Alpha Technologies APP60S User manual

APP60S
Service Power
Supply
ALPHA TECHNOLOGIES
Copyright © 1998 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies.
OPERATOR’S MANUAL

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CAUTION
RISK OF ELECTRICAL SHOCK
CAUTION: TO REDUCE THE RISK OF ELECTRICAL
SHOCK, AND ENSURE THE SAFE OPERATION OF THIS
UNIT, THE FOLLOWING SYMBOLS HAVE BEEN PLACED
THROUGHOUT THE MANUAL. 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
IMPORTANT OPERATING INSTRUCTIONS. THIS PROCE-
DURESHOULDBEPERFORMEDONLYBYQUALIFIEDSER-
VICE PERSONNEL.
IMPORTANT SAFETY INSTRUCTIONS
CONTAINED IN THIS MANUAL
SAVE THESE INSTRUCTIONS

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IMPORTANT SAFETY PRECAUTIONS
POWER SUPPLIES SHOULD BE SERVICED ONLY BY QUALIFIED PERSONNEL.
POWER SUPPLIES CONTAIN MORE THAN ONE LIVE CIRCUIT. EVEN THOUGH AC IS
NOT PRESENT AT THE INPUT, IT MAY BE PRESENT AT THE OUTPUT.
WHEN USING AN EXTERNAL SERVICE DISCONNECT, VERIFY THAT IT IS EQUIPPED
WITH A HIGH MAGNETIC CIRCUIT BREAKER PROPERLY RATED (AMPERAGE) FOR
USE WITH THE POWER SUPPLY.
WHEN IN STORAGE, BATTERIES SHOULD BE CHARGED AT LEAST ONCE EVERY
THREE MONTHS TO ENSURE OPTIMUM PERFORMANCE AND BATTERY LIFE.
WEAR EYE PROTECTION, SUCH AS SAFETY GLASSES OR A FACE SHIELD, WHEN-
EVER WORKING WITH BATTERIES.
USE GLOVES WHEN HANDLING BATTERIES. BATTERY ELECTROLYTE IS ACIDIC
AND MAY CAUSE BURNS.
NEVER SMOKE NEAR BATTERIES. SPARKS, FLAMES OR OTHER SOURCES OF
IGNITION MAY CAUSE A BATTERY EXPLOSION.
ALWAYS CARRY A SUPPLY OF WATER, SUCH AS A WATER JUG, TO WASH THE
EYES OR SKIN IN THE EVENT OF EXPOSURE TO BATTERY ELECTROLYTE.
USE PROPER LIFTING TECHNIQUES WHENEVER HANDLING THE ENCLOSURE,
POWER MODULE OR BATTERIES. GROUP 31 SIZE BATTERIES, USED IN THE
MAJORITYOFCABLETELEVISIONAPPLICATIONS,CANWEIGHASMUCHAS70LBS.
USE A BUCKET TRUCK, OR SUITABLE SAFETY EQUIPMENT SUCH AS A SAFETY
HARNESS AND CLIMBING SPIKES, WHEN SERVICING POLE INSTALLATIONS.
ALWAYS SWITCH THE POWER SUPPLY’S BATTERY CIRCUIT BREAKER TO OFF
BEFORE DISCONNECTING BATTERY CABLES. THIS GREATLY REDUCES THE
CHANCE OF SPARK AND POSSIBLE BATTERY EXPLOSION.
DO NOT ALLOW LIVE BATTERY WIRES TO CONTACT THE ENCLOSURE OR POWER
SUPPLY CHASSIS. POSSIBLE EXPLOSION OR FIRE CAN OCCUR.
BEFORE PLACING A CURRENT LOAD ON THE BATTERIES, (SUCH AS WHEN
SWITCHING THE POWER SUPPLY TO STANDBY), USE THE ENCLOSURE DOOR AS
A SHIELD IN THE EVENT OF A BATTERY EXPLOSION.
INSPECT BATTERIES FOR SIGNS OF CRACKS, LEAKING OR SWELLING.
WHEN REPLACING BATTERIES, ALWAYS USE THOSE OF AN IDENTICAL TYPE.
NEVER INSTALL OLD OR UNTESTED BATTERIES.
CHECK THE BATTERY’S DATE CODE. BATTERIES OLDER THAN SEVERAL YEARS
SHOULD NOT BE USED.
AVOID THE USE OF UNINSULATED TOOLS OR OTHER CONDUCTIVE MATERIALS
WHEN HANDLING BATTERIES OR WORKING INSIDE THE ENCLOSURE.
SPENTORDAMAGEDBATTERIESARECONSIDEREDENVIRONMENTALLYUNSAFE.
ALWAYS RECYCLE USED BATTERIES.

