Alpha Technologies Alpha Outback Energy AlphaCap-665 User manual

Your Power Solutions Partner
AlphaCap-665
Installation & Operation Manual
Part # 013-015-B2
Effective: 07/2020

AlphaCap-665
NOTE:
Photographs contained in this manual are for illustrative purposes only. These photo-
graphs may not match your installation.
NOTE:
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, contact Alpha and Outback Energy GmbH or your nearest AOE representative.
NOTE:
AOE 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 inconsistent with its intended purpose, or if installed or oper-
ated in an unapproved manner, or improperly maintained.
Copyright
Copyright © 2014 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technolo-
gies.
No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or transmit-
ted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or otherwise
without prior explicit written permission from Alpha Technologies.
This document, the software it describes, and the information and know-how they contain constitute the proprietary,
confidential and valuable trade secret information of Alpha Technologies, and may not be used for any unauthorized
purpose, or disclosed toothers without the prior written permission ofAlpha Technologies.
The material contained in this document is for information only and is subject to change without notice. While
reasonable efforts have been made in the preparation of this document to assure its accuracy, Alpha Technologies
assumes no liability resulting from errors or omissions in this document, or from the use of the information contained
herein. Alpha Technologies reserves the right to make changes in the product design without reservation and with-
out notification to its users.
Worldwide Corporate Offices
Alpha and Outback Energy GmbH reserves the right to make changes to the products and information contained in this document without notice. Copyright © 2020 Alpha and Outback Energy GmbH. All
Rights reserved.
Headquarter Germany
Hansastrasse 8
D-91126 Schwabach
Tel: [phone]
Fax: [phone]
Mail: [email protected]
France and Benelux
[e-mail]
Spain
[email protected]
For more information please visit www.alpha-outback-energy.com
Russia
[e-mail]
Africa
[email protected]
Eastern Europe
[email protected]
Middle East
[email protected]

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Table of Contents
1. Safety....................................................................................................................................4
1.1 Safety Symbols .......................................................................................................................... 4
1.2 General Safety ........................................................................................................................... 4
1.3 Mechanical Safety...................................................................................................................... 4
1.4 Electrical Safety ......................................................................................................................... 5
1.5 Battery Safety ............................................................................................................................ 5
2. Introduction ...........................................................................................................................6
2.1 Scope of the Manual .................................................................................................................. 6
2.2 Product Overview....................................................................................................................... 6
2.3 Ordering Information .................................................................................................................. 6
3. Features................................................................................................................................7
3.1 Electrical .................................................................................................................................... 7
3.2 Input ........................................................................................................................................... 7
3.3 Output ........................................................................................................................................ 7
4. Operating Temperature .........................................................................................................8
4.1 Operating range ......................................................................................................................... 8
4.2 High-temperature shutdown....................................................................................................... 8
4.3 Ambient versus case temperature ............................................................................................. 8
4.4 Temperature effects ................................................................................................................... 8
4.5 Electrical .................................................................................................................................... 8
4.6 Signals ....................................................................................................................................... 9
5. Inspection............................................................................................................................10
5.1 Packing Materials..................................................................................................................... 10
5.2 Check for Damage ................................................................................................................... 10
5.3 General Receipt of Shipment................................................................................................... 10
6. Installation and Connections...............................................................................................11

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013-015-B2 Rev C
6.1 Safety Precautions....................................................................................................................11
6.2 Tools Required ..........................................................................................................................11
6.3 Wall Mount ................................................................................................................................11
6.4 Connections ............................................................................................................................. 12
7. Maintenance .......................................................................................................................13
8. Warranty and Service Information ......................................................................................14
8.1 Technical Support .................................................................................................................... 14
8.2 Warranty................................................................................................................................... 14
8.3 Battery Warranty ...................................................................................................................... 14
8.4 Return of Material ................................................................................................................... 14
8.5 Service Centers ....................................................................................................................... 14
9. Acronyms and Denitions ...................................................................................................15
10. Certication.......................................................................................................................16

