

• Green LED ON: Output ON with no Alarms• Flashing Green LED: Output ON with Minor or Major Alarms• Double-Flashing Green LED: Self-Test is in progress• Green LED OFF: Output is OFF• Red LED OFF: No Major Alarms• Flashing Red LED: Major Alarms / Output is at Risk• Alternating Red and Green Flashing LEDs: Power Supply Initialization and Battery String Qualification

• Test Button: A manual standby test that can be initiated to verify the state of the batteries and inverter circuitry.• LRI (Local Remote Indicator) Connection Port: A port that is connected to a red LRI lamp or LED circuit (rated at

less than 150mA at 12Vdc) that is located on the outside of enclosures. The Local Remote Indicator connector must match a Tyco 640457-3 (MTA-100 type) connection. This form of status monitoring allows operators to check the operational status of the power supply without opening the enclosure.

• TPR (Tamper) Connection Port: This port allows the user to remotely monitor the power supply for tampering. The Tamper connector must match a Tyco 640457-2 (MTA-100 type) connection.

• Battery Temp Connection Port: This port connects to the PTS (Precision Temperature Sensor) to monitor battery temperatures.

• ETH Connection Port: An Ethernet (RJ45) port that allows the user to remotely monitor the power supply or connect a computer to configure/verify settings on the power supply.

• Battery Input 12V or 24V Connection Port: This port connects the batteries (12V or 24V depending on the model) to the inverter of the power supply.

• Auxiliary Output: This is a 230V/30W output that is available whenever there is output voltage, and can be used to power cable modems.

• Output, or, Output 1 (N = Neutral, ~ = Line): The AC output is marked for easy identification. The Service Power Inserter (SPI) connects into the Output terminal block.

• Output 2 (N = Neutral, ~ = Line) (24V Only): For the EM models with this feature, this output is wired in parallel to Output 1 and provides an additional connection point to the output.

• V SEL, 48V, 60V, 87V (24V Only): These connections allow for configuring of the output voltage. A jumper wire (14 gauge) can be used to connect to “V SEL” and one of the voltage settings (48V, 60V, 87V).

• Handle: A foldable carrying handle for the power supply.

9

8

7

6

5

4

3

21

11

12

13

10

R

1311

10

8

7654

3

2

1

12

9

13017-897-B0-001, Rev. A (06/2015)


1.2 Theory of Operation

1.2.1 AC (Line) Operation

The power supply routes utility power to the primary winding of the ferroresonant transformer through contacts of the transfer isolation relay. Simultaneously, the inverter redirects power for the control circuitry and battery charging. The ferroresonant transformer and AC capacitor form the resonant tank circuit, providing noise and spike attenuation, output short circuit current limiting, and output voltage regulation.

1.2.2 Standby Operation

The power supply enters standby operation for significant AC line drops, spikes or outages. Line isolation relay switches prevent power back-feeding to the utility during the transfer from AC line to standby operation. The power supply monitors the condition of the batteries and the inverter during standby operation. Since a prolonged AC line outage could severely discharge the batteries, resulting in permanent damage, the power supply disables the inverter when the batteries drop to a predetermined cutoff voltage. See Table 1-1.

Table 1-1, Low Battery Cutoff (EOD)

Low Battery CutoffString Low Battery Cutoff

AlphaCell HP Batteries (EOD) (Fixed)String Low Battery Cutoff

Other Batteries (EOD) (Fixed)12V Model 24V Model 12V Model 24V Model10.2VDC(1.70 V/C)

20.4VDC(1.70 V/C)

10.5VDC(1.75 V/C)

21.0VDC(1.75 V/C)

Use a true RMS AC voltmeter to measure the output voltage. Non-RMS reading meters will NOT provide accurate readings for a ferroresonant transformer.

NOTICE:

Battery string composition, size, and load requirements determine duration of standby mode.NOTICE:

14 017-897-B0-001, Rev. A (06/2015)


1.2.3 Charger Modes of Operation

Table 1-2, Charger Modes of Operation

When enabled, the Automatic 30-Minute Refresh will engage upon completion of Accept mode after a single discharge of more than 30% (based on deep discharge algorithm) when the last REFRESH was executed at least 30 days prior.

NOTICE:

Charger Modes of OperationAlphaCell Batteries OTHER Batteries

HP GXL XTV Default Minimum MaximumFloat V/C 2.25 2.27 2.25 2.27 2.10 2.35

Accept V/C 2.35 2.40 2.35 2.40 2.20 2.45Automatic

30-Minute Refresh On/Off

(See Notice)

ON ON OFF OFF OFF OFF

Manual 24-Hour Refresh On/Off

OFF (Programmable)

OFF (Programmable)

OFF (Programmable)

OFF (Programmable) OFF ON

Refresh V/C 2.45 2.45 2.45 2.45 2.40 2.50Rest On/Off

(Programmable) ON (Default) OFF (Default) ON (Default) OFF OFF ON

Temperature Compensation -4mV / °C / cell -5mV / °C / cell -3.3mV / °C /

cell-5mV / °C / cell

(Programmable)0mV / °C /

cell-5mV / °C /

cell

15017-897-B0-001, Rev. A (06/2015)


The type of battery (3-stage - other; 4-stage - AlphaCell GXL or XTV; or 5-stage - AlphaCell HP) used in the system determines the EM Power Supply’s temperature compensation setting.

3-Stage Charger Modes (BULK/ACCEPT/FLOAT):

The 3-stage charge is applied to battery types other than the AlphaCell GXL, AlphaCell XTV and the AlphaCell HP.

BULK charge is a “Constant Current” charge. As the charge is returned to the battery, the voltage increases to a specific threshold (the ACCEPT mode voltage). The charger then switches to ACCEPT mode. The BULK charger mode generally returns the battery charge state to 80 percent of rated battery capacity.

ACCEPT charge is a “Constant Voltage” charge. This voltage is temperature-compensated to ensure longer battery life and proper completion of the charge cycle. This cycle is complete when the charging current into the battery becomes less than 0.5A or approximately six hours elapses from the time ACCEPT mode was entered, at which time the charger switches to the FLOAT mode of operation.

FLOAT charge is a temperature-compensated charge. During FLOAT mode, the battery is fully charged and ready to provide backup power. The charger provides a small maintenance charge to overcome the batteries self-discharge characteristics and other minor DC loads within the power supply.

Fig. 1-3, 3-Stage Charger Modes

If a battery type other than an AlphaCell is installed, it is the responsibility of the technician to review the proper charging specifications for the battery used. See Section 1.2.3, Charger Modes of Operation for instructions on initiating REFRESH Mode.

NOTICE:

Battery Voltage

Battery Current

BULKConstant Current Mode (10A max) until battery voltage reaches the ACCEPT level (2.40V/cell)

ACCEPTConstant Voltage Mode (2.40V/cell) until battery current demand drops below .5A or time out based on 4 minutes per Ah battery capacity

FLOATConstant Voltage Mode (2.27V/cell)

16 017-897-B0-001, Rev. A (06/2015)


4-Stage Battery Charger (BULK/ACCEPT/FLOAT/REST)

This preset value is applied to AlphaCell XTV batteries.

A REST stage is added, after BULK, ACCEPT and FLOAT states.

REST: Charger is turned off (if ENABLED) and leaves the batteries without external voltage applied on the battery.Removing charged voltage and allowing the battery to sit in an open circuit environment maximizes the battery life byeliminating the chance of overcharging individual cells inside the 12V battery.

After any discharge/recharge cycle, once the charger reaches FLOAT mode, it will wait 24 hours in FLOAT mode beforegoing to REST mode. On a daily basis, without any discharge cycle, the batteries will be in FLOAT for 25% and REST(charger off) for 75% (6 hours float, 18 hours rest).

REST mode is terminated if voltage drops to less than 2.12VPC. Upon exiting REST mode due to a voltage below2.12VPC, a BULK/ACCEPT cycle will be initiated. The battery charger voltage is temperature-compensated at -0.004VDC per cell per degree C to ensure a safe battery cell voltage and to maximize battery life.


Battery Voltage

Battery Current



FLOATConstant Voltage Mode (2.25V/cell)Initial 24 hours

RESTCharger Off Open Circuit Voltage18 hours

FLOAT AND REST CYCLESCharger off for 18 hoursFloat for 6 hours

A manual REFRESH charge mode is recommended to be applied to all new batteries upon installation.NOTICE:

If an external load is connected to the batteries, such as a cable modem, Rest Mode must be programmed to OFF.NOTICE:

17017-897-B0-001, Rev. A (06/2015)


4-Stage Battery Charger (BULK/ACCEPT/REFRESH/FLOAT):

This preset value is applied to AlphaCell GXL batteries.

A 30-minute REFRESH charge is added, after BULK and ACCEPT states, before dropping down to FLOAT state, when the batteries are discharged more than 30% and it has been more than 30 days since the last REFRESH charge.

REFRESH mode “boosts” the individual cell voltage of batteries that may have been in storage before they were placed on permanent FLOAT. Refresh can be initiated manually via menu selection or automatically when the battery date code is updated. The REFRESH charge is a one-time, 24-hour charge to raise individual cell voltage to 2.45VDC, and may bypass the BULK and ACCEPT states if the batteries are fully charged. The batteries are temperature-compensated to ensure safe battery cell voltage and maximum battery life.


Battery Voltage

Battery Current



FLOATConstant Voltage Mode (2.27V/cell)

REFRESHConstant Voltage Mode (2.45V/cell) for 30 minutes


18 017-897-B0-001, Rev. A (06/2015)


5-Stage Battery Charger (BULK/ACCEPT/REFRESH/FLOAT/REST):

This preset value is applied to AlphaCell HP batteries.REST: Charger is turned off (if ENABLED) and leaves the batteries without external voltage applied on the battery. Removing charged voltage and allowing the battery to sit in an open circuit environment maximizes the battery life by eliminating the chance of overcharging individual cells inside the 12V battery.

After any discharge/recharge cycle, once the charger reaches FLOAT mode, it will wait 24 hours in FLOAT mode before going to REST mode. On a daily basis, without any discharge cycle, the batteries will be in FLOAT for 25% and REST (charger off) for 75% (6 hours float, 18 hours rest).

REST mode is terminated if voltage drops to less than 2.12VPC. Upon exiting REST mode due to a voltage below 2.12VPC, a BULK/ACCEPT cycle will be initiated. The battery charger voltage is temperature-compensated at -0.004VDC per cell per degree C to ensure a safe battery cell voltage and to maximize battery life.


