Powernode System Enclosures ® Site Preparation and Installation PN-3 Models PN-4 Models Effective: March, 2002 ® © 2002 TM
PN-3 & PN-4 www.alpha.com 031-103-B0-003 Rev. C Protecting The Power in Communications.
Powernode System Enclosures PN-3, PN-4 Models Site Preparation and Installation 031-103-B0-003 Rev. C — © 2002 Alpha Technologies This manual covers the installation of the PN-3 and PN-4 Enclosure. Installation may involve connection to the electrical utility lines and fuel vapor (Natural Gas or Propane). Always work with the local utilities when connecting the enclosure to these utilities and observe all local and national laws which may be applicable for your area.
PN-3 & PN-4 Table of Contents Product Safety .................................................................................................................................... 6 Important Notes About Installation .................................................................................................... 7 Product Information, Customer Service or Technical Support ............................................................ 8 1. Introduction........................................................
PN-3 & PN-4 List of Figures Figure 1-1; Enclosure as it Arrives from Alpha ...................................................................................................................... 9 Figure 1-2; Packing Label Location ........................................................................................................................................ 9 Figure 1-3; PN-3 Specifications ..............................................................................................................
Product Safety Important Safety Instructions Used Throughout this Manual CAUTION HAZARDOUS CONDITION To reduce the risk of injury or death caused by electrical shock, explosion of fuel or moving parts; and to ensure the continued safe operation of this product, the following symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention. Dangerous Voltage This symbol indicates a “dangerous voltage” may exist in this area of the product.
Product Safety Important Notes About Installation © 2002 • The system must be installed only by qualified service personnel. • Always consult local codes for mounting pad requirements. • Consult local utility codes for additional cabinet grounding and utility requirements. • Consult the local gas company for correct meter type and riser location. • Whenever possible, it is best that the enclosure be installed above flood zones .
Contacting Alpha Technologies Product Information, Customer Service or Technical Support For general product information and customer service 7:00 AM to 5:00 PM Pacific Time, call: 1-800-863-3930 To obtain complete technical support 7:00 AM to 5:00 PM Pacific Time, or for after-hours emergency support, call: 1-800-863-3364 (7 days per week, 24 hours a day) Product Returns Returns for Repair In the event of a need for repair, Alpha products may be returned by either method listed below: Downloa
1. Introduction 1.1 Introduction To ensure operator safety: • Enclosures must be installed only by qualified personnel and in accordance with all applicable electrical codes. • Use eye protection whenever working with batteries. • Use only sealed, lead-acid type batteries (gelled-electrolyte or equivalent, 65 Ah min.) Unpacking and Inspection: Carefully remove the enclosure from the shipping container. Verify that: • The correct unit was shipped (either Alpha PN-3 or PN-4 enclosure).
1. Introduction 1.2 PN-3 and PN-4 Powernode Enclosure Alpha's PN Series Power Module enclosures offer complete flexibility and modular expendability for Cable TV powering applications. The Modular Tray system simplifies installation while allowing for future expansion or reconfiguration. The PN Series is designed to accommodate current system power requirements while allowing the cost-effective addition of power capacity, as well as enhanced reliability options, when new services are integrated.
2. Pre-Installation 2.1 Site Preparation The site must be planned so that the enclosure will receive good air flow. If possible, in areas of extreme heat, it is best to position the enclosure so that it will be shaded from the afternoon sun. In areas of prevailing winds, it is best that the enclosure be located so that the sides of the cabinet face the winds instead of the doors. This will greatly reduce the buildup of sand or snow against the enclosure’s air vents.
2. Pre-Installation 2.2 Concrete Pad Preparation Pads can either be poured on site, or precast by Alpha Technologies. Available concrete pad configurations and part numbers can be found in section 5, "Alpha Part Numbers". 5 3 7 2 8 1 6 7 4 Figure 2-2; Single-Wide Concrete Pad for PN-3 and PN-4 1 All dimensions shown in inches. Mounting holes and sweeps indexed from this position. 2 Indicates PN-3 and PN-4 pedestal enclosure mating surface.
