Alpha Technologies APP 9022S User manual

APP9015S
APP9022S
ServicePowerSupply
Installation and Operation Manual
Effective: May 2002
®
© 2002 TM

3
© 2002 TM 016-537-B0-002 Rev. B
APP 9015S
APP 9022S
Service Power Supply
Installation and Operation Manual
016-537-B0-002, Rev. B
May, 2002
© 2002 Alpha Technologies
®

4
© 2002 TM 016-537-B0-002 Rev. B
Table1-1; Specifications ............................................................................ 11
List of Tables
Table of Contents
Contact Alpha ..................................................................................................... 6
Safety .................................................................................................................. 7
Safety Symbols Used in this Manual...............................................................................................7
SafetyPrecautions..........................................................................................................................7
Utility PowerConnection Notes .......................................................................................................8
Unpacking and Inspection ................................................................................ 9
1. Introduction
1.1 The APPServicePower Supply..............................................................................11
1.2 TheoryofOperation ................................................................................................ 12
1.3 APPService Power Supply Features ..................................................................... 12
2. Installation
2.1 APP SPSInstallation andPower Module Removal ................................................. 16
3. Trouble-Shooting
3.1 Trouble-ShootingGuide .......................................................................................... 18
3.2 APP 9022S Schematic .......................................................................................... 20
3.3 Returns, Repair,andPartsOrdering ...................................................................... 21

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© 2002 TM 016-537-B0-002 Rev. B
Table of Figures
Figure1-1; APP 9015S ServicePower Supply, Front Panel.........................14
Figure1-2; APP 9022S ServicePower Supply, Front Panel.........................15
Figure2-1; 20AServicePowerInserter ........................................................17
Figure2-2; 25AServicePowerInserter ........................................................17
Figure3-1; APP9022S Service PowerSupply Schematic ...........................20

Contact Alpha
016-537-B0-002 Rev. B 6© 2002 TM
General product information
and customer service
7:00 AM to 5:00 PM Pacific Time
1-800-863-3930
To obtain complete technical support
7:00 AM to 5:00 PM Pacific Time
or
For after-hours emergency support
7 days per week, 24 hours a day
1-800-863-3364

Safety
7
© 2002 TM 016-537-B0-002 Rev. B
Safety Precautions
• TheAPPService PowerSupply must be installed andserviced byqualified personnel.
• Alwaysuse proper lifting techniques wheneverhandling units, modulesor batteries.
• Verify the voltagerequirementsof the equipmentto beprotected (load), theACinput
voltage to the power supply (line), and the output voltage of the system prior to
installation.
• The utility service panel must be equipped with a properly rated circuit breaker for use
with this power supply.
• Do NOTexceed the output rating of the power supply, when connecting the load.
• Use a bucket truck or suitable climbing equipment, such as safety harness and
spikes,whenever installing orservicing pole-mount installations.
• Do not let exposed battery cables come in contact with the chassis or enclosure.
Safety Symbols Used in this Manual
To reduce the risk of electrical shock, injury or death caused by moving parts or the
explosionof fuel, andto ensurethe safe operationof this unit,the following symbolshave
beenplaced throughout thismanual. Where thesesymbols appear,servicing mustonly be
performedbyqualifiedpersonnel.
Dangerous Voltage
This symbol indicates that a “dangerous voltage” exists in this area of the product.
Usecaution whenever working inthe area topreventelectrical shock.
Attention
Thissymbol indicates importantinstallation, operation ormaintenance instructions.
Always follow these instructions closely.
CAUTION
HAZARDOUS CONDITION

Safety
016-537-B0-002 Rev. B 8© 2002 TM
Utility Power Connection Notes
NOTE: UL and NEC require that a service disconnect switch (UL listed) be
provided by the installer and be connected between the power source and
the Alpha power supply. Connection to the power supply must include an
appropriate service entrance weather head.
CAUTION: A “high magnetic” trip breaker must be used in order to accommodate the
high-inrush currents normally associated with the start-up of ferroresonant
transformers (400 Amp, no-trip, first-half cycle). Do not replace this
breaker with a conventional service entrance breaker. Alpha recommends
only Airpax breakers because of increased reliability in this powering
application.
CAUTION: Installation must be performed by qualified service personnel only, and in
compliance with local electrical codes. Connection to utility power must
be approved by the local utility before installing the power supply.
Warning! Do not unplug output connector while unit is in operation! Circuit breaker
must be turned off first.