Battery Voltage

Battery Current



FLOATConstant Voltage Mode (2.27V/cell)Initial 24 hours

-REFRESHConstant Voltage Mode (2.45V/cell) for 30 minutes

RESTCharger Off Open Circuit Voltage18 hours


If an external load is connected to the batteries, such as a cable modem, Rest Mode must be programmed to OFF.NOTICE:

19017-897-B0-001, Rev. A (06/2015)

2.0 Installation2.1 Installation ProcedureThe Alpha EM Power Supply can be shelf-mounted within a variety of Alpha enclosures

2.1.1 Pre-installation Inspection

1. Remove the power supply from the shipping container. Confirm the power supply, including the Precision Temperature Sensor (PTS) and all other ordered options are included.

2. During shipping, components might shift. Carefully inspect the power supply and other contents for possible shipping-related damage, such as loosened or damaged connectors. If any items are damaged or missing, contact Alpha Technologies or the shipping company immediately. Most shipping companies have a short claim period.

3. Complete a pre-installation inspection before installing the power supply.

Read the Safety Precautions and Grounding Connection Notes before installing the power supply.

CAUTION!

Use the original shipping container if the power supply needs to be returned for service. If the original container is not available, make sure the unit is well packed with at least 77mm of shock-absorbing material to prevent shipping damage.

NOTICE:

Alpha Technologies is not responsible for damage caused by improper packaging of returned units. Do not use polystyrene foam-based packing material.

CAUTION!

20

2.0 Installation, continued

017-897-B0-001, Rev. A (06/2015)

2.2 EM Power Supply Start-Up Procedure

2.2.1 Parts and Connection Ports Overview

Fig. 2-1, Overview of EM Power Supply

Battery Connector to Inverter

Ethernet Port (Web Page Interface)

Output 1 Terminal Block

Auxiliary Terminal Block

Removable MOV

Battery Terminals (Positive Terminal On Left)11

10

12

11 11

9

12LED Indicators

Self-Test Button

Tamper Switch Connector

Precision Temperature Sensor (PTS)

1

2 1

4

3

5

4

6

5

8

9

7

8

10

3

Service Power Inserter (SPI)

LRI Interface to Power Supply2

7

6

21


017-897-B0-001, Rev. A (06/2015)

2.2.2 Battery Installation Options and Wiring Diagram

Load batteries into cabinet with the positive terminals (+) facing forward. Batteries are numbered 1 through 2, from right to left.

Fig. 2-2, 12-Volt Battery Wiring Diagram

Fig. 2-3, 24-Volt Battery Wiring Diagram

POS

NEG

R E D (+)

B L A C K (-)

POS

NEG

POS

NEG

R E D (+)

B L A C K (-)

Verify battery voltage, cable color, connection and polarity are correct before proceeding.


22


017-897-B0-001, Rev. A (06/2015)

Fig. 2-4, Precision Temperature Sensor (PTS), p/n 746-331-20

2.2.3 Threaded Insert Terminals

Battery hardware and torque specifications are specific to the battery manufacturer’s specifications. See Table 4-1 for AlphaCell battery specifications.

Fig. 2-5, Battery Terminal/Fuse Bolt Stack-Up

PTS

Battery Terminal

Split Washer

Split Washer

Flat Washer

Flat Washer Battery Cable

Battery Cable Flat Washer

SpacerFuse

Threaded insert terminals require the use of 19mm bolts. The use of 25.4mm bolts will seriously damage the battery. The only exception is the terminal with the large spacer for the in-line fuse link. Apply NO-OX grease on all exposed connections.

CAUTION!

23


017-897-B0-001, Rev. A (06/2015)

2.2.4 Installation Procedure

Refer to section 2.2.1 Parts and Connections Overview for location of the connections during installation.

1. Wire the battery cable kit and PTS as shown in Section 2.2.2 and 2.2.3. (Do not connect the battery cable to the EM Power Supply)

2. Connect the Precision Temperature Sensor to the port on the front of the EM Power Supply.3. (If applicable) Route the Local/Remote Indicator cable through the shelf and connect it to the LRI port on the EM

Power Supply.4. (If applicable) Connect the Tamper cable to the port on the front of the EM Power Supply (for the installation of the

Tamper Switch see the manufacturer’s installation instructions).5. Remove the cover on the terminal block and connect the Network Load to the Output 1 terminal block (See Fig.

2-6). Torque the screw (5.0 kgf.cm) on the terminal block to secure the wires. 6. (If applicable / 24V Only) With the terminal block cover removed, connect the Network Load to the Output 2

terminal block (See Fig. 2-6). Torque the screw (5.0 kgf.cm) on the terminal block to secure the wires.7. (If applicable) With the terminal block cover removed, connect the auxiliary load to the Auxiliary Output terminal

block. Torque the screw (5.0 kgf.cm) on the terminal block to secure the wires.8. (If applicable / 24V Only) Using the included jumper wire (14 gauge), connect one end to the V SEL port, and

the other end into the desired voltage: 48V, 60V, or 87V. (It is likely that this is already configured to the proper voltage.)

9. After wiring the terminal block, screw the terminal block cover back into place.10. With the utility breaker turned off, plug in the line cord to the utility outlet and the EM Power Supply.11. Connect the battery cable to the Battery Input connector on the EM Power Supply.12. Turn on the utility breaker.13. Verify no alarms are present after power up initiation (it may take up to 60 seconds for alarms to clear). Alarms are

verified via the flashing Alarm LED or the web interface.14. If the alarms do not clear after 60 seconds, access the web interface for further information (see section 2.3.1

Local Web Interface Access).15. Once the unit is running on line voltage (solid green Output LED), perform a Self Test by pressing and holding the

test button for 1-2 seconds. The green Output LED will signify it is in test mode by flashing twice for a set period of time.Wait for the Output LED to go back to a solid green state. This signifies that the self test is finished.

16. Perform a standby test by shutting off the utility breaker and verifying that the unit goes into standby and supports the load.

17. Re-apply AC power by turning on the utility breaker. Verify that the unit goes into Line Mode.

Before applying power, verify that the power supply rating is matched to AC input utility. Verify a low-resistance ground is installed in accordance with your local electrical regulatory authority.

NOTICE:

Properly install and test all batteries, battery connections and battery cables before connecting them to the power supply.

CAUTION!

During a no-load startup, the power supply may reduce output voltage to 75-80% of rated output voltage until a load of greater than 1.5A is applied.

NOTICE:

24


017-897-B0-001, Rev. A (06/2015)

Fig. 2-6, Removal of the Terminal Block Cover (12V and 24V)

R

R

R

R

R

R

R

R

25


017-897-B0-001, Rev. A (06/2015)

2.3 EM Power Supply Web InterfaceThe EM Power Supply provides embedded Ethernet communications for connecting locally or remotely with a computer, allowing the user to configure the settings in the power supply via a Web interface.

2.3.1 Local Web Interface Access

The EM Power Supply’s Ethernet port is used as a local connection point, allowing the user to connect directly to the EM Power Supply Web interface. This interface allows the user to verify/configure common communication parameters and view the status of the power supply and battery values. The Ethernet port on the EM Power Supply is a fully functional standard Ethernet port, capable of providing all the functionality of any standard Ethernet connection.

To access the EM Power Supply Web interface locally utilizing a Web browser, use the following procedure:

1. Connect a standard Ethernet cable (CAT5 or better) between the EM Power Supply Ethernet port (ETH) and a laptop or computer’s network interface port.

2. Launch a Web browser.3. Enter the default IP address (192.168.200.1) of the EM into the Web browser’s address field.4. The power supply’s Web interface will load (Fig. 2-7).5. At the bottom of the Web page, select the preferred language.

Fig. 2-7, Local EM Power Supply Web Interface

The following web browser settings should be ‘enabled’ for proper rendering/download of the web pages:• JavaScript• Cookies• Activex Controls• Downloads• Active Scripting• Show Pictures

These settings are typically enabled in the web browser by default.

NOTICE:

26


017-897-B0-001, Rev. A (06/2015)

Use the following procedure to configure a static IP address on a laptop or computer with the Windows 7® operating system:

1. Click the Start button (lower left button on most Windows 7® computers).2. When the window pops up, click Control Panel (usually about half way down the second column).3. Click Network and Sharing Center.4. Click Local Area Connection.5. Click the Properties option.6. In the dialog box (Fig. 2-8), select Internet Protocol (TCP/IPv4) and then click the Properties button.7. The Internet Protocol (TCP/IPv4) Properties dialog box will open. (Fig. 2-9). 8. Record the existing IP address and Subnet mask in order to later return the computer to its original state.9. Select “Use the following IP address”. Enter the values as shown (i.e. IP address 192.168.200.10 and Subnet

mask 255.255.255.0). 10. Click the OK button and attempt to connect to the EM Power Supply once again using the default IP address in

your Web browser.11. To restore network settings, repeat Steps 1 through 7, then click “Obtain an IP address automatically” or “Use the

Following IP address” (based on the original settings recorded in Step 8), then click “Close”.

If the home page of the EM Power Supply web interface does not load using the default IP address, the network configuration on the computer that is being used to connect to the EM Power Supply may require a temporary static IP address to be configured.

NOTICE:

Fig. 2-8, Windows 7 Local Area Connection Screen

Fig. 2-9, Windows 7 Internet Protocol (TCP/IPv4) Screen

27


017-897-B0-001, Rev. A (06/2015)

Use the following procedure to configure a static IP address on a laptop or computer with the Windows 8® operating system.

1. Right click the Windows® Logo (lower left button on most Windows 8® computers).2. Scroll through the list that appears and click Network Connections.3. Right click on Ethernet and select Properties.4. The Ethernet Properties dialog box will open.5. In the dialog box (Fig. 2-10), select Internet Protocol (TCP/IPv4) and then click the Properties button.6. The Internet Protocol (TCP/IPv4) Properties dialog box will open. (Fig. 2-11). 7. Record the existing IP address and Subnet mask in order to later return the computer to its original state.8. Select “Use the following IP address”. Enter the values as shown (i.e. IP address 192.168.200.10 and Subnet

mask 255.255.255.0). 9. Click the OK button and attempt to connect to the EM Power Supply once again using the default IP address in

your Web browser.10. To restore network settings, repeat Steps 1 through 7, then click “Obtain an IP address automatically” or “Use the

Following IP address” based on the original settings recorded in Step 8, then click “Close”.

For configuration of the EM Power Supply, see Section 3.5: Configuring the EM Power Supply.NOTICE:

Fig. 2-10, Windows 8 Ethernet Properties Screen

Fig. 2-11, Windows 8 Internet Protocol (TCP/IPv4) Screen

28


017-897-B0-001, Rev. A (06/2015)

2.4 EM Power Supply Communications

2.4.1 System Diagram

Fig. 2-12, Representative System Arrangement

1. The EM contains both SCTE-HMS Management Information Base (MIB) and the proprietary Alpha MIB tables. The SCTE-HMS MIBs are industry standard MIB tables that store power supply data from the CIB tables. The Alpha MIB contains all of the data of the SCTE-HMS MIBs. It also contains additional power supply settings and values, and EM configuration values.