2. Pre-Installation 2.
2. Pre-Installation Enclosure Grounding, continued &211(&7,21 0$'( :,7+ %851'< &211(&725 3 1 <*+5 & : 25 Side view UFER Ground 30 inches (48,9$/(17 SE GEC conduit & wires #2 bare copper wire No separation is required. 2 (m fee in t ) 2.
3. Installation 3.1 Transportation and Lifting The PN-3 or PN-4 cabinet as shipped weighs approximately 100-150 lbs. A safe means of transportation to the site and a safe procedure for unloading the enclosure is necessary. Do not transport or lift with a device that may not be able to bear the unit's weight, and do not place the unit upon a surface that will not be able to fully support it. 3.
3. Installation 3.3 Utility Powering The XM2 Power Supplies are powered by either 120VAC or 240VAC (depending upon the model), attached to an external service entrance. The size of the service conductors must be based upon the actual size of the utility service and be in accordance with applicable electrical code requirements. The utility conduit may be placed in one of two locations, depending upon the utility service entrance requirements.
3. Installation Utility Powering, continued 3.3 3.3.1 Connection Procedure for the BBX-100A-8POS Service Disconnect: 1. Locate the service entrance panel on the enclosure (exterior). Remove the cover to access the circuit breaker assembly. If this service panel is to be used as the primary service entrance, neutral must be bonded to ground by installing the green ground screw (provided) in the hole in the neutral bus. 2.
3. Installation Utility Powering, continued 3.3 3.3.2 Connection Procedure for the BBX-70A Service Disconnect: 1. Locate the service entrance panel on the enclosure (exterior). Remove the cover to access the circuit breaker assembly. If this service panel is to be used as the primary service entrance, neutral must be bonded to ground by installing the green ground screw (provided) in the hole in the neutral bus. 2. Remove the knockout located at the base of the service entrance to accept the conduit.
3. Installation 3.3.3 Sample Input Power Panels For more information on available models of the Input Power Panel, refer to "PN Series Options", section 4.4. Service and Distribution Load 15A Service Main 15A Line 1 From Service Supply Line 2 15A 50A Neutral N Main Bonding Jumper Grounding Electrode Conductor G 120V/15A 240V/15A 240V/15A 240V/15A BBX-100A-8POS Primary Service: 1) Main Bonding Jumper is Installed. 2) Grounding Electrode Conductor is Installed.
3. Installation Sample Input Power Panels, continued 3.3.3 Service and Distribution Load Main Disconnect 20A Line 1 From Feeder Supply 20A Line 2 50A Neutral N Equipment Grounding Conductor G 15A NO Main Bonding Jumper 120V/20A 120V/15A 120V/20A BBX-100A-8POS Secondary Service: 1) Main Bonding Jumper is NOT Installed. 2) Grounding Electrode Conductor is NOT Installed. 3) Lightning Protection is part of feeder supply.
3. Installation Sample Input Power Panels, continued 3.3.3 Service and Distribution Line 1 15A Line 2 From Feeder Supply Load 20A Neutral N Equipment Grounding Conductor G NO Main Bonding Jumper 120V/20A 120V/15A BBX-70A Secondary Service: 1) Main Bonding Jumper is NOT Installed. 2) Grounding Electrode Conductor is NOT Installed. 3) Lightning Protection is part of feeder supply.
3. Installation 3.4 Coaxial Cable to Service Power Inserter (SPI) Installation 3.4.1 SPI to Ground Bar Connection Procedure Tools List: 1" Socket (3/8" drive) 3/8" Rachet #2 Phillips Screwdriver Zip Tie Gun 1). Install SPI by tightening the attached coaxial connector to the equipment tray. Figure 3-10; Connector Fitting in Rear of Equipment Tray 2). Secure SPI ground wire to the SPI with attached screw, and connect to enclosure ground bar. Figure 3-11; Location of SPI in Equipment Tray 3).