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1. Safety
SAVE THESE INSTRUCTIONS: This manual contains important safety instructions that must
be followed during the installation, servicing, and maintenance of the product. Keep it in a safe place. 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.
1.1 Safety Symbols
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following sym-
bols have been placed throughout this manual. Where these symbols appear, use extra care and attention.
The use of ATTENTION indicates specic regulatory/code requirements that may affect the
placement of equipment and /or installation procedures.
NOTE:
A NOTE provides additional information to help complete a specic task or procedure.
Notes are designated with a checkmark, the word NOTE, and a rule beneath which the
information appears.
WARNING!
WARNING presents safety information to PREVENT INJURY OR DEATH to personnel.
Warnings are indicated by a shock hazard icon, the word WARNING, and a rule beneath
which the information appears.
CAUTION!
CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment. Cautions are designated with a yellow warning triangle, the word CAUTION,
and a rule beneath which the information appears.
HOT!
The use of HOT presents safety information to PREVENT BURNS to the technician or
user.
1.2 General Safety
WARNING!
This system is designed to be installed in a restricted access location that is inacces-
sible to the general public.
1.3 Mechanical Safety
• Keep hands and tools clear of fans. Fans are thermostatically controlled and switch on automatically.
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components and sharp edges.

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1.4 Electrical Safety
WARNING!
WARNING!
WARNING!
Before working with any live battery or power system, follow these precautions:
a. Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.
b. Wear safety glasses with side shields at all times during the installation.
c. Use OSHA approved insulated hand tools.
Lethal voltages are present within the power system. Always assume that an electrical
connection or conductor is energized. Check the circuit with a voltmeter with respect to
the grounded portion of the enclosure (both AC and DC) before performing any installa-
tion or removal procedure.
• Do not work alone under hazardous conditions.
• A licensed electrician is required to install permanently wired equipment. Input voltages can range up to 240 Vac.
Ensure that the utility power is disconnected and locked out before performing any installation or removal proce-
dure.
• Ensure that no liquids or wet clothes come into contact with internal components.
• Hazardous electrically live parts inside this unit are energized from the batteries even when the AC input power is
disconnected.
1.5 Battery Safety
• Servicing and connection of batteries must be performed by, or under the direct supervision of, personnel knowl-
edgeable of batteries and the required safety precautions.
• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all metal-
lic objects from your hands and neck.
• Use OSHA approved insulated hand tools. Do not rest tools on top of batteries.
• Batteries contain or emit chemicals known to cause cancer and birth defects or other reproductive harm. Battery
post terminals and related accessories contain lead and lead compounds. Wash your hands after handling bat-
teries.
Follow battery manufacturer’s safety recommendations when working around battery
systems. Do not smoke or introduce an open ame when batteries (especially vented
batteries) are charging. When charging, batteries vent hydrogen gas, which can ex-
plode.
• Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the battery
manufacturer for recommended local authorized recyclers.
Hazardous voltages are present at the input of power systems. The DC output from rec-
tiers and batteries, though not dangerous in voltage, has a high short-circuit current
capacity that may cause severe burns and electrical arcing.

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2. Introduction
2.1 Scope of the Manual
This instruction manual explains the installation, interconnection, and operation of Alpha Technologies’ AlphaCap-665
short duration backup supply module. To aid the user with installation, frequent reference is made to specifications
and drawings located at the rear of the manual.
•Specifications 013-015-B1
• Outline Drawing 013-015-06
• Customer Connections 013-015-08
2.2 Product Overview
The product is designed to be used for short duration power backup (holdup) of 48 Vdc powered remote loads such
as xDSL and FTTx equipment.
The AlphaCap system uses an array of Ultra™ capacitors in conjunction with a DC-DC converter board. Similar to a
battery, the system is paralleled on the 48 Vdc bus of the load.
A typical application is holding up remote equipment that are deployed using network or line powering systems and
that are susceptible to brief outages due to transients and Ground Fault Interupt (GFI) resets. Another application is
local powered remote systems deployed with battery eliminators (DC rectifier without battery backup).
The AlphaCap-665 provides continuous voltage output for a load up to 750W over a period of time.
2.3 Ordering Information
This product is available to order under the following part numbers and list options:
Description Part Number/List Option
AlphaCap-665 013-015-20
Basic module *List 0
* Default option
The above information is valid at the time of publication. Consult factory for up-to-date ordering information.