2. Power supply parameters can be monitored locally using a personal computer and a standard Ethernet cable.3. The EM transmits data via Ethernet to a modem which bridges to the customer network topology.4. A Network Interconnection Device may be required as a bridge between the twisted pair Ethernet from the EM

and the customer network, such as DOCSIS, Ethernet Passive Optical Network (EPON), or Ethernet over Coax (EoC). Network Interconnection Devices include, but are not limited to, DOCSIS modems, routers (wireless), bridges, switches, and other similar devices.

5. The Dynamic Host Control Protocol (DHCP) server must be provisioned with the EM’s MAC Address.6. The optional Configuration File and firmware files will be placed by the user in the Root Directory of the Trivial File

Transfer Protocol (TFTP) Server.7. A Network Management System (NMS) or MIB Browser allows remote monitoring of parameter values and

changing of settings in SNMP MIB tables. SCTE-HMS and Alpha MIBs must be installed in the browser. Alarms and traps can be set and monitored.

8. The power supply may be accessed remotely through its Web Page by placing its IP address into a standard Internet Web browser.

Power Supply

Local Computer

Ethernet Network

Network Interconnection Device

DHCP Server TFTP Server

SNMP-based Network Management System

Web Browser

1

2

4

5 6

8

3

7

1

2

34

5

6

7

8

29


017-897-B0-001, Rev. A (06/2015)

2.4.2 Network Connectivity

Data from the power supply is accessed and managed through the EM’s IP address, which is assigned by the DHCP server. Consequently, the Network Management System (NMS) that monitors the power supplies must have access to the EM through the same network.

Different networks use different security methods to ensure network integrity, but common considerations are:

• MAC filtering may have to be modified to allow registration of addresses starting with 00:90:EA. • For SNMP access, UDP ports 161 and 162 must not be blocked.• For TFTP access, port 69 must not be blocked.• For HTTP access, port 80 must not be blocked.• For SNTP access, port 37 must not be blocked.• Firewalls must allow TFTP, DHCP, SNMP communication to the EM. • If the address of the TFTP server is different than the DHCP server, the response from the DHCP server must

contain the TFTP address.

2.4.3 System Configuration and Installation

The setup for the EM’s Communications features is comprised of two steps:

1. Configuring the Network: Provisioning the DHCP Server with the Power Supply’s MAC Address.2. Setting Options: The EM is designed for out-of-the-box, “plug and play” operation, but non-default settings such

as SNMP trap destination addresses may be required for the Network Management System (NMS). SNMP trap addresses can be set automatically via the optional configuration file atiem01.cfg (See Section 2.6, Setting Communication Options, for Details).

These steps can be performed independently of one another. However, configuring the network prior to field installation will allow the installation to be verified while personnel are still on-site. Performing field installation before network configuration might result in additional field service calls to correct mistakes.

Carefully read the following section in order to understand the dependencies within the system before performing system configuration or hardware installation.

30


017-897-B0-001, Rev. A (06/2015)

2.4.4 EM Start-Up and Reboot Routine

Fig. 2-13, Start-Up Routine: Order of Operations

Fig. 2-13 above, read left-to-right, indicates the order of operations as the Power Supply establishes communications. There are certain conditions that must exist for each step to occur, resulting in successful data monitoring and management. The numbers below correspond to the numbered arrows above.

Table 2-1, Ethernet LEDs and Indications

Network Management System

MIB Browser

Web Browser

Power Supply



Plant Network

Firewalls

TCP

/IP N

etw

ork

TCP

/IP N

etw

ork

Routers

Switches

TFTP Server

TOD Server

DHCP Server

5

4

3

2

1

Ethernet Port LEDs and IndicationsBottom Ethernet LED

Link / Activity LED DefinitionNo Link Off

Link OnActivity Blinking

Top Ethernet LEDNetwork Setup LED Definition

Self-test button active at startup Fast Flashing (1/4s ON, 1/4s OFF)Waiting for a DHCP address Slow Flashing (1/2s ON, 1/2s OFF)

DHCP address received and assigned Solid ONNo Link One 1/4s blink in 8 second intervals

Local address (192.168.200.1) Two 1/4s blinks in 8 second intervalsStatic address assigned Three 1/4s blinks in 8 second intervals

No address assigned OFF

31


017-897-B0-001, Rev. A (06/2015)

2.5 Network Configuration

2.5.1 Provisioning the DHCP Server with the MAC Addresses

Provision the DHCP server with the EM’s MAC Address.

The MAC Address is located in two places: on top of the EM power supply and on the packing slip.

Fig. 2-14, MAC Address Label

2.5.2 Network Configuration with atiem01.cfg file

The use of atiem01.cfg is optional and provides an automated method for deploying Alpha proprietary SNMP MIB parameters, such as SNMP Trap Destination Addresses, to field-installed EM power supplies.

1. Creating atiem01.cfg

To create the atiem01.cfg file, enter the desired SNMP OIDs and values from the Alpha MIB into a Type-Length-Value (TLV) file as TLV type-11 entries using a TLV editor as TLV type-11. The file must be named “atiem01.cfg” and placed in the root directory of the TFTP server. EM settings are updated according to values defined in this file at startup and after every 24 hours of operation.

Sample atiem01.cfg entries:

SNMP MIB Object (11) [Len = 24]: atiMgmtSnmpTrapAddress.1 / 10.20.30.40SNMP MIB Object (11) [Len = 24]: atiMgmtSnmpTrapAddress.2 / 10.20.30.50SNMP MIB Object (11) [Len = 23]: atiMgmtSysTamperPolarity.0 / 1

MAC Address Label

32


017-897-B0-001, Rev. A (06/2015)

2. Downloading atiem01.cfg

The EM will attempt to download the proprietary configuration file atiem01.cfg from a TFTP server at the IP address of the DHCP server. It will attempt to download at startup and every 24 hours thereafter. In many networks, the TFTP server is blocked or disabled, preventing the EM from being able to download the file. In this case, either enable access to the TFTP server or use one of the alternate methods for specifying the name and location of the configuration file.

3. Changing Default atiem01.cfg Download Settings

The following table explains the download options available for the atiem01.cfg file.

Table 2-2, atiem01.cfg Download Options

2.6 Setting Communication OptionsCommunications Settings may be changed through the Alpha MIB remotely using an SNMP MIB browser or automatically by placing the SNMP parameters into the proprietary configuration file atiem01.cfg

Table 2-3, Communications Module Communication Parameters

atiem01.cfg Download OptionsParameter Comments Value Search Order

DHCP Server IPServer or Relay Agent Address from DHCP lease (No Change Neccessary)

As Set 1

DHCP Option 54 Server IP

Server or Relay Agent Address from DHCP lease As Set 2

DHCP Option 66 Server Name DHCP IP Server IP from DHCP lease As Set 3

DHCP Option 66 Server IP Server Address from DHCP lease As Set 4

Before setting options, verify UDP ports 37, 69, 161, 162 and TCP port 80 are not blocked.NOTICE:

Communications Module Communications ParametersSNMP Parameter Type Description Value

atiMgmtSnmpTrapOnNormalOID: 1.3.6.1.4.1.926.1.3.1.5.1.0 Integer Send SNMP trap when alarmed

condition returns to normal state1 = Disabled

2 = Enabled (Default)

33


017-897-B0-001, Rev. A (06/2015)

2.7 SNMP Community StringsThe power supply’s community strings used for SNMP communication to the EM can be configured by the operator. The default power supply’s read-only community string is AlphaGet. The default read-write community string is AlphaSet. These settings can be configured via the EM Setup File (atiem01.cfg) or remotely using SNMP by including the parameters below:

Table 2-4, Community String Setup Parameters

2.8 SecurityAdditional SNMP security to the EM proprietary MIBs may be required if the power supply data is exposed on the public network, to prevent packet sniffing and community string deciphering.

A Secure Access List method provides SNMP security to the EM.

2.8.1 Security Using the Secure Access List

The EM provides an alternative method of providing additional SNMP security by limiting access to its IP address. The Secure Access List method limits remote SNMP access to four IP addresses. Only the IP addresses listed in the SNMP Access Table are able to read or write to the Alpha MIB parameters from the public network.

The IP address entries in the SNMP Access Table can be set through the EM Setup File (atiem01.cfg), or remotely using SNMP by including the following Alpha MIB parameters:

Table 2-5, Secure Access Table Parameters

Community String Setup ParametersMIB Parameter Object ID Description Value

atiMgmtSnmpCommGet 1.3.6.1.4.1.926.1.3.1.4.1.0 Read Community String AlphaGet(default)[desired value]

atiMgmtSnmpCommSet 1.3.6.1.4.1.926.1.3.1.4.2.0 Read / Write Community String AlphaSet(default)[desired value]

Secure Access Table ParametersMIB Parameter Object ID Description Value

atiMgmtSnmpAccessTable 1.3.6.1.4.1.926.1.3.1.2 Table of SNMP Access Addresses Object Identifier

atiMgmtSnmpAccessAddress.1 1.3.6.1.4.1.926.1.3.1.2.1.2.1 SNMP Access IP Address #1 0.0.0.0 (Default)atiMgmtSnmpAccessAddress.2 1.3.6.1.4.1.926.1.3.1.2.1.2.2 SNMP Access IP Address #2 0.0.0.0 (Default)atiMgmtSnmpAccessAddress.3 1.3.6.1.4.1.926.1.3.1.2.1.2.3 SNMP Access IP Address #3 0.0.0.0 (Default)atiMgmtSnmpAccessAddress.4 1.3.6.1.4.1.926.1.3.1.2.1.2.4 SNMP Access IP Address #4 0.0.0.0 (Default)

34


017-897-B0-001, Rev. A (06/2015)

2.9 Configuring a Static IP AddressThe EM IP, Subnet Mask and Gateway Addresses can be set either via DHCP (default) or manually, either through the web page or via the below SNMP settings:

Table 2-6, Static IP Address Settings

2.9.1 Recovering from an Incorrect Static IP Address

To recover from configuring an incorrect Static IP Address

1. Press and hold the self-test button while the EM is powered up until the Ethernet port’s top LED begins flashing rapidly.

2. The power supply will then resume the normal IP address assignment (192.168.200.1).3. If no SNMP or HTTP access is detected within 1 minute, the EM will begin requesting an address via DHCP.

After configuring the Static settings the Communications Module must be reset in order for the settings to take effect.