Unpacking and Inspection
9
© 2002 TM 016-537-B0-002 Rev. B
Verify that the following items have beenincluded inthe shipping container:
APP 9015S:
1. APP9015S Service PowerSupply
Alphap/n:016-529-20
2. Powercord with 5-20Pplug (120VAC)
Alphap/n:874-935-20
3. Powercord with 6-15Pplug (240VAC)
Alphap/n:874-935-21
4. Y-cable with Jones connectors
Alphap/n:874-949-21
5. Y-cable with 25Aconnectors
Alphap/n:874-949-20
APP 9022S:
1. APP9022S Service PowerSupply
Alphap/n:016-537-20
2. Powercord with 5-20Pplug (120VAC)
Alphap/n:874-726-20
3. Powercord with 6-15Pplug (240VAC)
Alphap/n:847-727-20
4. Output cable, single Jones
Alphap/n:874-728-20
NEMA5-20Plug
NEMA6-15Plug
NEMA5-20Plug
NEMA6-15Plug

Unpacking and Inspection
016-537-B0-002 Rev. B 10 © 2002 TM
Inspect the contents. If items are damaged or missing, contactAlpha Technologies and the
shipping company. Most shipping companies have a limited claim period, so it is important to
reportdamage immediately.
7. Optional10-Ft cord with30A connector
and Twist Lockplug(125VAC)
Alphap/n:874-935-22
Save the original shipping container.
In the event that a unit must be returned for service,Alpha requests that it be packaged in
its original shipping container. If the original container is not available, make sure the unit
is packed with at least three inches of shock absorbing material to prevent shipping
damage.
NOTE: Do not usepopcorn-type material.AlphaTechnologiesis not
responsiblefor damage causedby improper packingon returned
units.
6. Optional 30-Ft Output kit, includes:
Alpha p/n (for kit): 745-094-20
a. Y cable adapter for Jones connector
Alphap/n:874-949-34
b. Y cable adapter for 25A connector
Alphap/n:874-949-33
c. 30-Ft cable
Alphap/n:874-949-32
APP 9022S, continued
a
b
c
NEMAL5-30RPlug

1. Introduction
11
© 2002 TM 016-537-B0-002 Rev. B
Table1-1; Specifications
*Figuresshownreflectusewithpowercordsuppliedwithunit.
For22A@120V,useoptional30A125Vcord(27Amax).
†Outputvoltagew/inputfrequency=60Hz.Otherwise±10%
MODEL APP 9015S APP 9022S
Input Voltage (VAC) 120/240 ± 15% 120/240 ± 15%
Input Frequency
(Hz)
60 ± 3% 60 ± 3%
Input Current
(A)
12 12.5 @ 240 VAC max*
22 @ 120 VAC max*
Output Voltage
(VAC)
60/75/90 ± 5%† 60/75/90 ± 5%†
Output Current (A) 15 Continuous
Output Power (VA)
(Continuous)
1350
Output Current Limit 150% of Output
Rating
150% of Output
Rating
Efficiency 90% typical
@rated load
90% typical
@rated load
Finish Flat Black Flat Black
Operating
Temperature Range
-40° F to +122° F
(-40° C to +50° C)
-40° F to +122° F
(-40° C to +50° C)
Dimensions (in/mm)
(H x W x D)
9" x 9.5" x 13.75"/
241 x 229 x 349
9" x 9.5" x 13.75"/
241 x 229 x 349
Weight (lbs/kg) 47/21 60/27
Enclosure Type NEMA 1 NEMA 2
1350/1650/1950
17 (120 VAC in*)
22 Continuous
(240 VAC in*)
TheAPPService Power Supply(SPS)isaportabledeviceusedtoprovidetemporarypowerwhile
the existing power supply is being serviced. The APP SPS can be used in either pole- or ground-
mountenclosurestoprovidesignalprocessingequipmentinCableTelevisionandBroadbandLAN
distributionsystemswithcurrent-limited,regulatedAC power.
The APP SPS contains a front panel ammeter to measure the output current to the load; an output
breaker to protect against excessive short circuit currents; an "Output" indicator to verify AC output
power;aninputbreakertoprovideadditionalvoltageprotection;anda60/75/90VACswitchfor
outputvoltageselection.
1.1 The APP Service Power Supply