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3. Features
3.1 Electrical
The AlphaCap-665 is designed with a single connector for input and output for a single “+” and “-” connection to the
–48 Vdc system bus similar to a battery.
3.2 Input
The AlphaCap-665 has a built in charge limit of 160 mA to ensure only minimal DC power provisioned to the remote
load is consumed.
The AlphaCap will recharge to full capacity within 30 minutes regardless of depth of discharge.
3.3 Output
The unit supplies 665W continuous power for 4.5 seconds under nominal operating conditions. The unit will supply
665W for at least 3 seconds down to –40°C (–40°F).
Under nominal operating conditions, the maximum duration holdup is 30 seconds on a 130W load. The Alpha-
Cap-665 can provide up to 750W of power for 3.8 second duration under normal operating conditions.

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4. Operating Temperature
4.1 Operating range
The AlphaCap-665 operating range is -40°C to +65°C (-40°F to +149°F).
4.2 High-temperature shutdown
A temperature of +65°C will trigger a high-temperature shutdown. Normal holdup and charging functions will resume
when the temperature drops to +60°C (+140°F). In other words, there is a 5°C (9°F) hysteresis.
4.3 Ambient versus case temperature
In most cases, the temperature limitations are based on the ambient temperature. Because a fully charged Alpha-
Cap-665 dissipates very little heat, the case temperature is assumed to be equal to the ambient temperature.
4.4 Temperature effects
4.4.1 Holdup duration
The holdup duration decreases as the temperature increases. The power output also affects the holdup duration,
making this a 3-dimensional analysis.
4.4.2 Capacitor life expectancy
High temperatures decrease the life of an AlphaCap-665, for example:
350 W load at 25°C (77°F) 11 s of holdup after 10 years.
350 W load at 45°C (113°F) 8 s of holdup after 10 years.
350 W load at 55°C (131°F) 4 s of holdup after 10 years.
4.5 Electrical
The AlphaCap-665 is designed with a single connector for input and output for a single “+” and “-“ connection to the
–48 Vdc system bus similar to a battery.

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4.6 Signals
LED Indicator - The AlphaCap-665 has a bi-color LED displayed at two locations on the chassis. LED indications
are as follows:
• Green (Solid): OK
• Green (Flashing): Charging
• Green / Amber (Alternating): Backup
• Green / Red (Alternating): Over-charging, charging circuit failure
• Red (Solid) or OFF: Module Fail.
Alarm Relay - The AlphaCap-665 has a dry contact alarm relay to signal module failure. The alarm relay
is a normally closed (NC)configuration. During normal operating conditions, the relay is energized for open
circuit, and on alarm the relay de-energizes closing the relay. The alarm relay will trigger under the following
conditions:
• Capacitor fully discharged
• Low voltage input shutdown
• Cap overcharge shutdown
• Over temperature shutdown
• Internal voltage reference error
• Blown fuse.

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5. Inspection
5.1 Packing Materials
All Alpha products are shipped in rugged, double walled boxes and suspended via solid inserts to minimize shock
that may occur during transportation. Packaging assemblies and methods are tested to International Safe Transit
Association standards. Power systems are custom packaged in heavy-duty plywood crates.
Products are also packaged with Cortex. This plastic wrap contains a corrosive-inhibitor that protects the product
from corrosion for up to two years.
Rectifiers and batteries are shipped on individual pallets and are packaged according to the manufacturer’s guide-
lines.
5.1.1 Returns for Service
Save the original shipping container. If the product needs to be returned for service, it should be packaged in its
original shipping container. If the original container is unavailable, make sure that the product is packed with at least
three inches of shock-absorbing material to prevent shipping damage.
Alpha Technologies is not responsible for damage caused by improper packaging of returned products.
5.2 Check for Damage
Before unpacking the product, note any damage to the shipping container. Unpack the product and inspect the
exterior for damage. If any damage is observed, contact the carrier immediately.
Continue the inspection for any internal damage. In the unlikely event of internal damage, inform the carrier and con-
tact Alpha Technologies for advice on the impact of any damage.
5.3 General Receipt of Shipment
The inventory included with your shipment depends on the options you have ordered. The options are clearly
marked on the shipping container labels and bill of materials.
If you have any questions before you proceed, call Alpha Technologies: 1 888 462-7487.