NOTICE:

Static IP Address SettingsMIB Parameter Object ID Description Value

atiMgmtSysMonitoringCpeStaticMode 1.3.6.1.4.1.926.1.3.2.2.5.2.1.0 Method of IP Address Assignment

1 = DHCP2 = Static

atiMgmtSysMonitoringCpeStaticAddress 1.3.6.1.4.1.926.1.3.2.2.5.2.2.0 Static IP Address 0.0.0.0 (Default)atiMgmtSysMonitoringCpeStaticMask 1.3.6.1.4.1.926.1.3.2.2.5.2.3.0 Static IP Subnet Mask 0.0.0.0 (Default)

atiMgmtSysMonitoringCpeStaticGateway 1.3.6.1.4.1.926.1.3.2.2.5.2.4.0 Static IP Gateway 0.0.0.0 (Default)

35017-897-B0-001, Rev. A (06/2015)

3.0 Operation3.1 Start-Up and Test

3.1.1 Self Test Operation

1. The power supply should be operating correctly (solid green Output LED) with no alarms present.2. Press the TEST button on the front of the power supply to start the Self Test. The test will run for a preset time. 3. While in Self Test mode (Double-Flashing Output LED), output voltages should appear within the ranges listed in

Table 3-1. To cancel a Self Test in progress press the TEST button a second time.

Table 3-1, AC Output

3.2 Automatic Performance TestThe power supply periodically performs an Automatic Self Test. It verifies the state of the batteries and inverter circuitry. The automatic test feature has several parameters that determine the frequency and duration of automatic tests. A running test may be halted manually by pressing the TEST button.

The automatic test feature is on by default. To turn auto-test off, change Test Interval to 0 days in the EM Configuration Menu of the Web interface. Auto-test may be enabled at any time by changing the test interval to any numerical value (excluding “0”). The default test interval is 30 days.

The test sequence process begins with a check to verify the batteries are connected. If the batteries are discharged or not connected, the power supply does not attempt to operate in inverter mode, preventing a drop of the load.

Next, the power supply switches to standby mode for a pre-programmed period. Successful completion of a test sequence indicates the unit is operating normally in standby mode, the battery voltage did not drop below a preset threshold and the output was stable throughout the test. Failure of a test is indicated by a Self Test Fail alarm, which can be cleared by subsequently running a successful test for at least one minute.

In addition to automatic testing, the operator can manually initiate a Self Test. A running test may be halted at any time by pressing the TEST button on the front panel (below the OUTPUT and ALARM LEDS).

The Test Inhibit command prevents an automatic test scheduled to occur in the next week. This command is useful if periodic maintenance of the power supply is scheduled close to the next scheduled automatic test. Use this feature when inclement weather might cause a utility failure. The Test Inhibit command functions in the following manner:

Possible measurement points for output voltage are the output terminal block screws, an unused output terminal block, or the SPI coax.

NOTICE:

Upon startup, the EM Power Supply must validate the battery string. This can take a few minutes on the 24V unit. During this time, a Self Test cannot be initiated.

NOTICE:

Output Voltage Regulation (% Range)Voltage Setting Voltage Range

48VAC 45.6VAC / 50.4VAC60VAC 57VAC / 63VAC87VAC 82.7VAC / 91.3VAC

36

3.0 Operation, continued

017-897-B0-001, Rev. A (06/2015)

1. If an outage occurs when the Countdown is less than 7 days that meets the self-test criteria (Inverter Mode Time > Test Duration, no Output Fail and no Low Batt Warning), set the Test Countdown to the Test Interval (default = 30 days).

2. If the Test Countdown is less than 7 days and the Test Inhibit is manually set, set the Test Countdown to the Test Interval plus the remaining days on the countdown to avoid synchronizing the self-test time on multiple power supplies.

3. If the Outage less than 5 minutes, there is no change to the Test Countdown.4. If the Outage is greater than 5 minutes, but does not meet the self-test criteria, set the Test Countdown to 7 days.

3.3 Providing Power via Portable Generator or InverterIn the event of an extended utility failure, an external AC power source can provide backup power to the system. This backup power enables the power supply to continue charging the batteries ensuring uninterrupted service to the network. Follow the documentation and connection procedures listed below.

3.3.1 AC Powering

Should it become necessary to power the CATV system with a portable AC generator, truck-mounted AC generator or truck-mounted inverter, follow the procedures below for the protection of service personnel and powering system equipment.

Connection Procedure:

1. Determine if there is output power to the system by measuring at the output terminal block, or via the Web interface. If there is still power to the system, check the battery voltage on the Web interface: • If the battery voltage is greater than 11.5VDC (12V Model) or 23.0VDC (24V Model), then approximately one

hour remains to complete the changeover to generator power before the cable system loses power to its customers.

• If the battery voltage is less than the previous numbers, move rapidly as there is not much time until the system fails. However, exercise caution as there are dangerous voltages in the system.

2. Verify the AC Input breaker from the utility powering system is in the OFF position. This ensures that if power returns suddenly, there will not be a surge in power. This also ensures when the generator is connected it will not put AC voltage back onto the power lines.

3. Properly ground the generator by connecting a #6 AWG wire from the grounding lug on the output panel of the generator to either a driven ground rod or the strand ground on the pole to which the power supply is mounted. If working with a ground-mounted power supply, locate the grounding point inside the enclosure and clamp on to that point.

4. After the generator is properly grounded, unplug the power supply from the convenience outlet inside the enclosure and plug the power supply input cable into the generator output. Use an outdoor-rated approved extension cord. Recommend min 14AWG for 230V installations.

5. Start and operate the generator according to the generator operation manual.6. After the power from the generator is applied to the power supply, use the Web interface to increase the

Frequency Input Tolerance to ±6Hz from the normal ±3Hz, inhibiting the power supply from switching to battery backup if the generator occasionally does not operate on the proper frequency. It is not uncommon for smaller (4 kilowatt or less) sized generators to get “off frequency” due to the step loading of the power supply.

Grounding the generator is mandatory for safety and for proper operation of the power supply.

CAUTION!

37


017-897-B0-001, Rev. A (06/2015)

3.3.2 Using a Truck-Mounted Inverter or Generator

To use a truck-mounted inverter or generator, follow the steps listed in Section 3.3.1, AC Powering with the additional step of grounding the truck. Run the ground wire from an unpainted point on the truck chassis to either a driven ground rod or strand ground to complete the grounding circuit. The rubber tires on the truck insulate it from being grounded in all but the most exceptional circumstances.

3.4 Resumption of Utility Power

1. Before turning on the AC voltage input breaker, use a voltmeter to verify the input voltage is within specifications.2. When the proper voltage is present, verify the battery voltage indicated on the Web interface is greater than

11.5VDC (12V Model) or 23.0VDC (24V Model). Disconnect the power supply from the generator output and plug the power supply input cord into the convenience outlet within the enclosure. The power supply operates on battery backup for this short period of time, but exercise caution during this changeover as the grounding circuit to the power supply is broken.

3. If the batteries are at or below the low voltage cutoff, then the power supply will NOT transfer to battery backup and there will be a momentary power outage to the cable system while you make this changeover.

4. Turn on the AC input power.5. Shut down the generator and remove the grounding system. If necessary use the Web interface to return the

Frequency Input Tolerance back to the normal ±3Hz range.

Ground the vehicle before operating a truck inverter or truck-mounted generator. Failure to do so places service personnel at risk for electric shock.


Use caution when disconnecting and reconnecting a generator to utility power. Dangerous voltages are present.


Exercise care to ensure that both powering systems are not connected at the same time or damage to the power supply and the generator may result.

CAUTION!

• The Power Supply must be serviced by qualified personnel.• Use heavy gloves when handling a unit that has recently been taken out of service. The ferroresonant

transformer generates heat that may cause burns if handled with bare hands.• Alpha Technologies is not responsible for battery damage due to improper charger voltage settings.

Consult the battery manufacturer for correct charger voltage requirements.• Always wear safety glasses when working with batteries.

CAUTION!

38


017-897-B0-001, Rev. A (06/2015)

3.5 Configuring the EM Power SupplyAll operational functions, system testing, menus and alarms are available via the EM Power Supply Web interface (See section 2.3 for connecting to the Web interface). Descriptions of the menu functions are as follows:

Table 3-2, Main Menu Functions

Main Menu FunctionsMenu Function

POWERClicking on the POWER hyperlink opens the Power Information and Configuration Menu. From this menu, the operator can view the current Power Supply configuration and adjust parameters.

BATTERYClicking the BATTERY hyperlink opens the Battery Information and Configuration Menu. From this menu, the operator can view battery information and/or modify battery parameters.

ALARMClicking the ALARM hyperlink opens the Alarm Menu. From this menu, the operator can view any existing alarms (major or minor) currently effecting the EM Power Supply.

COMMS (Communications)

Clicking the COMMS hyperlink opens the Communication Information and Configuration Menu. From this menu, the operator can view and/or modify COMM parameters.

39


017-897-B0-001, Rev. A (06/2015)

Default Username and Password

• Username: Alpha• Password: AlphaSet

Fig. 3-1, Web Interface, Login Notification

The initial page on the EM Power Supply Local Web Interface displays general information about the power supply and allows configuration of the page’s displayed language:

Fig. 3-2, Web Interface, HOME Menu

When a change is made to the EM Power Supply Web Interface and the “Save” button is clicked, the Web page will prompt the user for a login and password.

NOTICE:

40


017-897-B0-001, Rev. A (06/2015)

Clicking on the POWER hyperlink opens the Power Information and Configuration Menu:

Fig. 3-3, Web Interface, POWER Menu

• Self Test: When programmed to “On”, the power supply automatically starts a Self Test. Range: On / Off.• Test Interval (Days): The Test Interval becomes active when programmed by the operator (or when the unit runs in

inverter mode for more than 5 minutes). The power supply delays the start of a scheduled Self Test for seven days if the test countdown is less than seven days. Range: 0 - 365 Days.

• Test Countdown (Days): The number of days remaining before the next scheduled automatic Self Test initiates. Range: 0 - 365 Days.

• Test Duration (Minutes): This sets the number of minutes of a battery maintenance cycle test. This applies to automatically or manually initiated tests. Range: 5 - 180 Minutes.

• Enclosure Fan: This setting allows the user to know if the power supply is in an enclosure with a fan Range: Yes / No.

• Discharge Level: This is the setting for the amount of battery discharge to be performed during self-test, either manual or automatic. “TIMED” is the default and will use the time set in the Test Duration parameter. Deep discharge levels of 10%, 20%, 30%, 40% and 50% may be set. When set, the batteries will be discharged by the specified capacity percentage one time. Upon completion, the setting will revert back to Timed. Range: Timed, 10 - 50%.

• Frequency Range (Hz): This limit establishes the acceptable input frequency range outside of which standby operation is initiated. Range: 1 - 6 Hz.