3. Installation 3.4.2 Conduit Placement Conduit location is in the back of the enclosure, on the right side. (Location is specified on concrete pad.) Figure 3-13; Conduit Location Figure 3-14; Coaxial Connectors © 2002 TM 23 031-103-B0-003 Rev.
3. Installation 3.5 Battery Installation 3.5.1 Battery Safety Notes Electrical Hazards Battery systems represent a risk of electrical shock and high short circuit currents. The following precautions must be observed when maintaining batteries: • Remove all personal metal objects (watches, rings, etc.) • Use insulated tools. • Wear eye protection and rubber gloves. • Observe circuit polarities. • Do not make or break live circuits. • Do not lay metal tools and hardware on top of the batteries.
3. Installation 3.5.2 Battery Identification Each battery contains a DATE CODE usually located near the positive (+) terminal of the battery. This date code must be recorded in the maintenance log (MAINTENANCE manual). If batteries other than those installed by Alpha are used, consult the battery manufacturers’ documentation for date code type and placement. 0702 MONTH: (JUL) 07 YEAR: 2002 Figure 3-15; Alpha Cell Battery Date Code 3.5.
3. Installation 3.5.4 Battery Terminal Assembly Procedure These illustrations show the Battery Terminal assembly for vertically mounted battery posts. Refer to the battery manufacturers’ specifications for tightening torque. Battery Cable Battery Terminal Flat Washer Flat Washer Split Washer Bolt Nut Figure 3-17; Vertically Mounted Battery Post 3.5.5 Battery Installation Procedure 1.
3. Installation 3.5.6 Battery Installation Layout _ To "Battery Input" + Upper Battery Tray 1 Fuse Location 3 2 36VDC configuration _ + To "Battery Input" Upper Battery Tray 4 Fuse Location 1 2 3 48VDC configuration Figure 3-18; Battery Installation Arrangement © 2002 TM 27 031-103-B0-003 Rev.
3. Installation 3.5.6 Battery Arrangement, Power Supply Connection, continued Module Tray _ + XM Series Quick Disconnect Battery Connector Upper Battery tray 4 5 6 Fuse Location Lower Battery tray 1 2 3 Fuse Location Figure 3-19; Wiring Diagram for two 36V Battery Strings — PN3 Enclosure 031-103-B0-003 Rev.
3. Installation 3.5.6 Battery Arrangement, Power Supply Connection, continued Module Tray _ XM Series Quick Disconnect Battery Connector + Upper Battery tray 8 6 5 7 Lower Battery tray 1 Fuse Location 4 2 3 Fuse Location Figure 3-20; Wiring Diagram for two 48V Battery Strings — PN3 Enclosure © 2002 TM 29 031-103-B0-003 Rev.
3. Installation 3.5.6 Battery Arrangement, Power Supply Connection, continued Module Tray _ + XM Series Quick Disconnect Battery Connector Upper Battery tray 7 8 9 Fuse Location Middle Battery tray 4 5 6 Fuse Location Lower Battery tray 1 2 3 Fuse Location Figure 3-21; Wiring Diagram for three 36V Battery Strings — PN4 Enclosure 031-103-B0-003 Rev.
3. Installation 3.5.6 PN4 Battery Arrangement, Power Supply Connection, continued Module Tray _ + XM Series Quick Disconnect Battery Connector Upper Battery tray 9 12 10 11 Fuse Location Middle Battery tray 5 8 6 7 Fuse Location Lower Battery tray 1 4 2 3 Fuse Location Figure 3-22; Wiring Diagram for three 48V Battery Strings — PN4 Enclosure © 2002 TM 31 031-103-B0-003 Rev.
3. Installation 3.5.7 Battery Temperature Sensor Sensor wiring connects to Temperature Sensor Input connector of XM2 Power Supply. Use adhesive tape to attach the sensor so that the flat side of the sensor is flush to the side of the battery. TM ® Figure 3-23; Battery Temperature Sensor Mounting Location To prevent incorrect temperature readings, attach the Battery Temperature Sensor associated with each XM2 Power Supply on different batteries. 031-103-B0-003 Rev.