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6. Installation and Connections
Only qualified personnel should install the product which shall be mounted in a clean and dry environment.
6.1 Safety Precautions
Refer to the Safety section at the front of this manual.
6.2 Tools Required
Various insulated tools are essential for the installation. Use this list as a guide:
• Battery lifting apparatus if required.
• Electric drill with hammer action, 1/2" capacity.
• Various crimping tools and dies to match lugs used in installation.
• Load bank of sufficient capacity to load largest rectifier to its current limit.
• Digital voltmeter equipped with test leads.
• Cable cutters.
• Torque wrench: 1/4" drive, 0 - 150 in-lb.
• Torque wrench: 3/8" drive, 0 - 100 ft-lb.
• Insulating canvases as required (2' x 2', 1' x 1', 3' x 3', etc.).
• Various insulated hand tools including:
- Combination wrenches. - Ratchet and socket set.
- Various screwdrivers. - Electricians knife.
• Battery safety spill kit required for wet cells only:
- Protective clothing. - Face shields.
- Gloves. - Baking soda.
- Eye wash equipment.
• Cutters and wire strippers (#14 to #22 AWG) [2.5 to 0.34 mm²].
6.3 Wall Mount
The standard unit consists of a one-piece top, sides with cutouts and a bottom cover. The unit may be installed with
the wall mounting holes in the flanges of the chassis. See drawing 013-015-06.
The product must be mounted in a clean and dry environment.

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6.4 Connections
All wiring connections are accessible at the side of the module. See drawing 013-015-08.
6.4.1 Grounding
Two standoffs (#10-32, 5/8” center) are provided on the chassis for earth ground.
6.4.2 Power
Connect –48 and +RTN power supply connections to the 2-position Tyco (193839-1) terminal block provided using
#12-18 AWG TEW 90 wire or equivalent.
The mating connector requires a Mate-N-Lok Amp 770017-1 (housing) and two (2) Amp 193841-1 crimp contacts.
Ensure power supply connection is to a voltage source within the limits of the device configuration. Refer to the tech-
nical specifications in this manual.
6.4.3 Alarm
Alarm relay connection at the AlphaCap-665 is made via an Amp Mate-N-Lok connection. The relay is rated for a
maximum load of 2A / 60W. The connector located on the AlphaCap is Amp 2-1445055-2.
The mating connector required for connecting to the alarms on the AlphaCap is Amp 1445022-2 (housing). The
housing requires two (2) Amp 794610-1 female crimp contacts:
• Pin 1 on the connector = Common
• Pin 2 on the connector = NC

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7. Maintenance
Although very little maintenance is required with Alpha systems, routine checks and adjustments are recommended
to ensure optimum system performance. These procedures should be performed at least once a year.
Only qualified service personnel should do the repairs.
The following table lists a few maintenance procedures for this system.
Use extreme care when working inside the unit while the system is energized. Do not
make contact with live components or parts.
Circuit cards, including RAM chips, can be damaged by static electricity. Always wear a
grounded wrist strap when handling or installing circuit cards.
Ensure redundant modules or batteries are used to eliminate the threat of service inter-
ruptions while performing maintenance on the system’s alarms and control settings.
Stored energy hazard. Do Not Open the cover. No serviceable parts inside.
WARNING!
Table A — Sample maintenance log
Procedure Date Completed
Inspect all system connections. Re-torque if necessary.
Verify alarm/control settings.