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Table of Contents
1. INTRODUCTION 1
1.1 The APP60S Service Power Supply
1.2 Theory of Operation
1.3 Specifications
1.4 Unpacking and Inspection
2. APP60S FRONT PANEL 4
2.1 Ammeter
2.2 AC Output Fuse
2.3 AC Input Fuse
2.4 AC LINE Indicator
2.5 30 / 60 VAC Switch
2.6 ON / OFF Switch
2.7 "Jones" Connector
2.8 AC Line Cord
3. INSTALLATION AND OPERATION 6
3.1 APP60S Installation and Power Module Removal
4. TROUBLE-SHOOTING AND REPAIR 8
4.1 Repair Instructions
4.2 Parts Ordering Instructions
4.3 Trouble-shooting Guide
5. WARANTY 9
ILLUSTRATIONS (contained in the manual)
APP60S Front Panel
PME and PWE Pole-mount Enclosures
UPE and UPE/M Ground-mount Enclosures
SPI (Service Power Inserter)
APP60S Installation and Wiring Diagram
APP60S Service Power Supply
i

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INTRODUCTION
1.1 THE APP60S SERVICE POWER SUPPLY
The APP60S Service Power Supply is a portable device used to provide temporary power
for Alpha AP Series standby power supplies and XP Series uninterruptible power supplies
while they are being serviced. The APP60S can be used in either pole or ground-mount
enclosuresto provide signal processingequipmentinCable Television and BroadbandLAN
distribution systems with current-limited, regulated AC power.
The APP60S Service Power Supply contains a front panel ammeter to measure the output
currenttotheload;anoutputfusetoprotectagainstexcessiveshortcircuitcurrents;a"LINE"
indicator to verify AC input power from the utility; an input fuse to provide additional voltage
protection; and a 30/60 VAC switch for output voltage selection (48/60 for 50 Hz units).
ULListedand CSA Approved, the APP60S ServicePowerSupply is designed to be rugged,
reliable and versatile. Alpha Technologies, recognized as an international market leader in
the field of backup power, offers complete technical support and prompt, reliable service to
ensure that your power supply continues to provide years of trouble-free operation.
1.2 Theory of Operation
The APP60S Service Power Supply contains a ferroresonant transformer and a resonant
capacitor. During AC LINE operation, utility power is fed into the primary winding of the
ferroresonant transformer, T1. An AC capacitor, C1, forms the resonant circuit of the
ferroresonanttransformerwhichprovidesexcellentnoiseandspikeattenuation,shortcircuit
current limiting, and output voltage regulation. Note: The ferroresonant transformer
produces a "quasi" square wave output which resembles a rounded square wave.
During LINE operation, AC power enters the APP60S where it is regulated (at the required
outputvoltage) and passed onto the load viatheSPI(ServicePowerInserter)located inside
the power supply enclosure. A switch, located on the SPI, toggles output power from the
power supply requiring service to the APP60S.
IMPORTANT NOTE: WHEN MEASURING THE OUTPUT VOLTAGE OF
FERRORESONANT TRANSFORMERS, USE ONLY A TRUE RMS AC VOLTMETER.
NON-RMS READING METERS ARE CALIBRATED TO RESPOND TO PURE SINE
WAVES AND WILL NOT PROVIDE AN ACCURATE READING WHEN MEASURING A
"QUASI" SQUARE WAVE OUTPUT.
1
1. INTRODUCTION

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1.3 SPECIFICATIONS
MODEL APP60S APP60S E
Input Voltage (VAC) 120 +/-15% 220/240 +/-15%
Input Frequency (Hz) 60 50
Input Current Max. (A) 9 4.8
Output Voltage (VAC) 60/30 +/-5% 60/30 (60/48) +/-5%
Output Current (A) 14 14
Output Power (VA) 840 840
Output Current Limit 150% of maximum output rating
Efficiency 90% typical @ rated load
Operating Temperature Range -400to +1220F (-400to +500C)
Dimensions 7" W x 10" H x 13" D (170mm x 250mm x 330mm)
Weight 34 lbs. (15 kg)
Finish ASA 61 Gray Epoxy Powder Paint
Specifications @ 770F (250C)
1. INTRODUCTION
2

