PowerNode System Enclosures PN-3/PN-4 Technical Manual PN-3 and PN-4 Models Effective: April 2007 Alpha Technologies
Power Alpha Technologies ®
PowerNode System Enclosures PN-3 and PN-4 Models Technical Manual 031-103-B0-004, Rev. D Effective Date: April, 2007 Copyright© 2007 Alpha Technologies, Inc. member of The GroupTM NOTE: Photographs contained in this manual are for illustrative purposes only. These photographs may not match your installation. NOTE: Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding.
Table of Contents Safety Notes .......................................................................................................................... 6 1.0 Introduction ................................................................................................................. 8 2.0 Unpacking and Inspection .......................................................................................... 9 3.0 Site Preparation ...........................................................................
List of Figures Fig. 1-1, PN-3 Specifications .............................................................................................................................. 8 Fig. 1-2, PN-4 Specifications .............................................................................................................................. 9 Fig. 2-1, Enclosure as it Arrives from Alpha ....................................................................................................... 9 Fig.
Safety Notes Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference. To reduce the risk of injury or death, 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.
Battery Safety Notes WARNING! Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery installation, maintenance, service and replacement must be performed only by authorized personnel. Chemical Hazards Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contain dilute sulfuric acid, which is harmful to the skin and eyes. Emissions are electrolytic, and are electrically conductive and corrosive.
1.0 Introduction Alpha's PN Series Power Node enclosures offer complete flexibility and modular expandability 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.
2.0 Unpacking and Inspection 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, 65Ah min). Unpacking and Inspection: Carefully remove the enclosure from the shipping container. Inspect the contents.
3.0 Site Preparation The site must be planned so that the enclosure will receive good air flow. In areas of extreme heat, 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.
3.0 Site Preparation, continued 3.1 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 6. 38.0 REF 26.0 REF 18.6 REF 21.86 15.86 14.36 5 3 7 9.36 9.06 7.55 2 24.0 REF 36.0 REF 7.6 REF 8 0 1 1.42 3.11 6 7 4 6.42 8.14 28.33 18.64 21.83 22.33 13.83 5.90 7.58 0 5.87 3.67 2.10 0.42 9.67 14.14 Fig.
3.0 Site Preparation, continued 3.2 Enclosure Grounding Connection Made With Burndy Connector P/N YGHR58C2W 3 2 et Fe . in M Enclosure Footprint Opening for Sweeps Opening for Sweeps #6 AWG 4 Opening for Sweeps 5 #2 AWG 2 Two 8’ ground rods placed a min. of 6’ apart 1 Connection Made With Burndy Connector P/N YGHP58C2W-2TN Fig.
3.0 Site Preparation, continued 3.2 Enclosure Grounding, continued Connection Made With Burndy Connector P/N YGHR58C2W-3 Or Equivalent Side View UFER Ground 30 inches conduit & wires 2 (m fee in t ) 3 SE GEC No separation is required #2 bare copper wire E nc los ure F ootprint Opening for Sweeps Opening for Sweeps #2 AWG 4 #2 AWG 5 20 feet (minimum) Opening for Sweeps 2 1 Connection Made With Burndy Connector P/N YGHP58C2W-2TN Or Equivalent Fig.
3.0 Site Preparation, continued 3.3 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.
4.0 Installation 4.1 Utility Powering XM2 Power Supplies are powered by either 120Vac or 240Vac (depending on the model), attached to an external service entrance. The size of the service conductors must be based on 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.
4.0 Installation, continued 4.1 Utility Powering, continued 4.1.1 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 bonding screw (provided) in the hole in the neutral bus. 2.
4.0 Installation, continued 4.1 Utility Powering, continued 4.1.2 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 bonding screw (provided) in the hole in the neutral bus. 2.
4.0 Installation, continued 4.1 Utility Powering, continued 4.1.3 Sample Input Power Panels For more information on available models of the Input Power Panel, refer to Section 5.0, PN Series Options.
4.0 Installation, continued 4.1 Utility Powering, continued 4.1.3 Sample Input Power Panels, continued Service and Distribution L oad Main Disconnect 20A L ine 1 From Feeder Supply 20A L ine 2 50A Neutral Equipment Grounding Conductor 15A N G NO Main B onding J umper 120V /15A 120V /20A 120V /20A B B X-100A- 8P OS Secondary Service 1) Main bonding jumper is NOT installed. 2) Grounding electrode conductor is NOT installed. 3) Lightning protection is part of feeder supply.
4.0 Installation, continued 4.1 Utility Powering, continued 4.1.3 Sample Input Power Panels, continued Service and Distribution Load Line 1 15A Line 2 From Feeder Supply 20A Neutral N Equipment Grounding Condutor G NO Main Bonding Jumper 120/20A 120/15A BBX-70A GFCI Secondary Service 1) Main bonding jumper is NOT installed. 2) Grounding electrode conductor is NOT installed. 3) Lightning protection is part of feeder supply. IPP-120-1 Fig.
4.0 Installation, continued 4.2 Coaxial Cable to Service Power Inserter (SPI) Installation 4.2.1 SPI to Ground Bar Connection Procedure Tools List: • 1" Socket (3/8" drive) • 3/8" Ratchet • #2 Phillips Screwdriver • Zip Tie Gun 1. Install SPI by tightening the attached coaxial connector to the equipment tray. Connector Fitting 2. Secure SPI ground wire to the SPI with attached screw. 3. Terminate stripped end of wire at enclosure ground bar. 031-103-B0-004, Rev.
