Alpha XM 6005 Series, Technical Manual

Page 1: ...1997 AlphaTechnologies XM XPSERIES Uninterruptible Power Supplies XM 6005 Series XM 6007 Series XM 6010 Series XM 6012 Series XM 6015 Series Technical Manual 017 039 B0 006 06 99...

Page 2: ...UAL WHERE THESE SYMBOLS APPEAR SERVICING SHOULD BE PERFORMED ONLY BY QUALIFIED PERSONNEL DANGEROUS VOLTAGE A DANGEROUS VOLTAGE EXISTS IN THIS AREA OF THE POWER SUPPLY USE EXTREME CAUTION ATTENTION IMP...

Page 3: ...approximately 10 of the output rating of the power supply must be connected to the output Failure to do so could damage the load or the unit s ferroresonant power transformer Damage caused by this con...

Page 4: ...ULE OR BATTERIES GROUP 31 SIZE BATTERIES USED IN THE MAJORITY OF CABLE TELEVISION APPLICATIONS CAN WEIGH AS MUCH AS 70 LBS USE A BUCKET TRUCK OR SUITABLE SAFETY EQUIPMENT SUCH AS A SAFETY HARNESS AND...

Page 5: ...ER CHARGED FIRST CHECK FOR DEFECTIVE BATTERIES AND THEN VERIFY CORRECT CHARGER VOLTAGE SET TINGS BATTERYPREVENTIVEMAINTENANCE BATTERIES SHOULD BE INSPECTED EVERY THREE TO SIX MONTHS TO ENSURE OPTIMUMP...

Page 6: ...witch 2 2 2 FLOAT LED 2 2 3 EQUALIZE LED 2 2 4 RECHARGE LED 2 3 SystemStatusBlock 2 3 1 LINE POWER LED 2 3 2 STANDBYPOWER LED 2 3 3 ACOUTPUT LED 2 4 OutputCurrentDisplay 2 4 1 LEDDisplay 2 5 SDD Stand...

Page 7: ...XP Adaptor 5 17 APP60S Service Power Supply 5 18 Batteries 5 19 ABC 12 BatteryCharger 5 20 Enclosures 5 21 PS Series Pedestal Supports 5 22 DataLogger 5 23 AC Series Amp Clamps 5 24 CAT PAK ComputerA...

Page 8: ...ERYFAILURE 7 2 3 3 INVERTERFAILURE 7 3 Power Module Shutdown 8 MAINTENANCE 42 8 1 CheckBatteryTerminalsandConnectingWires 8 2 CheckBatteryOpenCircuitVoltage 8 3 CheckBatteryVoltageUnderLoad 8 4 CheckB...

Page 9: ...Modes of Operation APP60S Service Power Supply DataLogger DRAWINGS located at the back of the manual PME Pole mount Enclosure Installation and Wiring UL CSA PWE Pole mount Enclosure Installation and...

Page 10: ...ly backup power can continue for several hours When utility line power returns the XM Series power module waits momentarily for the utility voltage and frequency to stabilize and then initiates a smoo...

Page 11: ...ransfer isolation relay K101 At the same time power is directed to the auxiliary transformer T101 which provides power for the control circuitry A charger inverter winding on transformer T1 supplies t...

Page 12: ...sfer back to utility power without interruption of service to the load The battery charging circuit is then activated to recharge the batteries in preparation for the nextpoweroutage 1 2 3 ChargerOper...

Page 13: ...Frequency Hz Current Max A 1 Low AC Ref VAC OUTPUT Voltage VAC Current Max A Power VA BATTERIES Number Voltage VDC Backup Time Hrs WEIGHTS lbs kg MODEL CONFIGURATION INPUT Voltage VAC Frequency Hz Cu...

Page 14: ...2 45 VDC per cell 24 VDC Systems 25 9 VDC to 29 4 VDC selectable 36 VDC Systems 39 0 VDC to 44 1 VDC selectable 48 VDC Systems 52 0 VDC to 58 8 VDC selectable TemperatureCompensation 24 VDC Systems 0...

Page 15: ...st in Progress LED Check Batteries LED Check Inverter LED 2 2 Charger Status Block Charge Mode Switch Float LED Equalize LED Recharge LED 2 3 System Status Block Line Power LED Standby Power LED AC Ou...

Page 16: ...arms If a fault is detected during the APM self test mode the TEST RESET switch resets the enclosure s flashing LRI Local and Remote Indicator and the SSR Standby Status Relay alarms however the red C...

Page 17: ...2 2 FLOAT green LED The green FLOAT LED indicates that the battery charger is delivering a float charge to the batteries 2 2 3 EQUALIZE yellow LED The yellow EQUALIZE LED indicates that the battery c...

Page 18: ...operating from its battery backup When AC from the utility is lost the green LINE POWER LED goes OFF and the red STANDBY POWER LED comes ON as the unit transfers to inverter operation Whenever the red...