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1.4 Unpacking and Inspection
CarefullyremovetheAPP60Sfromitsshippingcontainer. Makesurethatthefollowingitems
have been included:
1. APP60S Service Power Supply.
2. Operator's Manual.
Inspect the contents. If items are damaged or missing, contact Alpha Technologies and the
shipping company immediately. Most shipping companies have only a short claim period.
SAVE THE ORIGINAL SHIPPING CONTAINER.
In the event a unit needs to be returned for service, it should be packaged in its original
shippingcontainer. Iftheoriginalcontainerisnotavailable,makesuretheunitispackedwith
atleast three inches of shock-absorbingmaterial to prevent shippingdamage. Note: Do not
use popcorn-type material. Alpha Technologies is not responsible for damage caused by
improper packaging on returned units.
READ THE OPERATOR'S MANUAL.
BecomefamiliarwiththeAPP60SServicePowerSupply. Review theillustrations contained
in the manual before proceeding. If you have questions regarding the safe installation or
operation of this unit, contact Alpha Technologies or your nearest Alpha representative.
TO ENSURE OPERATOR SAFETY
1. Powersuppliesshouldbeservicedonlybyqualifiedpersonnelandalwaysinaccordance
with applicable electrical codes.
2. Use eye protection whenever working around batteries.
3. Useabuckettruck,orsuitableclimbingequipmentsuchasasafetyharnessandclimbing
spikes, whenever installing or servicing pole-mount installations.
1. INTRODUCTION
3

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2. APP60S FRONT PANEL
4
2.7
2.8
2.4
2.5
2.6
2.3
2.2
2.1
APP60S Service Power Supply
2.1 Ammeter
2.2 AC Output Fuse
2.3 AC Input Fuse
2.4 AC LINE Indicator
2.5 30 / 60 VAC Switch
2.6 ON / OFF Switch
2.7 "Jones" Connector
2.8 AC Line Cord

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2. APP60S FRONT PANEL
5
2.1 Ammeter
Thefrontpanelammeterdisplaysoutputcurrentflowingfromthepowermoduleintotheload.
It is extremely useful in determining the status of the plant during maintenance and trouble-
shooting. When there is no load at the output, the ammeter reads zero. When the meter
reads above the rated output of the APP60S, such as 18 or 20 Amps, an overload or short
circuit condition may exist in the load.
2.2 AC Output Fuse
The15AmpACoutputfuseprotectstheloadfromexcessivedurationsofshortcircuitcurrent.
If the front panel ammeter reads zero, indicating no output to the load, this fuse should be
checked and replaced if necessary.
2.3 AC Input Fuse
The12AmpACinputfuseprotectstheAPP60Sfromshortcircuitconditions,especiallywhen
itis used inconjunction with a generator during outage conditions. If the unit does not come
ONwhenpowerisapplied,firstverifythattheunit ispluggedinto theconvenienceoutlet and
thatthe main AC circuit breakerisintheON position. Then check the inputfuseandreplace
it if necessary.
2.4 AC LINE Indicator (Green)
The AC LINE indicator displays the presence of utility AC at the input. If the indicator does
notlightwhentheunitisswitchedON,firstverifythattheunitispluggedintotheconvenience
outletandthemainACcircuitbreakerisinthe ONposition. Ifnecessary, checktheAC input
fuse and replace it if necessary.
2.5 30 / 60 VAC Switch
The 30 / 60 VAC switch is used to select the desired output voltage. For 50 Hz applications,
the switch is configured for 48 / 60 VAC.
2.6 ON / OFF Switch
The ON / OFF switch is used to apply or remove power from the APP60S.
2.7 "Jones" Connector
The APP60S "Jones" connector plugs directly into the Service Power Inserter's mating
connector to provide output power to the load. Note: The SPI's "ALT/ON" switch must be in
the "ALT" position to accept power from the APP60S.
2.8 AC Line Cord
The APP60S AC line cord plugs directly into the enclosure’s convenience outlet.

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3. INSTALLATION AND OPERATION
Black and White wires
from power module's output
"Jones" Connector
accepts mating plug
from APP60S
"ALT/ON" Switch
SPI Service Power Inserter
(shown in PWE and UPE/M enclosures)
Location of SPI and Convenience Outlet
(inside Alpha Enclosures)
Internal Power Box
(with Convenience Outlet)
SPI
(above upper shelf
on right-hand side of
the power box)
PWEPole-mountEnclosurePMEPole-mountEnclosure
Internal Power Box
(with Convenience Outlet)
SPI
(on lower shelf)
Convenience Outlet
(on module shelf)
SPI
(beneath battery shelf -
behind front panel)
Convenience Outlet
(on module shelf)
UPEGround-mountEnclosure UPE/MGround-mountEnclosure
6
SPI
(inside module
compartment
on back wall)