1. Introduction
016-537-B0-002 Rev. B 12 © 2002 TM
1.2 Theory of Operation
TheAPPSPScontainsaferroresonanttransformerand aresonantcapacitor.(RefertoFigure3-1,
APP 9022S schematic.) During AC LINE operation, utility power is fed into the primary winding of
theferroresonanttransformer, T1. An ACcapacitor,C1,forms the resonant circuitofthe
ferroresonanttransformerwhichprovidesnoiseandspikeattenuation,shortcircuitcurrentlimiting,
andoutputvoltageregulation.Note:Theferroresonanttransformerproducesa"quasi"squarewave
outputwhichresemblesaroundedsquarewave.
AC power enters the Service Power Supply where it is regulated to 60, 75 or 90 VAC, and passed
ontotheload via theServicePowerInserter (SPI), locatedinsidethepower supply enclosure.A
switch,located on theSPI, transfers outputpower from thepower supply requiringservice to the
APP SPS.
NOTE: Whenmeasuringtheoutputvoltageof ferroresonanttransformers,useonlya
trueRMSACvoltmeter.Non-RMSreadingmetersarecalibratedtorespondto
puresinewavesandwillnotprovideanaccuratereadingwhenmeasuringa
"quasi"squarewaveoutput.
1.3 APP Service Power Supply Features
OutputCurrent(Ammeter)
TheAmmeterdisplaysoutputcurrentflowingfrom thepower moduleto the load.When
there is no load at the output, the Ammeter reads zero.
OutputBreaker
TheAC outputbreaker protects theload fromexcessive durations of short circuitcurrent, or
anout-of-phase(orbuck)condition.Ifthefront panelammeterreadszero,indicatingno
output to the load, this breaker must be checked, and reset if necessary.
Input Breaker / Power Switch
TheAC inputbreaker protects theService PowerSupply from shortcircuit conditions,
especially when it is used in conjunction with a generator during outage conditions. If the
unit does not turn ON when power is applied, first verify that the unit is plugged into the
convenience outlet and that the main AC circuit breaker is in the ON position.
Output Power Indicator (9022) / Pilot Light (9015)
TheOutputPowerLamp displays the presenceofoutputACvoltage.
Warning! Do not unplug output connector while unit is in operation! Circuit breaker
must be turned off first.

1. Introduction
13
© 2002 TM 016-537-B0-002 Rev. B
1.3 APP Service Power Supply Features, continued
Output Voltage Selector
The VAC switch is used to select the desired output voltage. Output options are 60, 75 and
90 Volts.
NOTE: Verify that output voltage settings are correct before connecting load to
supply. Do not rotate switch when unit is in operation. Always remove
powerfromunit when selectingoutputsettings.
60/ 75/ 90 VAC Output Connector
The 60/ 75/ 90 VAC output connector supplies up to 22 Amps of power to a Service Power
Inserter(SPI)throughanoutputcable.
OutputCables
9015S:
Included with the APP 9015S is an output cable used to connect the Service Power Supply
totheSPI,viaafour-pinJonesconnector.
9022S:
Included with the APP 9022S are two 6-ft output "Y" cables. One cable terminates with two
Jonesconnectors, andprovidesservicepowertooneortwoseparate 20ASPIs.Theother
cable terminates with two 25A connectors, for 25A SPIs.
InputConnector
Input Connector is used to connect the APP SPS to line power through an AC line cord.
Thecord plugsdirectlyintoenclosure convenienceoutlet.
9015S:
Includestwopowercordsfor120VACor240VACoperation.
NOTE: Beforeconnectingpower cord,Inputvoltagemustfirstbe selectedviathe
120/240InputVoltageSelector switch.
9022S:
Includes two power cords. One with a 5-20P plug to set voltage to 120 VAC; and one with a
6-15P plug to set voltage to 240 VAC.
9022sOption:30-FtOutputCables
A 30-foot output kit is available. This kit provides "Y" cables for both 25A and Jones
connectors.Alphapartnumber: 745-094-20.
9022S Option: 10-Ft Cord w/30A Connector and Twist Lock Plug (125VAC)
For full current output with a 120 VAC input, use with a twist lock receptacle. This line cord
isequipped withaNEMAL5-30P plug.Alphapartnumber: 874-935-22.

1. Introduction
016-537-B0-002 Rev. B 14 © 2002 TM
Figure1-1; APP 9015S ServicePower Supply, FrontPanel
12
3
4
5
6
7
8
1. OutputCurrent
2. 120/240VInputVoltageSelector
3. 20AMPAC Input Breaker/PowerSwitch
4. 120/240VInputConnector
5. 60/75/90OutputSelectorDial
6. 60/75/90VOutputConnector
7. 20 AMP Output Breaker
8. Pilot Light
1.3 APP Service Power Supply Features, continued

1. Introduction
15
© 2002 TM 016-537-B0-002 Rev. B
Figure1-2; APP9022S Service PowerSupply, Front Panel
1
2
3
4
5
6
7
1. OutputCurrent
2. OutputPowerIndicator
3. 30 AMP Output Breaker
4. 60/75/90VOutputConnector
5. 60/75/90OutputSelectorDial
6. 120/240VInputConnector
7. 15 AMP AC Input Breaker/
PowerSwitch
1.3 APP Service Power Supply Features, continued