4.0 Installation, continued 4.2 Coaxial Cable to Service Power Inserter (SPI) Installation, continued 4.2.2 Conduit Placement Conduit location is in the back of the enclosure, on the right side. The location is specified on concrete pad. Fig. 4-9, Conduit Location Fig. 4-10, Coaxial Connectors 22 031-103-B0-004, Rev.
4.0 Installation, continued 4.3 Battery Identification Each battery contains a DATE CODE. This date code must be recorded in the maintenance log. If batteries other than those sold by Alpha are used, consult the battery manufacturers’ documentation for date code type and placement. 09 06 MONTH: (SEP) 09 YEAR: 2006 Fig. 4-11, Alpha Cell Battery Date Code 4.4 Battery Terminal Connections The accompanying drawings are for illustrative purposes only.
4.0 Installation, continued 4.4 Battery Terminal Connections, continued Remove one 1" bolt from the Battery Cable Kit (BCK) hardware for making the fuse terminal connection. For all other terminals, use the 3/4" hardware included with the batteries. 3/4" bolt (included with battery) 1" bolt from BCK Fig. 4-13, Fuse Terminal Connection for Threaded Insert Batteries NOTE: Use a corrosion inhibitor (such as NCP-2) on battery terminals.
4.0 Installation, continued 4.4 Battery Terminal Connections, continued Refer to the battery manufacturers’ specifications for tightening torque. Nut Split Washer 1" x 1/4-20 Bolt Flat Washer Split Washer Battery Cable Flat Washer 3/4" x 1/4-20 Bolt Fuse Flat Washer In-line Fuse Link Spacer Battery Terminal Fig. 4-15, Hardware Installation for Fuse Terminal on Threaded Insert Battery Battery Cable Flat Washer Split Washer Battery Terminal Flat Washer Bolt Nut Fig.
4.0 Installation, continued 4.5 Battery Installation Procedure 1. Place the batteries on their respective shelves as shown in the figures below. 2. Connect the three (or four) batteries in series (negative to positive) to achieve 36Vdc (or 48Vdc). Route the battery cables inside the vertical rail for connection to the power supply. Torque terminal connector according to battery manufacturer recommendations (see battery label for torque specifications).
4.0 Installation, continued 4.5 Battery Installation Procedure, continued 4.5.1 Connecting the Battery Remote Temperature Sensor (RTS) The Remote Temperature Sensor (RTS) wiring connects to Temperature Sensor Input connector of XM2 Power Supply. Tape the sensor to the side of the middle battery in the string, so that the flat side of the sensor is flush to the side of the battery.
5.0 PN Series Options 5.1 Star Lock Security Bolt 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. See Section 6.0, Alpha Part Numbers, for PN Series options shown in this section. NOTE: The Security Key is a special tool that must be ordered separately. Alpha recommends ordering security keys for each maintenance crew. 1.
5.0 PN Series Options, continued 5.2 Battery Interface Unit (BIU) The BIU is used in Powernode systems with multiple power supplies 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. Upper Battery Shelf Lower Battery Shelf (PN-3) Middle Battery Shelf (PN-4) BIU Installed Under Upper Batter Shelf Fig. 5-1, Battery Interface Unit Installed 5.
5.0 PN Series Options, continued 5.4 Input Power Panel (IPP) There are four basic configurations of the IPP. Each is available in 120V and 240V. Units in Figs 5-6, 5-7, and 5-8 are factory pre-wired, include Square-D high-magnetic breakers for each power supply, and provide a GFCI convenience outlet. Fig. 5-6, IPP for Three Power Supplies Fig. 5-7, IPP for Two Power Supplies Fig, 5-8, IPP for One Power Supply Fig. 5-9, Breaker Duplex Option (BDO) For single power supply (NOT factory pre-wired) 5.
5.0 PN Series Options, continued 5.6 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 6.0 for part numbers. Auto Transformer Fuse Holder Fig.
6.
7.0 Pre-cast 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 +.25 0.25 -.125 REF. 0.000 38.
7.0 Pre-cast Pads, continued +3.0 -0.0 3.00 REF. 0.25 0.000 +.25 -.125 REF. 64.2 REF 26 REF 18.6 REF 26 REF 18.6 REF 21.86 15.86 14.36 2 2 2 2 9.06 7.55 24.0 REF 7.55 REF 36.0 REF 1 .000 1.42 3.11 2 2 8.14 54.58 48.08 48.58 44.76 40.08 32.08 33.83 21.83 24.08 25.83 26.12 18.64 13.83 5.83 7.58 9.67 5.87 3.67 2.17 0.42 .000 14.14 Fig.
7.0 Pre-cast Pads, continued 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 2 11.11 9.11 7.55 14.71 REF 1 7.6 REF .000 1.42 3.11 3.60 0.6 2 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 14.14 Fig. 7-3, Double-wide Pad, for CE 3x2/9x2 and CE8/9 or PN 3/4 Part Number: PCD 3-3x: 641-071-10 PCD 3-3x: 641-068-10 4" diameter opening (2 places). 5" x 8" opening (3 places).
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