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8. Warranty and Service Information
8.1 Technical Support
Free Technical Support is part of the AOE customer satisfaction commitment. The phone numbers below can also
be used to access a wide range of service solutions both at your premise and at the AOE facility nearest you.
Tel: [phone]
Mail: [email protected]
8.2 Warranty
from the date of shipment from the factory. The warranty provides for repairing, replacing or issuing credit (at AOE’s
discretion) for any equipment manufactured by it and returned by the customer to the factory or other authorized
location during the warranty period.
There are limitations to this warranty coverage. The warranty does not provide to the customer or other parties any
remedies other than the above. It does not provide coverage for any loss of profits, loss of use, costs for removal or
installation of defective equipment, damages or consequential damages based upon equipment failure during or after
the warranty period. No other obligations are expressed or implied. Warranty also does not cover damage or
equipment failure due to cause(s) external to the unit including, but not limited to, environmental conditions, water
damage, power surges or any other external influence.
The customer is responsible for all shipping and handling charges. Where products are covered under warranty AOE
will pay the cost of shipping the repaired or replacement unit back to the customer.
8.3 Battery Warranty
Note that battery warranty terms and conditions vary by battery and by intended use. The most common battery
warranty provided by Alpha is a two year full replacement warranty with a pro-rated warranty for the following three
years. Pro rated warranty provides a credit applicable toward the purchase of new batteries from AOE. The credit is
calculated as the purchase price multiplied by the percentage of the battery life that was not available (in months).
Battery warranty coverage is lost where the battery charge is not maintained for 6 months. Contact your AOE sales
representative or the Technical Support team at the above number to understand your entitlements under Battery
Warranty.
8.4 Return of Material
Please contact Technical Support at the number above to obtain a Service Repair Order (or Return Material Autho-
rization) number BEFORE sending material back. This will ensure that your service needs are handled promptly and
efficiently.
8.5 Service Centers
For more information, refer to the AOE website: www.alpha-outback-energy.com

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9. Acronyms and Definitions
AC Alternating current
ANSI American National Standards Institute
AWG American Wire Gauge
BTU British thermal unit
CAN Controller area network
CEC Canadian Electrical Code
CSA Canadian Standards Association
CX Cordex™ series; e.g., CXC for Cordex System Controller
DC Direct current
DHCP Dynamic Host Conguration Protocol
DSL Digital Subscriber Line
EIA Electronic Industries Alliance
EMC Electromagnetic compatibility
EMI Electromagnetic interference
ERM Electromagnetic Compatibility and Radio Spectrum Matters
ESD Electrostatic Discharge
FCC Federal Communications Commission (for the USA)
GFI Ground Fault Interupt
GSM Group Speciale Mobile (global system for mobile communications)
HVSD High voltage shutdown
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IP Internet Protocol
LED Light emitting diode
LVD Low voltage disconnect
MIL One thousandth of an inch; used in expressing wire cross sectional area
MOV Metal oxide varistor
MTBF Mean time between failures
NC Normally closed
NEC National Electrical Code (for the USA)
NO Normally open
OSHA Occupational Safety & Health Administration
OVP Over voltage protection
RAM Random access memory
RU Rack unit (1.75”)
TCP/IP Transmission Control Protocol / Internet Protocol
THD Total harmonic distortion
UL Underwriters Laboratories
VRLA Valve regulated lead acid

