ADTRAN Power Supply 6 Amp Power User Manual

®
Total Access Rackmount 6-Amp Power  
Supply Battery Charger  
Installation and Maintenance Practice  
Document Number: 61180043L2-5D  
CLEI: VAPUKT0C_ _  
June 2005  
 
Revision History  
Revision  
Date  
Description  
D
June 2005  
Updated to remove Dual PS/BC Jumper Cable. Document format  
updated with revision D.  
Conventions  
The following typographical conventions are used in this document:  
This font indicates a cross-reference link. First-time references to tables and figures are  
shown in this font.  
This font indicates screen menus, fields, and parameters.  
THIS FONT indicates keyboard keys (ENTER, ESC, ALT). Keys that are to be pressed simulta-  
neously are shown with a plus sign (ALT+X indicates that the ALT key and X key should be  
pressed at the same time).  
This font indicates references to other documentation and is also used for emphasis.  
This font indicates on-screen messages and prompts.  
This font indicates text to be typed exactly as shown.  
This font indicates silkscreen labels or other system label items.  
This font is used for strong emphasis.  
NOTE  
Notes inform the user of additional but essential information or  
features.  
CAUTION  
Cautions inform the user of potential damage, malfunction, or dis-  
ruption to equipment, software, or environment.  
WARNING  
Warnings inform the user of potential bodily pain, injury, or death.  
61180043L2-5D  
iii  
 
Total Access Rackmount 6-Amp Power Supply Battery Charger Installation and Maintenance Practice  
Training  
ADTRAN offers training courses on our products. These courses include overviews on product  
features and functions while covering applications of ADTRAN’s product lines. ADTRAN  
provides a variety of training options, including customized training and courses taught at our  
facilities or at customer sites. For more information about training, please contact us.  
Training Phone:  
Training Fax:  
800-615-1176, ext. 7500  
256-963-6700  
Training Email:  
iv  
61180043L2-5D  
 
