Alpha APP60S User manual

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97
APP60S
Service Power Supply
Operator's Manual
© 1992

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97
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
IMPORTANTOPERATINGINSTRUCTIONS. THISPROCEDURESHOULD
BE PERFORMED ONLY BY QUALIFIED SERVICE PERSONNEL.
IMPORTANT SAFETY INSTRUCTIONS
CONTAINED IN THIS MANUAL
SAVE THESE INSTRUCTIONS

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97
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, WHENEVER
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 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 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.

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97
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
LIST of ILLUSTRATIONS
Fig. 1 APP60S Front Panel 4
Fig. 2 PME and PWE Pole-mount Enclosures 6
Fig. 3 UPE and UPE/M Ground-mount Enclosures 6
Fig. 4 SPI (Service Power Inserter) 6
Fig. 5 APP60S Installation and Wiring Diagram 7
APP60S Service Power Supply
i

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97
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
theyarebeingserviced. TheAPP60Scanbeusedineitherpoleorground-mountenclosures
to provide signal processing equipment in Cable Television and Broadband LAN distribution
systems with current-limited, regulated AC power.
The APP60S Service Power Supply contains a front panel ammeter to measure the output
current to the load; an output fuse to protect against excessive short circuit currents; a
"LINE"indicatorto verify AC input power from the utility; an input fusetoprovide additional
voltage protection; and a 30/60 VAC switch for output voltage selection (48/60 for 50 Hz
units).
UL Listed and CSA Approved, the APP60S Service Power Supply 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 TheoryofOperation
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
ferroresonant transformer which provides excellent noise and spike attenuation, short
circuitcurrent limiting,andoutput voltageregulation. Note:The ferroresonanttransformer
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) andpassedonto theloadvia theSPI(Service PowerInserter)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 ACCU
RATE READING WHEN MEASURING A "QUASI"
SQUARE WAVE OUTPUT.
1
1.INTRODUCTION
1.1 THEAPP60SSERVICEPOWERSUPPLY

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97
1.3 Specifications
MODEL APP60S APP60S E APP6014S-J5
Input
Voltage (VAC) 120 ±15% 220/240 ±15% 100/115 ±15%
Frequency (Hz) 60 50 50
Current Max. (A) 9 4.8 12
Output
Voltage (VAC) 60/30 ±5% 60/30 (60/48) ±5% 30/60 ±5%
Current (A) 14 14 14
Power (VA) 840 840 420/840
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)
FinishASA 61 Gray Epoxy Powder Paint
Specifications @ 770F (250C)
1. INTRODUCTION
2

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97
1.4 UnpackingandInspection
CarefullyremovetheAPP60Sfromitsshippingcontainer. Makesurethatthefollowingitems
have been included:
1. APP60S Service Power Supply.
2. Operator's Manual.
Inspectthecontents. Ifitems 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
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 use popcorn-type material. Alpha Technologies is not responsible for damage
caused by improper packaging on returned units.
READ THE OPERATOR'S MANUAL.
Become familiar with the APP60S Service Power Supply. Review the illustrations 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. Powersuppliesshould be serviced only by qualified personnel and always inaccordance
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

016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97016-001-B0-002 6/97
016-001-B0-002 6/97
2. APP60S
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
3.1 APP60S Installation and Power Module Removal