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10. Certification
About CSA and NRTL
CSA (Canadian Standards Association also known as CSA International) was established in
1919 as an independent testing laboratory in Canada. CSA received its recognition as an NRTL
(Nationally Recognized Testing Laboratory) in 1992 from OSHA (Occupational Safety and Health
Administration) in the United States of America (Docket No. NRTL-2-92). This was expanded
and renewed in 1997, 1999, and 2001. The specific notifications were posted on OSHA’s official
website as follows:
• Federal Register #: 59:40602 - 40609 [08/09/1994]
• Federal Register #: 64:60240 - 60241 [11/04/1999]
• Federal Register #: 66:35271 - 35278 [07/03/2001]
When these marks appear with the indicator “C and US” or “NRTL/C” it means that the
product is certified for both the US and Canadian markets, to the applicable US and Canadian
standards. (1)
Alpha rectifier and power system products, bearing the aforementioned CSA marks, are certi-
fied to CSA C22.2 No. 60950-01 and UL 60950-01. Alpha UPS products, bearing the afore-
mentioned CSA marks, are certified to CSA C22.2 No. 107.3 and UL 1778.
As part of the reciprocal, US/Canada agreement regarding testing laboratories, the Standards
Council of Canada (Canada’s national accreditation body) granted Underwriters Laboratories
(UL) authority to certify products for sale in Canada. (2)
Only Underwriters Laboratories may grant a licence for the use of this mark, which indicates
compliance with both Canadian and US requirements. (3)
NRTLs capabilities
NRTLs are third party organizations recognized by OSHA, US Depart-
ment of Labor, under the NRTL program.
The testing and certifications are based on product safety standards
developed by US based standards developing organizations and are
often issued by the American National Standards Institute (ANSI). (4)
The NRTL determines that a product meets the requirements of an ap-
propriate consensus-based product safety standard either by success-
fully testing the product itself, or by verifying that a contract laboratory
has done so, and the NRTL certifies that the product meets the require-
ments of the product safety standard. (4)
Governance of NRTL
The NRTL Program is both national and international in scope with
foreign labs permitted.
(1)www.csagroup.org
(2) www.scc.ca
(3) www.ulc.ca
(4) www.osha.gov

Specifications for Alpha Technologies’ AlphaCap-665
013-015-B1 Rev B
Page 1 of 2
Input
Voltage: –48 to –56 Vdc
Current (Charge): 160 mA ±10% maximum
Output
Voltage: –46 Vdc ±3%
Power: 665 W nominal
750 W maximum
Duration Backup: 4.5 seconds, 665 W @ 5 to 55°C
3 seconds minimum, 665 W load over full temperature range
30 seconds maximum duration at low load
3.8 seconds, 750 W load
Interface
Display: Status indicator LEDs (2)
Alarm: Relay output connection for system fail
Connections
I/O (–48V / +RTN): Tyco (193839-1) connector
Mate with Amp 770017-1 (housing) plus 2x Amp 193841-1 (contacts)
Chassis/Frame Ground: 2x #10-32 stud connections, 5/8" center
Alarm (single Form B relay): Amp 2-1445055-2; common with normally closed state terminations
Mate with Amp 1445022-2 (housing) plus 2x Amp 794610-1 (contacts)
Mechanical
Mounting: L-shaped brackets for wall mounting
Dimensions: 43.1 mm H x 183.4 mm W x 350.5 mm D (1.70" H x 7.22" W x 13.8" D)
Environmental
Temperature: 5 to 55°C nominal operating (41 to 131°F)
-40 to 65°C extended operating (-40 to 149°F). See manual for details on how
temperature affects performance.
Derated duration backup below 5°C, derated capacitor life above 55°C.
Humidity: 0 to 95% non-condensing
Elevation: -500 m to +4000 m, derated for ambient temperature above 2000 m to 40°C at
4000 m.
(-1640 feet to 13124 feet, derated for ambient temperature above 6562 feet to
104°F at 13124 feet).

Specifications for Alpha Technologies’ AlphaCap-665 Continued
013-015-B1 Rev B
Page 2 of 2
Compliance
This product is designed to meet or exceed the following:
UL 60950-1-2002
CSA C22.2 No. 60950
Telcordia (Bellcore) GR-1089-CORE (requirements where applicable)
In accordance with FCC requirements, we provide the following statement as specified in the FCC guidelines for
conformance to Part 15, Class A:
NOTE: This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful interference to
radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own
expense.
Any changes or modifications to this equipment not expressly described in this manual could void the FCC
compliance.
The above information is valid at the time of publication. Consult factory for up-to-date ordering information.
Specifications are subject to change without notice.