2. Installation
016-537-B0-002 Rev. B 16 © 2002 TM
2.1 APP SPS Installation and Power Module Removal
Warning! Do not unplug output connector or change setting of output selector while
unit is in operation! Circuit breaker must be turned off first.
Procedure
1. LocateServicePowerInserter(SPI)inenclosure.(RefertoFigures2-1and2-2.)For
20A SPI, plug APP SPS "Jones" connector into SPI. (Figure 2-1.) For 25A SPI
(9022S model only), plug APP SPS into red and white 25A connectors. (Figure 2-2.)
2 Determinetheline voltage of theUPS.
3. This step for APP 9015S model only:
Selectappropriateline voltage(120/240VAC)byusingtheInput VoltageSelector
switch.
4. Selectand connect appropriateline cord toInput Connector and plug intooutlet.
CAUTION: Do not use the 120 VAC cord to plug into GFCI outlet! The GFCI
outlet is intended for lights and tools only. If necessary, remove
the LAP and use that outlet.
5. Set the 60/75/90 Output Selector Dial to the desired voltage. Plug the APP SPS
power cord into the enclosure's convenience outlet. Switch the APP SPS ON, and
verify that the Output Power Indicator is lit.
6. Togglethe SPI's ALT/ON switch to ALT. This transfers output power from the module
to the APP SPS which can now be used to maintain regulated, non-standby power to
thecable plant until a replacementpower module hasbeen installed.
7. Switchthe battery breakeron thepower module OFF.
8. UnplugthepowermoduleLINEcordfromtheenclosureconvenienceoutlet.
9. Wait approximately 1 minute for the power module capacitors to fully discharge.
(Continuedonnextpage)
NOTE:Inspect all cables before installation. Replace or repair damaged cords.

2. Installation
17
© 2002 TM 016-537-B0-002 Rev. B
Andersonconnectorfrom
powersupply
"ALT/ON"Switch "ALT/ON"Switch
AndersonConnector
frompowersupply
JonesConnector
acceptsmatingplug
fromAPPSPS
Figure 2-1; 20A Service Power Inserter
(shown in PWE and UPE/M enclosures) Figure 2-2; 25A Service Power Inserter (shown in PWE and UPE/M enclosures)
25AConnectors
acceptmatingplugfrom
APPSPS
10. Disconnectthewiresfromthepowermodule.
CAUTION: Do not let exposed battery cables come in contact with the chassis
orenclosure.
11. Reversethisprocedurewhenreinstallingamodule.
CAUTION: Theferroresonanttransformergeneratesheatandmaycauseburns
ifhandledwithbarehands.
NOTE: Always test that the power module is operating correctly before
toggling the SPI's "ALT/ON" switch back to the ON position.
2.1 APP SPS Installation and Power Module Removal, continued

3. Trouble-Shooting
016-537-B0-002 Rev. B 18 © 2002 TM
3.1 Trouble-Shooting Guide
This guide is designed to cover typical symptoms, causes and solutions for trouble-shooting the
APP SPS. Alpha Technologies recommends that the power supply maintenance log accompany
unitsbroughtin for benchserviceto aid the technicianintrouble-shooting the problem.
Symptom #2:
No output to cable; AC line power available; Green “Output Power” indicator ON;And Ammeter
reads "0":
Probable Cause:
AC output breaker has tripped
SPI "ALT/ON" switch in wrong position
"Jones" connector loose or not
connected to SPI
Loose seizure screw inside SPI
Solution:
Reset output breaker
Move switch to "ALT" position
Check connection
Tighten screw
Symptom #1:
No output to cable; No AC line power; Green Output Power indicator OFF:
Probable Cause:
AC line cord unplugged
AC input circuit breaker tripped (or
input fuse open)
Utility power outage
Solution:
Plug inAC line cord
Reset AC circuit breaker
Use voltmeter to verify correct voltage
(120/240 VAC) at receptacle. Connect
generator in the event of an extended power
outage.

3. Trouble-Shooting
19
© 2002 TM 016-537-B0-002 Rev. B
3.1 Trouble-Shooting Guide, Continued
Symptom #3:
Incorrect output voltage; And/or Ammeter reads excessive current (above rated output of APP
SPS):
Probable Cause:
60/75/90 VAC switch in wrong position
Wrong type of voltmeter used
Under-loaded output (less than 1Amp)
Overloaded output
Short exists in load
MOV shorted in SPI
APP 9015S only: 120/240 V switch in
wrong position
Solution:
Move switch to required position
Use true RMS voltmeter
Connect load
Reduce load
Locate and remove short
Replace SPI
Set switch to correct line voltage

3. Trouble-Shooting
016-537-B0-002 Rev. B 20 © 2002 TM
Figure 3-1; APP 9022S Service Power Supply Schematic
240VAC Cord Set Alpha p/n: 874-935-21
Line 1 PinZ Line 2 PinX Gnd Center Contact Short Pin W to Y
120VAC Cord Set Alpha p/n: 874-935-20
Line PinW
PinX
Neutral Pin Y
PinZ
Gnd Center Contact
{ {
3.2 APP 9022S Schematic