• RMODE: An inverter control that limits the peak output voltage. Range: Enable / Disable.• Input Limit (Amp): When this limit is exceeded, the maximum battery charger current will be reduced to stay within

this limit. Range: (12V) 0 - 4, (24V) 0 - 7.• Set Defaults: When programmed to YES, the programmable data levels (with the exception of Last Standby Time,

Total Standby Time, Standby Events, Device Address, Total Run Time, and Language) are reset to the original factory settings. Range: Yes / No.

• Tamper Polarity: This setting defines whether or not the Tamper switch is normally open or closed. Range: Normally Closed / Normally Open.

• Slow Transfer: This setting reduces the power supply’s sensitivity to glitches on the AC input. The default setting is “disabled”, which is the most sensitive to the AC input, and transfers accordingly. Other settings include Level 1 - Level 9. “Level 9” is the least sensitive and is recommended for installations with poor AC line quality to minimize transfers.

• Latitude / Longitude: Clicking locate will determine the latitude and longitude of the power supply. This information can also be entered manually.

41


017-897-B0-001, Rev. A (06/2015)

Clicking the BATTERY hyperlink opens the Battery Information and Configuration Menu:

Fig. 3-4, Web Interface, BATTERY Menu

• # of Strings: This setting defines the number of battery strings connected to the power supply. Range: 1 - 4.• Battery Model: This setting will determine what battery model is connected to the power supply and manage the

battery accordingly.• Battery Capacity (Ah): The capacity of the battery strings attached to the power supply, defined in Ampere-hours

(Ah).• Float (V/C): This data is specific to the selected battery model for the FLOAT cycle.• Accept (V/C): This data is specific to the selected battery model for the ACCEPT cycle.• Refresh (V/C): This data is specific to the selected battery model for the REFRESH cycle.• Temp Comp (mV/C): This data is specific to the selected battery model for the Battery Temperature

Compensation.• Rest Enable: This setting enables the REST battery charger mode. Range: Yes / No.• Refresh Enable: This setting enables a 24-hour REFRESH charge of the batteries. Range: Off / On.• Heater Mat: This setting specifies whether or not a heater mat is in use. Range: Yes / No.

42


017-897-B0-001, Rev. A (06/2015)

Clicking the ALARM hyperlink opens the Alarm Menu (See Section 3.6 for detailed information on specific alarms):

Fig. 3-5, Web Interface, ALARM Menu

Clicking the COMMS hyperlink opens the Communication Information and Configuration Menu. On this page, the user can view and specify network addresses for the EM Power Supply:

Fig. 3-6, Web Interface, COMMS Menu

43


017-897-B0-001, Rev. A (06/2015)

3.6 Active AlarmsTwo LEDs on the front of the EM indicate the condition and status of the power supply:

1. The green Output LED, when lit, indicates the power supply is functioning normally and supplying output AC to the load. A flashing output LED indicates that an alarm has been detected. If the Output LED is off, the output is off.

2. The red Alarm LED flashes to indicate a major alarm has been detected. This state clears when the alarm is no longer present. Under typical operating situations, the red Alarm LED is off. This indicates normal power supply operation.

In the event of a failure, LEDs indicate whether the alarm is major or minor. The EM Power Supply Web Interface will specifically detail the alarm.

Fig. 3-7, Output and Alarm LEDs on the EM Power Supply

Alarms are classified in two categories:

• MAJOR Alarms are indications of a serious failure within the power supply, such as a loss of output voltage or a failed battery charger. Any situation that causes output failure is considered a Major Alarm. Major Alarms require immediate action to correct the failure. To correct Major Alarms, follow the alarm matrices on the following pages.

• MINOR Alarms indicate a less serious failure, such as defective PTS or loss of utility power. Corrective action can be delayed for a short time. To correct, follow the alarm matrices on the following pages.

OUTPUT

ALARM

TEST

ETH

BATTERY TEMP

BATTERY INPUT 12V

LRI

TPR

NOUTPUT

~

AUX230V/30WN

~

Condition Output AlarmNormal On Off

Minor Alarm Flash OffMajor Alarm Flash Flash

Self-Test Double-Flash OffOutput Off Off Flash

Power Supply Initialization / Battery String Qualification

Alternating Flash Alternating Flash

2

1

2

1

44


017-897-B0-001, Rev. A (06/2015)

Power Alarms

Active Alarm Probable Cause of Alarm Corrective Action Standby Disabled

POWER - Major Alarms

SELF TEST FAIL Output voltage failed or batteries less than 1.85 V/C during Self Test.

1. Check Batteries2. Check Power Board NO

LINE ISOLATION Line isolation has failed and battery standby operations are suspended.

1. Replace power supply as soon as possible YES

OUTPUT FAILURE The AC output has failed due to a bad power board, transformer, or oil capacitor.

1. Apply load >1.5A2. Output Overloaded3. Check Power Board4. Check Battery String

NO

OUTPUT OVERLOAD The output is overloaded or shorted 1. Output Short Circuit2. Check Output Current NO

CHARGER FAILURE Charger has failed to shut down; possible battery over temperature. 1. Perform Self Test NO

POWER BOARD TEMP

Power board heat sink has exceeded set temperature. (Stand-by operations suspended until temperature drops to a safe level).

1. Utility Failure2. Check Input Breaker3. Input Connections

YES (Until Temperatures

Drop)

CONFIG ERRORThe power supply is improperly configured and operation is suspended until error is corrected.

1. Wrong Input Voltage or Frequency

2. Wrong Battery StringNO

POWER BOARD No output detected with good batteries for 30 seconds. 1. Replace Power Supply YES

POWER - Minor Alarms

INPUT FAILURE Utility AC input has failed.1. Utility Failure2. Check Input Breaker3. Input Connections

NO

INPUT CURRENT LIMIT

AC Input current exceeds threshold setting.

1. Reduce Output Load2. Check Input Current

Limit Setting.NO

SURGE MOV FAIL The MOV board surge protection has failed and needs to be replaced. 1. Replace MOV Board NO

POWER BOARD EEPROM ERROR

There has been an error reading the EEProm on the power board. 1. Replace Power Supply NO

The alarm matrices on the following pages indicate the MAJOR/MINOR active alarms, the probable cause, troubleshooting items to check to correct the alarm condition, and whether or not Standby is disabled for that alarm type.

Table 3-3, POWER Alarms

45


017-897-B0-001, Rev. A (06/2015)

Table 3-4, BATTERY Alarms

Battery Alarms

Active Alarm Probable Cause of Alarm Corrective Action Standby Disabled

BATTERY - Major Alarms

NO BATTERIESDetected the absence of batteries (alarm inactive when battery capacity or number of battery strings is set to 0).

1. Check Battery Fuse at battery

2. Check Connections3. Check Battery Fuse on

Power Board.

YES

LOW BATT VOLTS Battery voltages below 1.833 V/C.

1. Check AC Input2. Restore AC Input3. Connect Generator4. Check Battery String

NO

HIGH BATT VOLTS Battery voltages above 0.25V/cell over target charger voltage.

1. Check Batteries2. Check Charger Settings3. Replace Power Board

YES

BATTERY EOD Batteries dropped below the low voltage shutdown level. 1. Low Battery Disconnect YES

BATTERY FAIL Charge current > 5.0A for 7 days while in float mode.

1. Check Batteries2. Replace Batteries NO

BATTERY - Minor Alarms

BATT TEMP PROBE Precision Temperature Sensor (PTS) failed or is not installed.

1. Check Connection2. Replace Sensor NO

REFRESH / BATT REFRESH ALARM Battery Temperature Exceeded 60°C.

1. Check Charger Settings2. Check Batteries3. Check Battery

Temperature

NO

46 017-897-B0-001, Rev. A (06/2015)

4.0 Maintenance4.1 Safety Precautions

• Only qualified personnel should service the power supply.• Verify the voltage requirements of the equipment to be protected (load), the AC input voltage to the power supply

(line) and the output voltage of the system prior to installation.• Equip the utility service panel with a properly rated circuit breaker for use with this power supply.• When connecting the load, DO NOT exceed the output rating of the power supply.• Always use proper lifting techniques whenever handling units, modules or batteries.• The power supply contains more than one live circuit. Even though AC voltage is not present at the input, voltage

may still be present at the output.• The battery string, which provides backup power, contains dangerous voltages. Only qualified personnel should

inspect or replace batteries.• In the event of a short-circuit, batteries present a risk of electrical shock and burns from high current. Observe

proper safety precautions.• Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can result in a fire or

possible explosion.• This power supply has been inspected by regulatory authorities for use in various Alpha enclosures. If you are

using a non-Alpha enclosure, it is your responsibility to ensure your combination conforms to your local regulatory requirements and the power supply remains within its environmental specifications.

47

4.0 Maintenance, continued

017-897-B0-001, Rev. A (06/2015)

4.2 Required Tools and EquipmentPrior to beginning maintenance, ensure that all required tools and equipment, including safety equipment, is available and functional.

The following is a list of the minimum equipment required to maintain and troubleshoot the EM Power Supply system and batteries:

• Digital voltmeter• 3mm or smaller slot screw driver• Phillips screw driver• Alan wrench• Dust mask• Socket wrenches, insulated• Box end wrenches, insulated• Torque wrench calibrated in newton/meters • Rubber gloves• Full face shield safety glasses• Plastic apron • Portable eyewash • Spill kit, including sodium bicarbonate solution • Fire extinguisher• True RMS Volt Meter with DC Amp clamp• Midtronics Conductance Meter

Optional equipment, depending on the type of maintenance being performed, includes:

• Service power supply• 100 amp momentary load test set• System load bank (DC if it’s to be performed at the battery and AC if it’s to be performed by loading a power

supply output— contact your Alpha Representative for more information).• No-Ox Corrosion Inhibitor• Paper towels and/or rags

48


017-897-B0-001, Rev. A (06/2015)

4.3 Power Supply System Maintenance

4.3.1 Preparing for Maintenance

The power supply system should be remotely monitored and physically inspected periodically. If the system has an automatic monitoring system to gather the electrical and environmental data, the remote checks should consist of evaluating the recorded data and visiting any site that does not meet the specifications listed in the detailed procedures below.

Notify anyone affected by the intended maintenance or troubleshooting activity. This should include but not be limited to anyone responsible for the status monitoring equipment at the headend or NOC.

4.3.2 Periodic Maintenance Tasks

Remote Status Monitoring of Power Supply Monthly Self Test:The following maintenance procedure requires a fully functional status monitoring system capable of remotely measuring and recording the following data from a Self Test:

• Self Test Result• Output Current• Output Voltage

Procedure:

1. If Self Test fails, a site visit is required2. If the output current is above 100%, a site visit is required3. If Output voltage is below 82.5V for 87V units, 57V for 60V units, or 45.6V for 48V units, a site visit is required.