Page 19: ...bove the rated output of the power supply such as 18 or 20 Amps an overload or short circuit condition exists in the load 2 4 1 LEDDisplay The LEDs are set in 2 Amp increments from 2 to 20 Amps howeve...

Page 20: ...TIME and STANDBY EVENT information can be toggled by briefly pressing the MODE switch NOTE To clear either the ELAPSED TIME or STANDBY EVENT memory select the desired mode Press and hold the MODE swi...

Page 21: ...rvice Power Inserter or ACI Lamp option SPI 5 BatteryConnector Red Positive Black Negative Connects to batteries 6 AC Output Fuse XM 6015 20A XM 6012 15A XM 6010 12A 7 Battery Circuit Breaker 60 Amp m...

Page 22: ...24 VDC 250mA Use only Alpha P N 740 139 20 24 Volt LRI Lamp and Socket 3 4 AC Output The SPI Service Power Inserter which couples output power to the load plugs directly into the AC OUTPUT connector T...

Page 23: ...Module Assembly to allow access to the board connectors located on the USM logic upgrade Status Monitoring communications and tamper switch cables plug directly into the board s keyed connectors 3 10...

Page 24: ...VAC 10 Amp 600 VA Output XM6010 E Module 230 VAC 50 Hz Input 60 VAC 10 Amp 600 VA Output XM6010 P Module 220 VAC 60 Hz Input 60 VAC 10 Amp 600 VA Output XM6010 24 Module 120 VAC 60 Hz Input 60 VAC 10...

Page 25: ...stem Status block The lamp comes ON only when the power supply is running on backup power STANDBY During normal AC line opera tion the lamp remains OFF Whenever a fault is detected during the APM self...

Page 26: ...dual battery sizes up to Group 31 PME enclosures only 5 12 MST Module Slide Tray The MST is designed for use on PME and PWE pole mount enclosures only and is compatible with all XM Series power module...

Page 27: ...the batteries and power module The battery compartment accommodates 3 Group 31 gelled electrolyte no maintenance batteries and is equipped with a battery slide tray except PME for easy access The modu...

Page 28: ...Technicians can learn and develop maintenance skills at their own pace before leaving the office thus reducing overall maintenance time and standardizing maintenance practices Even though the CAT PAK...

Page 29: ...optional enclosures Note Batteries are shipped separately 3 Operator sManual 4 Any other ordered options Inspect the contents If items are damaged or missing contact Alpha Technologies and the shippin...

Page 30: ...e lower mounting strap on the rear of the enclosure The bracket s flanges face away from the enclosure Secure the lower mounting bracket using the 3 8 x 3 4 hex bolt included with the enclosure 3 Mark...

Page 31: ...nd UPE M ground mount enclosures Installation is as easy as digging a hole to the appropri ate depth to accommodate the base of the pedestal support and backfilling using a suitable material See 1 3 2...

Page 32: ...onal service entrance breaker High magnetic circuit breakers for Square D service entrances are available from Alpha Technologies Description Alpha Part No Square D High Inrush Breaker 470 013 10 Q011...

Page 33: ...ssis are tight otherwise loss of power arcing or possible damage can occur During routine maintenance the seizure screw assembly can be accessed through the grommeted hole without removing the SPI s c...

Page 34: ...ck connects from the battery cable into the module s BATTERY connector The connectors are keyed and color coded to fit in one direction only 5 If an optional LRI lamp Local and Remote Indicator is inc...

Page 35: ...ld not be used unless thoroughly recharged and tested Procedure Refer to the Battery Wiring drawing located at the back of the manual 1 Place the batteries with the positive terminals forward on the e...

Page 36: ...BC 12 battery charger They should then be thoroughly tested under load prior to installation If after charging a battery varies more than 0 3 VDC from the others it should not be used Typical Battery...

Page 37: ...E WHEN RE INSTALLING THE MODULE MAKE SURE THE CARD EDGE CONNECTOR IS FIRMLY SEATED IN THE BACK PLANE ASSEMBLY Procedure 1 To remove the main module assembly grasp the handle on the left side of the un...

Page 38: ...e FLOAT jumper at JP1 located midway along the lower side of the main board see illustration on below The jumper is factory set at FLOAT 2 40 5V for a 36 Volt battery string and can be repositioned if...

Page 39: ...ged first check for defective batteries and then verify the correct charge voltage settings 6 INSTALLATION 30 Main Circuit Module Assembly top view with APM Logic Upgrade S402 S401 S401 S402 APMLOGICU...

Page 40: ...rd jumpers Section 6 9 2 This feature is used to automatically send an equalize voltage to the batteries at predetermined intervals and durations It is extremely useful in maintaining equal charges am...

Page 41: ...to Equalize and Self test switches are in their desired positions see section 6 10 Plug the USM logic card into connector J2 located on the component side of the APM card Set the USM switches accordin...