4. PN Series Options 4.1 Star Lock Security Bolt See section five, "Alpha Part Numbers" for PN Series options shown in this section. The Star Lock Security Bolt kit comes factory installed when ordered with a new enclosure. The kit can also be added to existing enclosures using the procedure below. NOTE: The Security Key is a special tool that must be ordered separately. Alpha recommends ordering security keys for each maintenance crew. 1).
4. PN Series Options 4.2 Battery Interface Unit (BIU) The BIU is used in Powernode systems with multiple power supplies and/or multiple battery strings, and an AlphaGen DC generator. The BIU provides a parallel DC bus with convenient connectors for each power supply and battery string. (For installation and operation instructions, refer to the BIU Installation Manual, part number 018-311-C1.
4. PN Series Options 4.3 Service Disconnects, continued Figure 4-8; MTS (Showing100A and 60A boxes) For applications requiring a protected AC generator. 4.4 Figure 4-9; FBX-60A Fused safety switch. For applications with high AIC rating requirements. Input Power Panel (IPP) There are four basic configurations of the IPP. Each is available in 120V and 240V.
4. PN Series Options 4.5 Cooling Fan Kit When using more than one power supply in the PN Series Enclosures, a cooling fan is required. The Cooling Fan kit includes an intake filter, located inside the front door of the enclosure by the ventilation louvers. The filter must be cleaned periodically as part of the power supply preventative maintenance program. Replacement fuses and filters are available. Refer to section five for part numbers.
4. PN Series Options 4.6 Lightning Arrester (LA-P+) The Lightning Arrester is available in 120VAC and 240VAC, and is installed by plugging into an IPP or BDO. Figure 4-17; LA-P+ Installed in BDO The unit is operating properly when the green LED is lit. Figure 4-18; Location of LED on LA-P+. © 2002 TM 37 031-103-B0-003 Rev.
5. Alpha Part Numbers 5.
5. Alpha Part Numbers 5.2 Pre-Cast Concrete Pads Alpha offers a line or precast, polymer concrete and reinforced concrete pads for the PN Series Enclosures. Polymer concrete is significantly lighter and more stable when compared to reinforced concrete. Both materials represent a significant savings in labor costs and quality improvement over "pour-in-place" pads. Other precast pad configurations are available. Contact your nearest Alpha representative for additional information. REF. 3.00 +3.0 -0.0 +.
5. Alpha Part Numbers Pre-Cast Concrete Pads, continued 5.2 3.00 REF. +3 .0 -0 .0 0.25 0.000 +.25 -.125 REF. 2 1 Figure 5-2; Double-Wide Pad, for CE8/9 or PN 3/4 Part Number: PCD 3-3: 641-072-10 (Reinforced concrete) PCC 3-3: 641-069-10 (Polymer concrete) 1 4" diameter opening (2 plcs.) 2 5" x 8" opening (6 plcs.) 031-103-B0-003 Rev.
5. Alpha Part Numbers Pre-Cast Concrete Pads, continued 5.2 3.00 REF. +3.0 -0.0 0.25 0.000 26 +.25 -.125 REF. 26 REF REF 19.5 REF 18.6 REF 21.86 15.86 14.36 2 11.11 9.11 7.55 14.71 REF 7.6 REF 1 .000 1.42 3.11 3.60 0.6 8.14 54.56 48.56 50.06 45.32 25.81 21.81 18.60 13.81 5.81 7.56 5.94 3.69 2.19 0.44 .000 9.69 14.
www.alpha.com Protecting The Power in Communications. UNITED STATES ASIA PACIFIC LATIN AMERICA Alpha Technologies 3767 Alpha Way Bellingham, WA 98226 Tel: (360) 647-2360 Fax: (360) 671-4936 Web: www.alpha.com CANADA Alpha Technologies Ltd. 4084 McConnell Court Burnaby, BC, V5A 3N7 Tel: (604) 430-1476 Fax: (604) 430-8908 UNITED KINGDOM Alpha Technologies Europe, Ltd.