On-Site Power Supply Preventive Maintenance

Maintenance Procedures:Exterior Site Inspection

1. Inspect the power supply cabinet security and condition.2. Inspect cabinet for integrity (securely mounted, service meter and conduit integrity, etc).3. Check all locks and hinges for proper operation and lubricate if necessary.4. Inspect integrity of ground wire and ground rod. Ensure wire is of acceptable gauge and proper connections are

tight at both ends, meeting NEC or Local Authority specs.

Interior Cabinet Inspection1. Remove any dust, debris, or rodent signs from enclosure, louvers or vents (use a dust mask if necessary). If

enclosure has filters, clean with compressed air or leaf blower.2. Check all interior locks, hinges and battery slide trays for proper operation and lubricate if necessary.3. Verify that SPI (ALT Box) is tight along with coaxial connection, ensuring that the power supply and sheath of coax

is grounded.4. Verify that the power supply has a Surge Arrestor that is in working condition. Replace the unit as needed.

Ensure personal preventive equipment (including rubber gloves, plastic apron, safety glasses, and face shield) is worn prior to proceeding.

CAUTION!

49


017-897-B0-001, Rev. A (06/2015)

Power Supply Component Inspection1. Before physical inspection of the power supply, verify normal operation on the EM Power Supply. Clear all Active

Alarms before proceeding.2. Check physical condition of the power supply; remove any dust or debris built up in or around openings.3. Inspect all cabling and connections of the power supply system. Verify that all cabling is intact and all connectors

are properly seated; resolve as needed.4. Turn off the utility input breaker to remove input power. The power supply goes into standby operation.5. Verify that there is no interruption to the output.6. After five minutes reapply utility power. The power supply then transfers back to Operation Normal, clears any

alarms and starts the battery charger (BULK, if needed.) This test adds standby events and time to the event counter.

Record the following data from the EM Web Interface and record in the EM system maintenance log:

• Output Voltage• Output Current• Input Voltage• Input Power• Output Power• Battery Temperature

4.3.3 Replacing the MOV

The MOV (Alpha p/n 746-575-20), located on the front of the EM Power Supply, may need to be replaced after a power surge. Refer to Fig. 4-1 to remove and replace the MOV. Contact your local Alpha representative to order an MOV replacement.

Fig. 4-1, Removing and Replacing the MOV

R

R

50


017-897-B0-001, Rev. A (06/2015)

4.4 Battery Maintenance

4.4.1 Battery Notes

• Always refer to the battery manufacturer’s recommendation for the following settings: FLOAT, ACCEPT and REFRESH charge voltages, REST Mode, and Battery Temperature Compensation. Failure to do so can damage the batteries.

• 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.

• If the batteries appear to be overcharged or undercharged, first check for defective batteries and then verify the correct charger voltage settings.

• During preventive maintenance, check battery terminals and connecting wires. Clean battery terminal connectors and ensure they are correctly torqued (torque specifications are listed on the top of the battery). Spray the terminals with an approved battery terminal coating such as NO-OX.

• Refer to the battery manufacturer’s recommendation for correct charger voltages and the power supply operation manual for corresponding charger settings.

• If necessary, number the batteries (2,1 left to right as shown in section 2.2.2 Battery Installation Options and Wiring Diagram) inside the enclosure for easy identification (refer to the appropriate enclosure installation guide).

• Establish and maintain a battery maintenance log.• If batteries are being stored prior to installation, recharge per manufacturer’s specifications to ensure optimum

performance and maximum battery service life.• The EM Power Supply has a refresh “boost charge” feature specifically designed to deal with a battery coming out

of storage. See Section 1.2.3, Charger Modes of Operation for instructions on initiating REFRESH Mode.

Lead-acid batteries contain dangerous voltages, currents, and corrosive material. Battery installation, maintenance, service, and replacement must only be performed by authorized personnel.


51


017-897-B0-001, Rev. A (06/2015)

4.4.2 Battery Maintenance Guidelines

For optimal performance, inspect batteries periodically for:

• Signs of battery cracking, leaking or swelling: The battery should be replaced immediately by authorized personnel using a battery of the identical type and rating (match conductance, voltages, and date codes as specified in this document).

• Signs of battery cable damage: Battery cable should be replaced immediately by authorized personnel using replacement parts specified by vendor.

• Loose battery connection hardware: Refer to documentation for the correct torque and connection hardware for the application.

• Do not attempt to add water to, or remove the vents (valves) from, the AlphaCell battery models. This is a safety hazard and voids the warranty.

• Apply NO-OX grease on all exposed connections.• When necessary, clean up any spilled electrolyte in accordance with all applicable regulations or codes.• Follow approved storage instructions.• Always replace batteries with those of an identical type and rating. Do not charge batteries in a sealed container.

Each individual battery should have at least 13mm of space between it and all surrounding surfaces to allow for convection cooling.

• All battery compartments must have adequate ventilation to prevent an accumulation of potentially dangerous gas. Never place batteries in a sealed enclosure. Exercise caution when maintaining and collecting data on the battery system.

4.4.3 Battery Disposal, Recycling and Storage Instructions

• Spent or damaged batteries are considered environmentally unsafe as they contain lead and dilute sulfuric acid. They should not be “thrown away” with common refuse.

• Always recycle used batteries in accordance with federal, state, provincial, and local regulations.• All lead acid batteries experience self-discharge while in open circuit storage. This causes circuit voltage and

capacity to decrease (see Fig.4-2 through 4-4), especially over long periods of time at higher temperatures.

During storage:

• The self-discharge rate is related to ambient temperature. The lower the temperature, the less the discharge. Batteries should be stored in a clean, ventilated, and dry location with an ambient temperature of 0ºC to 20ºC.

• It is important to track open circuit voltage which is related to the density of the electrolyte. If the open circuit voltage is lower than 12.6V or the batteries have been stored beyond the limits shown in Fig. 4-2 through 4-4, the batteries should be charged to avoid damage caused by self-discharge.

• All batteries should be fully charged before storage. Record the storage date and next supplemental charge date in a maintenance record and on the battery.

• Upon battery deployment, verify all batteries within each string measure in the range of +/- 0.3VDC of the string average.

The product warranty is void if the batteries are not stored and recharged in accordance with these guidelines.NOTICE:

52


017-897-B0-001, Rev. A (06/2015)

Fig. 4-2, Capacity vs. Storage Time for AlphaCell XTV

Fig. 4-3, Capacity vs. Storage Time for AlphaCell HP

Fig. 4-4, Capacity vs. Storage Time for AlphaCell GXL

12.60

12.65

12.70

12.75

12.80

12.85

12.90

12.95

13.00

70%

75%

80%

85%

90%

95%

100%

0 2 4 6 8 10 12 14 16 18 20 22 24

Volta

ge

Perc

ent S

tate

of C

harg

e

Storage Time (Months)

AlphaCell XTV Storage Time vs.Temperature

32ºF (0ºC)50ºF (10ºC)68ºF (20ºC)86ºF (30ºC)

(40ºC)

Storage Time (Months)0

03 6 9 12

25

50

75

100

15 18

Residual C

apacity (%)

0 3 6 9 12 15 18 21 242.1

2.13

2.16

2.15

2.17

2.14

2.12

2.11

80%

95%

90%

100%

85%

75%

70%

Per

cent

Sta

te o

f Cha

rge

OC

V P

er C

ell

Storage Time (Months)

25°C20°C30°C40°C

53


017-897-B0-001, Rev. A (06/2015)

4.4.4 Battery Capacity

The actual battery capacity is related to the utilization ratio of the active positive and negative materials within the battery. The utilization ratio is influenced by the depth of discharge, the structure of the battery, and the manufacturing technology. During normal usage, the factors that influence the actual capacity are discharge rate, depth of discharge, end voltage, and temperature.

• The higher the discharge rate, the lower the available capacity.• As batteries get colder, the available capacity is reduced (See Fig. 4-5 and 4-6). This is related to the kinetics of

the electrochemical reactions and the resistivity of the electrolyte.

Fig. 4-5, Efficiency vs. Temperature AlphaCell XTV Series

Fig. 4-6, Efficiency vs. Temperature AlphaCell HP Series

10%

0%-40ºC -30ºC -20ºC -10ºC 0ºC 10ºC 20ºC 30ºC 40ºC

20%

30%

40%

50%

60%

70%

80%

90%

100%

Per

cent

Rat

ed C

apac

ity A

vaila

ble

Although the battery can be operated at temperatures below -20ºC, the capacity and ability to discharge will be dramatically decreased. Similarly, temperatures approaching 50ºC will increase electrolyte loss and corrosion of the plates, resulting in a shorter battery life.

NOTICE:

-40°C -30°C -20°C -10°C 0°C 10°C 20°C 30°C 40°C

20%

30%

50%

70%

90%

10%

80%

60%

100%

40%

0%

Perc

ent R

ated

Cap

acity

Ava

ilabl

e

Efficiency VS. TemperatureAlphaCell 3.5HP and 4.0HP

4.0HP

3.5HP

Typical Gel

54


017-897-B0-001, Rev. A (06/2015)

4.4.5 Preparing for Battery Maintenance

The battery system should be remotely monitored and physically inspected periodically. If the battery system has an automatic monitoring system to gather the electrical and environmental data, the remote checks should consist of evaluating the recorded data and visiting any site that does not meet the specifications listed in the detailed procedures below.

You do not have to measure the electrolyte specific gravity or add water to the cells.

All batteries in the string should be numbered to facilitate recording and analysis of data unique to each unit.

Notify anyone affected by the intended maintenance or troubleshooting activity. This should include but not be limited to anyone responsible for the status monitoring equipment at the head-end or NOC.

55


017-897-B0-001, Rev. A (06/2015)

4.4.6 Periodic Battery Maintenance Tasks

On-Site Battery Preventive Maintenance

Required Equipment:• True RMS Volt Meter with DC Amp Clamp• Midtronics Conductance Battery Tester

Fig. 4-7, Flow Chart for Preventive Maintenance

Yes

No

Yes

Yes

No

Replace the individual failed battery with a battery that is within +/- .3 Volts of the string average.