Page 42: ...n P8 P9 P13 P14 require their jumpers across pins 2 3 SW4 is set to 0 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6 6 6 6 7 0 3 5 6 7 7 5 6 7 7 5 0 2 8 7 3 8 7 5 0 6 7 1 5 0 1 5 5 0 8 2 8 7 6 7 7 1 7 7 5 9 2 7 6 1 9...

Page 43: ...ns TMC 8061 transponders Transponders are internally mounted in Alpha power supply enclosures Select the following USM kit number according to your specific enclosure PWE 018 022 21 USM PME 018 022 22...

Page 44: ...nder is externally mounted in its own enclosure Select the following USM kit number according to your specific enclosure PWE 018 025 21 USM PME 018 025 22 USM UPE 018 025 23 USM UPE M 018 025 23 USM O...

Page 45: ...the HEM Headend Modem before being transmitted throughout the cable system They are received by the PSM Power Supply Modem located at each power supply location and directed to the USM A logic card Po...

Page 46: ...ZE LED comes ON verify the voltage at the BATTERY connector The voltage should closely match the EQU setting on the main circuit board assembly section 6 9 Note The battery charger is temperature comp...

Page 47: ...the output 7 2 1 3 TRANSFER or SELF TEST Mode On standard XM units When all three LEDs are ON at the same time the power module is in its transfer mode preparing to transfer back to AC LINE power The...

Page 48: ...2 EQUALIZEMode Indicates that the batteries are receiving an EQUALIZE charge On the standard XP Series power supplies EQUALIZE can only be activated by pressing the CHARGE MODE switch 7 2 2 3 RECHARGE...

Page 49: ...is required Under this condition the power supply will not be able to support inverter operation Refer to Maintenance 8 8 2 7 2 3 3 INVERTERFAILURE Indicates that the inverter has failed to produce AC...

Page 50: ...S power cord into the enclosure s convenience outlet Switch the APP60 S ON Note Verify that the 30 60 VAC selector is in the desired position 3 Toggle the switch on the SPI from ON to ALT 4 Switch the...

Page 51: ...rrent Inverter Events Accumulated Inverter Run Time Technician ID Number Power Supply Address Test Date and Time can be retrieved and stored in the DataLogger 8 MAINTENANCE 42 The Alpha Technologies D...

Page 52: ...ERATESHEAT AND MAY CAUSE BURNS IF HANDLED WITH BARE HANDS NEVER ATTEMPT TO RECALIBRATE A LOGIC CARD IN THE FIELD OTHER THAN SETTING BATTERY CHARGER VOLTAGE JUMPERS SECTION 6 9 OR APM AUTO MATIC PROGRA...

Page 53: ...ill be higher Record the float voltage in the power supply mainte nance log The jumpers at JP1 on the Main Circuit Module assembly are designed for easy calibration of float charge voltages for differ...

Page 54: ...eplace the plug in logic upgrade Reactivate self test to verify that the problem has been corrected If the power module continues to fail self test it should be replaced 8 9 Main Circuit Module and Lo...

Page 55: ...20 Plug In Module 120V 60 Hz 36V Batt w out SDD option XM 6007 6010 6012 6015 740 143 21 Plug In Module 230V 50 Hz 36V Batt w out SDD option XM E 6007 6010 6012 6015 740 143 23 Plug In Module 120V 60...

Page 56: ...Breaker 520 004 10 Fuseholder SPARE ENCLOSURE PARTS 020 019 31 Output Filter SPI for PME PWE PWV 020 019 32 Output Filter SPI for UPE 020 019 32 Output Filter SPI for UPE M 160 002 10 MOV for SPI 470...

Page 57: ...ging Marginal battery capacity Check batteries and replace if necessary SYMPTOM PROBABLE CAUSE REMEDY No output to cable AC output fuse open Replace fuse AC line power available Green AC OUTPUT LED of...

Page 58: ...ack plane connector assembly Faulty logic Replace main circuit module Inverter transistors damaged Replace power board Faulty standby relay Replace relay K101 SYMPTOM PROBABLE CAUSE REMEDY module does...

Page 59: ...r main circuit module Defective charger transistors Replace power board and or main circuit module SYMPTOM PROBABLE CAUSE REMEDY MOV in SPI darkened Lightning or other transient Replace MOV in SPI or...

Page 60: ...ditions of the LIMITED WARRANTY STATEMENT are contained in a separate written LIMITED WARRANTY STATEMENT included with the Operator s manual provided with this product If there are any warranty claims...

Page 61: ...ologies Cartel Business Estate Edinburgh Way Harlow Essex CM20 2DU Tel 44 1279 422110 Fax 44 1279 423355 GERMANY Alpha Technologies Hansastrasse 8 D 91126 Schwabach Tel 49 9122 997303 Fax 49 9122 9973...