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3.1 APP60S Installation and Power Module Removal
POWER MODULES SHOULD BE SERVICED ONLY BY QUALIFIED PERSONNEL.
POWER MODULES CONTAIN MORE THAN ONE LIVE CIRCUIT. EVEN THOUGH AC IS
NOT PRESENT AT THE INPUT, IT MAY BE PRESENT AT THE OUTPUT.
Note: Before powering down a module, always switch the battery breaker OFF (or remove
the battery fuse) before removing AC, otherwise the module will transfer into inverter
operation.
Procedure
1. Plug the APP60S "Jones" connector into the enclosure's SPI (Service Power Inserter).
2. Plug the APP60S power cord into the enclosure's convenience outlet. Set the 30/60
VAC selector switch to the desired voltage and switch the APP60S ON.
3. ToggletheSPI's"ALT/ON"switchto"ALT". Thistransfersoutputpowerfromthemodule
to the APP60S which can now be used to maintain regulated, non-standby power to the
cable plant until a replacement power module has been installed.
4. Switch the battery breaker on the power module OFF (or remove the battery fuse).
5. Unplug the power module's LINE cord from the enclosure's convenience outlet.
6. Wait approximately 1 minute for the power module's capacitors to fully discharge.
7. Disconnectthe wires from the sideof the power module. CAUTION:Do not let exposed
battery cables come in contact with the chassis or enclosure.
8. Remove the hold-down screw (AM Series modules only) and carefully slide the module
outoftheenclosure. CAUTION:Theferroresonanttransformergeneratesheatandmay
cause burns if handled with bare hands.
9. Reversethisprocedurewhenre-installingamodule. Note:Alwaystestthepowermodule
forproperoperationbeforetogglingtheSPI's"ALT/ON"switchbacktothe"ON"position.
Plug the AC Line cord into
enclosure's convenienceoutlet
Plugthe "Jones" connector into
ServicePowerInserter'smatingconnector
Selectrequired
outputvoltage
Switch the unit ON
3. INSTALLATION AND OPERATION
7
APP60S
Installation and Wiring

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4. TROUBLE-SHOOTING AND REPAIR
TROUBLE-SHOOTING AND REPAIR
The trouble-shooting guide is designed to display typical symptoms, causes and solutions,
startingwith themostobvious and workingsystematicallythrough theunit. AlphaTechnolo-
gies recommends that the power supply’s maintenance log accompany units brought in for
bench service to aid the technician in trouble-shooting the problem.
4.1 Repair Instructions
On units returned to Alpha Technologies for repair, a Return Material Authorization (RMA)
should first be obtained from Alpha's Customer Service Department. The RMA should be
clearly marked on the unit’s original shipping container. If the original container is no longer
available,theunitshouldbepackedwithatleast3inchesofshock-absorbentmaterial. Note:
Donotusepopcorntypepackingmaterial. Returnsshouldbeprepaidandinsured(CODand
freightcollectcannotbeacceptedwithoutprior approval). Note:It isrecommendedthatany
informationpertaining to the natureofthepower supply failure orproblem,alongwith a copy
of power supply's maintenance log, be included with the returned unit.
4.2 Parts Ordering Instructions
When ordering parts from Alpha Technologies, contact the Customer Service Department
directly at [phone]; or [phone] (Canada and International).
4.3 TROUBLE-SHOOTING GUIDE
SYMPTOM PROBABLECAUSE REMEDY
No outputto cable; ACLinecordunplugged. Plug in AC Line cord.
No AC line power;
Green “AC LINE” indicator OFF: AC input circuit breaker Reset AC circuit breaker
tripped(or inputfuseopen). (or replace 12 A fuse).
Utilitypoweroutage. Use voltmeter to verify
120VAC at receptacle.
Connectgeneratorif
extendedpoweroutage.
SYMPTOM PROBABLECAUSE REMEDY
No output tocable; AC output fuseopen. Replace 15 A fuse.
AClinepoweravailable;
Green “AC LINE” indicator ON; SPI "ALT/ON" switch Move switch to
and/orammeterreads "0": inwrongposition. "ALT"position.
"Jones" connector loose or Checkconnection.
notconnected to SPI.
Loose seizure screw inside SPI. Tightenscrew.
SYMPTOM PROBABLECAUSE REMEDY
Incorrect outputvoltage; 30 / 60 VAC switch in Move switch to
and/orammeterreads excessive wrongposition. requiredposition.
current(above ratedoutput of
APP60S): Wrong type of voltmeterused. Use true RMS meter.
Under-loadedoutput Connectload.
(less than 1 Amp).
Over-loadedoutput. Reduceload.
Short exists in load. Locate andremove short.
MOV shorted in SPI. ReplaceSPI.
8

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5. WARRANTY
9
WARRANTY.
Alpha Technologies, Inc., provides a LIMITED WARRANTY covering the performance
of its Broadband products. The terms and conditions 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, the purchaser (or purchaser’s representative) must follow the LIMITED
WARRANTY guidelines, described in the applicable LIMITED WARRANTY STATEMENT.

Printed in the USA 016-001-B0-002 6/97
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