Battery String Float Current

>0.5A

Log each battery’s conductance and

voltage

Disconnect Batteries

Record Information on Site Visit Record

Monitor as per PM Program

Site Visit

Battery Refurbishment

Plan

Return battery to warehouse

Ensure Power Supply is in Float

Mode

Battery > 0.5V

from the average string voltage

No

Does the individual battery pass the evaluation procedure outlined in the section: “Battery Evaluation

Procedures for AlphaCell Batteries”

Replace the string

56


017-897-B0-001, Rev. A (06/2015)

Procedure:

1. Verify the power supply is in FLOAT mode. 2. Use the DC Amp clamp to measure and record each individual battery string’s float current. 3. If the individual string float current is greater than 0.5 amps, replace the battery string. Measure and record the

individual battery conductance and voltage on the Site Visit Record. 4. If the string float current is less than 0.5 amps:

• Disconnect the batteries from the system.• Measure the battery conductance. If any reading is below the suspect level, refer to Table 4-1s for mhos

values for battery models.• Measure the battery voltage. If any reading is less than 12.6V, then replace all of the batteries in the string. • If any individual battery voltage varies more than 0.5V above or below the average for the string, replace the

string.

• Example: V1 = 13V, V2 = 13V• Average voltage = 13V• If either battery is greater than average by 0.5V, then the batteries should be replaced. Batteries removed

from the site should then be tested per Section 4.4.7, Battery Refurbishment Plan.• Log the site location, battery location, model, manufacturer date codes, voltage and conductance readings for

all batteries.

5. Record data on Battery Maintenance log. 6. Verify the spacing between the batteries from front to back is at least 13mm and that adjacent batteries do not

touch one another.7. Ensure the enclosure is clean and free of debris.8. Measure and record the battery’s temperature.9. Visually inspect the batteries for:

• Cleanliness • Terminal damage or evidence of heating or overheating • Container or cover damage

10. Check terminal posts for signs of corrosion. If corrosion is present, neutralize with a solution of 454g sodium bicarbonate (baking soda) to 3.8l of water. Rinse and dry.

11. Verify terminal posts are coated with NO-OX grease or a spray-on protectant. Reapply as needed.12. Torque all the interunit connecting hardware to the values noted in the tables on the next page.

57


017-897-B0-001, Rev. A (06/2015)

Table 4-1, On-Site Battery Preventive Maintenance

ParameterModel Number

220 Gold-HP 220GXL 195 Gold-HP 195GXLTerminal Type Threaded Insert Threaded Insert Threaded Insert Threaded Insert

Bolt Size 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC BoltAnnual Retorque 12.4N-m 12.4N-m 12.4N-m 12.4N-m

Open Circuit Voltage 12.84 12.84 12.84 12.84Average Float Voltage Range

(volts/unit) 13.5 to 13.8 13.5 to 13.8 13.5 to 13.8 13.5 to 13.8

20-Hour Ampere Rate to 1.75 V/C 5.45 5.45 5.00 5.00Typical Impedance @ 60Hz ohms 0.0050 0.0050 0.0050 0.0050Typical Conductance 7Hz mohs 960 to 1400 960 to 1400 880 to 1320 880 to 1320

Typical 10 Sec. Voltage @ 100 amp 11.4 11.4 11.3 11.3


165 GXL 3.5 HP 4.0 HP 100 XTVTerminal Type Threaded Insert Threaded Insert Threaded Insert Threaded Insert

Bolt Size 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt M6 x 12mmAnnual Retorque 12.4N-m 12.4N-m 12.4N-m 13.6N-m

Open Circuit Voltage 12.84 12.80 12.80 12.0Average Float Voltage Range

(volts/unit) 13.5 to 13.8 12.6 to 14.1 12.6 to 14.1 13.5 to 13.8

20-Hour Ampere Rate to 1.75 V/C 4.30 - - 2.75Typical Impedance @ 60Hz ohms 0.0055 2.7 2.2 0.005Typical Conductance 7Hz mohs 800 to 1200 1400 to 1850 1700 to 2500 700 to 800

Typical 10 Sec. Voltage @ 100 amp 11.2 - - -


150 XTV 195 XTV 240 XTVTerminal Type Threaded Insert Threaded Insert Threaded Insert

Bolt Size M6 x 20mm M6 x 20mm M6 x 20mmAnnual Retorque 13.6N-m 13.6N-m 13.6N-m

Open Circuit Voltage 12.0 12.0 12.0Average Float Voltage Range

(volts/unit) 13.5 to 13.8 13.5 to 13.8 13.5 to 13.8

20-Hour Ampere Rate to 1.75 V/C 4 5 5.5Typical Impedance @ 60Hz ohms 0.0045 0.0039 0.0034Typical Conductance 7Hz mohs 900 to 1100 1050 to 1250 1250 to 1550

Typical 10 Sec. Voltage @ 100 amp - - -

58


017-897-B0-001, Rev. A (06/2015)

4.4.7 Battery Refurbishment Plan

Fig. 4-8, Flow Chart for Battery Refurbishment Plan

1. DO NOT mix batteries of different models within in a string.2. DO NOT mix batteries from different manufacturers. Example: Alpha and MK.3. No battery age limit if it passes the other tests.

Does battery meet the minimum

conductance values? See Table: Alpha Cell Conductance Values, Healthy vs Suspect

Batteries

Measure and RecordConductance

Sort Batteries per Conductance &

Voltage

Batteries Returned from Site. Measure and document 24 hour Open Circuit Voltage (OCV).

(Must occur within 24 hours of removal from

charger)

Properly recycle batteries per local

requirements

Battery Refurbishment

Plan

Group re-deployable batteries as indicated for

future deployment as strings

No Yes

Does battery meet the minimum of

12.6 Volts for the 24 hour OCV?

Measure and Record Battery Voltage

Batteries stored in warehouses for

extended periods of time refer to Section

4.4.3, Disposal, Recycling and Storage

Instructions

59


017-897-B0-001, Rev. A (06/2015)

4.4.8 Battery Evaluation Procedures for AlphaCell Batteries

To help identify batteries approaching end-of-life in an operating power system, the following test should be performed at each maintenance interval. For accuracy, tests must be performed on fully charged batteries.

Conductance/Impedance Test – Measure the conductance of each battery. Any battery that possesses a conductance that is 50% less than the initial reading taken at the point of install can be considered suspect of being below 70% capacity and should be evaluated further. The battery temperature must be approximately the same each time this reading is taken (see Table 4-2 below). Use temperature compensation feature when using Midtronics meter.

Float Voltage Test – Measure the float voltage of each battery in the string that is on float charge. Any battery in the string measured at 13.2 volts or less is a suspect battery and should be further evaluated with the steps below. Any battery below 12.6 volts should be replaced. The 13.2 & 12.6 voltage values are based on a 25˚C temperature. Adjust the voltage for higher or lower temperatures per battery per degree Celsius. The higher the temperature above 25˚C the lower the voltage will have to be adjusted and vice-versa for temperature below 25˚C. The voltage adjusted per degree Celsius is specific to the battery model.

Battery Replacement Criteria – Batteries with a Siemens number of 400 or less should be replaced. Batteries with a Siemens number between 400 and 700 and failing the 10 minute Self Test should be replaced. If the Self Test passes, the batteries will not be replaced. Batteries with a Siemens number greater than 700 and passing the 10 minute Self Test should not be replaced. A battery that drops below 10.8 volts during the 10 minute Self Test is suspect.

Table 4-2, AlphaCell Conductance Values, Healthy vs. Suspect Batteries

AlphaCell Conductance Values, Healthy vs Suspect BatteriesMidtronics Conductance Models 3200/micro CELLTRON

Battery Model Approximate Conductance Values (MHOs) Healthy Battery @ 25°C Suspect Battery @ 25°C in MHOs

165 GXL 800-1200 <400170 XLT 1040-1560 <520195 GOLD-HP 880-1320 <440195 GXL 880-1320 <440220 GXL 960-1400 <480220 GOLD-HP 960-1400 <4803.5 HP 1400-1850 <6804.0 HP 1700-2500 <840100XTV 700-800 <300150XTV 900-1100 <400195XTV 1050-1250 <450240XTV 1250-1550 <500

60


017-897-B0-001, Rev. A (06/2015)

EM Power System Preventive Maintenance Checklist

Hub: Street: Date:

Site Number: City: County:

Equipment Identification & As-found Alarms:Power Supply Make-Model: PS1 Serial #:

Battery Make-Type:

Record as-found alarms: PS Input Wattage: PS Output Wattage:

Electric Meter #: Reading:

Battery Capacity:

Battery String Maintenance

Battery # Date Code ID NumberVoltage-No Load (VDC)Total String:

Voltage-Under Load (VDC)Total String:

Conductance - (mhos)

°C Corrected 25°C

A1:

A2:

B1:

B2:

Ignition Battery N/A

Battery String Replaced? Yes/No Clean and add anti-corrosive lubricant to battery terminals and lugs? Yes / No Battery Torque:

Power Supply Maintenance:

Power Supply # Power Supply Events AC Input Voltage (VAC) Output Voltage (VAC) Output Current (Amps)

Number Time A B

PS:

Clean and inspect each power supply? Yes / No Run Power Supply Auto-Test? Pass Fail Clear Power Supply Event Log? Yes / No

Enclosure lnterior and Exterior Maintenance Checklist:Items to Check Results Items to Check Results Items to Check Results

Clean dust/dirt from enclosure inside Yes / No Check LAPs OK/Replaced/None

InstalledTouchup paint enclosure exterior Yes / OK

Change or celan enclosure air filters Yes / No Check Lamps & LEDs OK/Replaced; Note

BelowNote condition of retaining walls

Pass I Fail;Note Below

Tighten all enclosure hardware Yes / No Cut weeds back 36” from enclosure Yes/No/NA Any pad undermining? None I Yes: Note Below

Inspect wire harnesses and connectors Pass / Fail Cleanup garbage within immediate

vicinity Yes / No / NA Any enclosure damage or vandalism

None I Yes: Note Below

Inspect battery temperature probes Pass / Fail Is powemode site ID legible? Yes / No / NA Generator Cord Present? Yes /No/

Installed

Inspect lor rodent and insect damage

Yes; Note Below/OK

Clean enclosure exterior & remove graffiti Yes / No

Comments & Replacement Parts Used:

PM Service Technician

61017-897-B0-001, Rev. A (06/2015)

123

5.0 Shut DownThe EM Power Supply contains more than one live circuit. During an emergency, utility power can be disconnected at the service entrance or main electrical panel to protect emergency personnel. However, power is still present at the output. To prevent the possibility of injury to service or emergency personnel, always follow this procedure to safely shutdown the Power Supply.

Emergency Shut Down Procedure:

1. Unplug the battery cable connection.2. Unplug the AC Input Line Cord from the service entrance.3. Disconnect the wires from the Output 1, Output 2 (if applicable), and auxiliary output terminal blocks.

Fig. 5-1, Emergency Shutdown

OUTPUT

ALARM

TEST

ETH

BATTERY TEMP

BATTERY INPUT 24V

LRI

TPR

V SEL

48 V

60 V

87 V

NOUTPUT 2

~

NOUTPUT 1

~

AUX230V/30WN

~

1

2

3

62 017-897-B0-001, Rev. A (06/2015)

6.0 Technical Specifications

Table 6-1, Technical Specifications

Technical SpecificationsParameters EM-605CE EM-608CE EM-615CE EM-910ENominal AC Input Voltage 230Nominal Input Frequency 50HzInput Frequency Tolerance (%) ±3Input Voltage Operating Range Tolerance (%) -30 / +25

Output Voltage (VAC) 48 / 60 48 / 60 48 / 60 / 87Output Voltage Regulation (%) -5 / +5Maximum Rated Output Current (Amps) 5 8 15 / 15 15 / 15 / 10Maximum Output Power (VA) 240 / 300 384 / 480 720 / 900 720 / 900 / 870Line Mode Efficiency ≥ 85% at 100% load w/ battery charger offStandby Efficiency ≥ 80% at

100% load ≥ 85% at 100% load

Bulk Charger Current (Amps @ 80% Load & Nominal Line) 10

Battery Voltage (VDC) 12 24

MechanicalInverter Non-removable inverter with integrated ethernet capabilityDimensions H x W x D (mm) 189.5 x 241.6 x 217.0 189.2 x 266.7 x 228.6Weight (kg) 11.8 15.0 22Input Power Connector IEC 320/C-14Battery Connector 2-position Red 50A Anderson Style Red/Black 75A Anderson StyleRemote Temp Sensor Ring lug fastens to negative terminal on batteryLRI Connector 3-Position MTA-100 Connector Mounting Shelf mounts inside suitably rated electrical enclosures. Additional kits may be

necessary if the unit is mounted outside of an electrically rated enclosure in order to meet EMC and safety requirements.

EnvironmentOperating Temperature -40°C to 55°CStorage Temperature -40°C to 70°CHumidity ≤ 95% non-condensingConformal Coating All Printed Circuit Board Assemblies to prevent moisture related failure

63

6.0 Technical Specifications, continued

017-897-B0-001, Rev. A (06/2015)

Table 6-1 Continued, Technical Specifications

Parameter EM-605CE EM-608CE EM-615CE EM-910EName Plate Rating (VAC) 230Input Window -/+ (% of Nominal Input) -30 / +25Input Range (VAC) 161 - 288Output Regulation -/+ (%) -5 / +5Load Range 1-5A 1-8A 1-15A 1-10AOutput Voltage Min/Max 48V (VAC) 45.6V / 50.4VOutput Voltage Min/Max 60V (VAC) 57.0V / 63.0VOutput Voltage Min/Max 87V (VAC) N/A 82.7V / 91.3V

Safety ComplianceEN 62040-1 x x xIEC/EN 60950-1: ED2 x x x xEN 60728-11 x x xCB Report x x x xCE x x xCNS 14336-1 x x xSARFT x x xEMC ComplianceEN62040-2 (UPS Equipment) x x xCategory C2 x x xClass B Conducted Limits x x xCNS 13438 Class A x x xCISPR 22 Class A x

64 017-897-B0-001, Rev. A (06/2015)

7.0 EM Power Supply Mounting OptionsAlpha offers a variety of mounting options for the EM Power Supply.

12V Model

Fig. 7-1, Wall Mount Rack (12V Only)

Fig. 7-2, Wall Mount Shelf

65

7.0 EM Power Supply Mounting Options, continued

017-897-B0-001, Rev. A (06/2015)

Fig. 7-3, NPS Cabinet for 2 Batteries

Fig. 7-4, LPE Cabinet for 1 Battery

66 017-897-B0-001, Rev. A (06/2015)

8.0 Web Interface GlossaryBattery Capacity: The capacity of the battery strings attached to a particular Intelligent CableUPS. When batteries are not attached, the setting must be programmed to “0.” This disables standby operations, including test mode, and disables the No Batteries Alarm. If batteries are attached, then this setting should be programmed to the rating of each battery. If the Power Supply is used in a non-standby application, the Battery Capacity variable must be programmed to “0” to disable the battery maintenance cycle portion of a Self Test.

Battery Model: The AlphaCell battery type can be specified via the web interface (if not AlphaCell, leave as default battery type, OTHER). If AlphaCell is selected, parameters for Accept, Float, Temp, Comp and Battery Capacity are automatically selected. If Other, these parameters will need to be manually set to the manufacturer’s recommended rating.

Battery Temperature: The temperature of the batteries sensed from the PTS connected to the front of the power supply.

Battery Voltage: The total battery string voltage.

Charger Accept Voltage: Battery Accept charge voltage control in volts per cell. This voltage (refer to Section 1 for details) is temperature compensated to ensure longer battery life. It properly completes the charge cycle and is factory set for AlphaCell batteries. If another manufacturer’s batteries are used, consult the battery manufacturer for Accept voltage levels.

Battery Current: The current going into or out of the batteries. The Battery Current will be displayed as a positive value when the batteries are charging (Charger Current), and will be negative when the batteries are discharging (standby mode).

Charger Float Voltage: Battery Float charge voltage control in volts per cell (refer to Section 1 for details). It is factory set for AlphaCell batteries. If another manufacturer’s batteries are used, consult the battery manufacturer for Float voltage levels.

Charger Mode: The mode of the battery charger which may be one of the following: OFF, TEST, BULK, ACCEPT, REFRESH, FLOAT, REST.

Charger Temperature Compensation: Battery charger temperature compensation control. Programming this parameter to “0.0” disables temperature compensation. It is factory set for AlphaCell batteries (refer to Section 1 for details). If another manufacturer’s batteries are used, consult the battery manufacturer for Charger Temperature compensation ranges.

Common Logical ID: Specifies the logical ID for the managed power supply used by network management systems. Some network management systems require this item to be blank. This item can be entered via the transponder Web page or status monitoring firmware.

Current Outage: When the Power Supply is operating in standby mode, this is a counter (in minutes) of how long the Power Supply has been in standby mode. This is not used for self-test events.

Discharge Level: This is the setting for the amount of battery discharge to be performed during self-test, either manual or automatic. “TIMED” is the default and will use the time set in the Test Duration parameter. Deep discharge levels of 10%, 20%, 30%, 40% and 50% may be set. When set, the batteries will be discharged by the specified capacity percentage one time. Upon completion, the setting will revert back to Timed.

EOD Voltage: The low battery (End of Discharge) voltage at which the inverter will shut off the output.

Frequency Range Limit (setting may be increased when powering with AC Generator): AC input voltage frequency range limit. This limit establishes the acceptable input frequency range outside of which standby operation is initiated.

Heater Mat Installed: If a battery heater mat is installed, this value can be programmed to Yes. The information is then available for the headend.

Input Current Limit: The maximum allowable input current. When this limit is exceeded, the maximum battery charger current will be reduced to stay within this limit.

67

8.0 Web Interface Glossary, continued

017-897-B0-001, Rev. A (06/2015)

Input Current: The AC input current to the Power Supply.

Input Frequency: The frequency of the AC input voltage.

Input Power: The total input power in Watts.

Input Voltage: The AC input voltage to the Power Supply.

Number of Battery Strings: Enter the number of battery strings installed here. This value is used with the Battery Capacity setting to set some of the battery charger parameters.

Operating Mode: The operating mode of the Power Supply will indicate Line when it is powering the output from the AC utility or Inverter when it is powering the output from the batteries.

Output Current: The total AC output current of the power supply.

Output Power: The total output power in Watts.

Output Voltage: The AC voltage at the output of the power supply.

Auxiliary Output Voltage: The AC voltage at the AUX output of the power supply.

Power Supply Priority Level: The operator may select the Power Supply priority level in context of its deployed location in the cable network. This setting is a reference for the customers only and does not affect the Power Supply performance. The settings are Normal (default), High, or Critical.

REFRESH Enable: This enables a 24-hour REFRESH charge of the batteries. This is recommended for batteries that have been in storage.

REST Enable: Enables the REST battery charger mode.

RMODE: An inverter control that limits the peak output voltage (for 87V output models the peak output voltage is limited to less than 115V; for 60V output models, the peak output voltage is limited to less than 85V).

Self Test: When programmed to YES, the Power Supply automatically starts a Self Test.

Set Defaults: When programmed to YES, the programmable data levels (with the exception of Last Standby Time, Total Standby Time, Standby Events, and Total Run Time) are reset to the original factory settings.

Test Countdown: The number of days remaining before the next scheduled automatic Self Test initiates. This variable is programmable and you can select the day the autotest sequence will begin. This counter has no effect if test interval is set to 0.

Test Duration: Automatic Self Test duration timer. This sets the number of minutes of a battery maintenance cycle test. This timer applies to automatically or manually initiated tests.

Test Inhibit: Becomes active when programmed by the operator (or when the unit runs in inverter mode for more than 5 minutes). The Power Supply delays the start of a scheduled Self Test for at least seven days if the test countdown is less than seven days (See Section 3.2, Automatic Performance Test for complete details).

Test Interval: Automatic Self Test control timer. The number of days between battery maintenance cycle tests. Set this value to zero to disable automatic Self Test.

Visit us at www.alpha.com

Alpha Technologies Inc.3767 Alpha WayBellingham, WA 98226 United StatesTel: +1 360 647 2360Fax: +1 360 671 4936

Alpha Technologies Europe Ltd.Twyford House ThorleyBishop’s StortfordHertfordshire, CM22 7PA United KingdomTel: +44 1279 501110Fax: +44 1279 659870

Alpha TechnologiesSuite 1903, Tower 1, 33 Canton Road, KowloonHong Kong City, ChinaPhone: +852 2736 8663Fax: +852 2199 7988

Alpha Technologies Ltd.7700 Riverfront GateBurnaby, BC V5J 5M4 CanadaTel: +1 604 436 5900Fax: +1 604 436 1233Toll Free: +1 800 667 8743

Alpha Technologies GmbHHansastrasse 8D-91126Schwabach, GermanyTel: +49 9122 79889 0Fax: +49 9122 79889 21

Alphatec Ltd.339 St. Andrews St. Suite 101 Andrea ChambersP.O. Box 564683307 Limassol, CyprusTel: +357 25 375 675Fax: +357 25 359 595

Alpha TEK oooKhokhlovskiy Pereulok 16Stroenie 1, Office 403Moscow, 109028 RussiaTel: +7 495 916 1854Fax: +7 495 916 1349

Alphatec BalticS. Konarskio Street 49-201Vilnius, LT-03123 LithuaniaTel: +370 5 210 5291Fax: +370 5 210 5292

Due to continuing product development, Alpha Technologies reserves the right to change specifications without notice. Copyright © 2015 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies. 017-897-B0-001, Rev. A (06/2015)

Documents

EM CableUPS 12V, 24V Technical Manual - Betsis · and maintenance, but also facilitates the proper operation and protection of the equipment within the network. Such a Such a grounding