Contents  
61180043L2-5D  
v
 
Total Access Rackmount 6-Amp Power  
Supply Battery Charger  
GENERAL  
This practice is an installation and maintenance guide for the ADTRAN® Total Access®  
Rackmount 6-Amp Power Supply Battery Charger (PS/BC). Figure 1 illustrates the PS/BC  
(P/N 1180043L2) right and left side panels.  
Figure 1. Total Access PS/BC  
Features  
The Total Access PS/BC features include the following:  
• –54 VDC at 6-amps output for multiple use  
• Modular connections for two backup battery packs  
• Modular power output connection  
• LED status for VAC, VDC, and battery charging  
• Full battery recharge in less than eight hours  
• Two PS/BC configuration options available  
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Total Access Rackmount 6-Amp Power Supply Battery Charger Installation and Maintenance Practice  
• Fuse protection  
• Positive ground  
• Battery Pack mounting hardware included  
• Completely automatic operation  
• Multiple protection features  
• Uninterrupted power output if backup battery connected  
• Meets NEBS Level 3 (all requirements of GR-63-CORE and GR-1089-CORE)  
• FCC and UL 60950 compliant  
Document Review  
This document contains important pre-installation information. Craft personnel should review  
the entire document as part of installation planning.  
DESCRIPTION  
The PS/BC rectifier is part of the Total Access Rackmount AC Power Supply/Backup Battery  
System (APS/BBS). The unit is designed to work in conjunction with one or two ADTRAN  
backup battery packs (P/N 1175044L1).  
Originally designed for the Total Access 1500 system, the PS/BC can be used in any appli-  
cation using 120 VAC input, and requiring up to –54 VDC, 6-amps output.  
In the Total Access 1500 configuration, the rectifier performs AC to DC conversion and when  
used with the dual battery provides up to eight hours of backup power for a fully populated  
Total Access 1500 bank (96 FXS circuits) with up to 50 percent off-hook circuits at any one  
time.  
For general use, the rectifier receives AC power from a standard 120 VAC wall outlet and  
converts this to –54 VDC, 6-amp output to the designated load plus recharging the single or  
dual battery, or maintaining battery at peak charge. Each battery has four series connected  
12 volt rechargeable cells.  
Single or Dual Battery  
Each battery string is rated for 3 amps of current and 7 amp-hours of capacity. Dual batteries  
are required if the load exceeds these ratings during AC power failure (backup battery mode).  
PS/BC Mounting Location  
The PS/BC normally mounts to the associated battery pack. The unit can also mount to a  
special bracket within a cabinet, or mount external to a cabinet against a wall.  
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Description  
Battery Disconnect Protection Circuit  
During battery operation a protection circuit disconnects battery from the main output when  
battery voltage drops below 39 VDC, preventing over discharge. When AC returns, the main  
output provides regulated –54 VDC, batteries recharge, and the system returns to normal.  
After the protection circuit initiates, the LEDs remain on (red), continuing to slowly drain the  
battery. When battery voltage drops to 35 VDC, all load is removed from the battery. If AC  
power will not be available for an extended period (several days), disconnect the battery to  
prevent unnecessary discharge.  
DC Over Voltage Protection  
The PS/BC has a protection circuit that disables the rectifier to protect the load from a high  
output voltage caused by rectifier failure. The backup battery or redundant PS/BC supports  
the load in this instance. The over voltage event can permanently disable the PS/BC. Confirm  
this by performing the following procedure:  
1. Disconnect the PS/BC from the AC source.  
2. Wait 30 minutes minimum.  
3. After 30 minutes plug back into the AC source.  
4. If the unit has recovered, the AC FAIL/UNIT FAIL/OVERLOAD LED will turn on green and the  
unit returns to service. If the LED does not turn on green, replace the PS/BC.  
Alarm Relays  
There are two uncommitted alarm relays associated with PS/BC operation:  
• AC Fail (ACF): Alarms if AC fails, the rectifier overloads, or the rectifier fails  
• Battery Low Voltage (BV): Alarms if either or both battery voltage drops below 42 VDC  
Fuse  
A standard 5×20 mm 5-amp fuse adjacent to the AC power cord protects AC power feed  
overload in case of rectifier failure.  
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Total Access Rackmount 6-Amp Power Supply Battery Charger Installation and Maintenance Practice  
LED Indication  
A set of three PS/BC multi color LEDs provide status for AC, DC, and battery charge condi-  
tions. See Table 1 for LED descriptions. Descriptions are also labeled on the PS/BC.  
Table 1. LED Descriptions  
LED  
Color Description  
AC FAIL/UNIT FAIL/OVERLOAD  
Green Normal 120 VAC operation  
Red AC fail or rectifier overload or fail  
BATTERY VOLTAGE  
CHARGING STATUS  
All LEDs  
Green Battery 1 and Battery 2 greater than 42 VDC  
Yellow Battery 1 or Battery 2 less than 42 VDC  
Red Battery 1 and Battery 2 less than 40 VDC  
Green Battery 1 and Battery 2 charged or recharging  
Yellow Battery 1 or Battery 2 discharging  
Red Battery 1 and Battery 2 fully discharged  
Off AC lost, Battery less than 35 VDC  
Note: Descriptions are the same for a single battery.  
Compliance  
This device complies with Part 15 of the FCC rules. Operation is subject to the following two  
conditions:  
1. This device may not cause harmful interference.  
2. This device must accept any interference received, including interference that may cause  
undesired operation.  
Changes or modifications not expressly approved by ADTRAN could void the user’s authority  
to operate this equipment.  
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Installation  
INSTALLATION  
C A U T I O N !  
SUBJECT TO ELECTROSTATIC DAMAGE  
OR DECREASE IN RELIABILITY.  
HANDLING PRECAUTIONS REQUIRED.  
After unpacking the Total Access PS/BC, inspect it for damage. If damage has occurred, file a  
claim with the carrier, then contact ADTRAN Customer Service. Refer to “Appendix A,  
Warranty” for further information. If possible, keep the original shipping container for  
returning the PS/BC for repair or for verification of shipping damage.  
CAUTION  
Electronic modules can be damaged by ESD. When handling mod-  
ules, wear an antistatic discharge wrist strap to prevent damage to  
electronic components. Place modules in antistatic packing mate-  
rial when transporting or storing. When working on modules,  
always place them on an approved antistatic mat that is electrically  
grounded.  
Shipping Contents  
The contents include the following items:  
• Rackmount 6-Amp Power Supply Battery Charger  
• Rackmount 6-Amp Power Supply Battery Charger Installation and Maintenance Practice  
• Appropriate wiring:  
– PS/BC to AC source (hardwired)  
– PS/BC to load  
– PS/BC alarm output  
• Battery Pack mounting hardware  
Separately purchased Rack Mounting Kits for the PS/BC are available for the following racks:  
• 19-inch (P/N 1175050L1)  
• 23-inch (P/N 1175051L1)  
61180043L2-5D  
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Total Access Rackmount 6-Amp Power Supply Battery Charger Installation and Maintenance Practice  
Mounting the PS/BC  
The PS/BC housing occupies a nominal area 15.35 inches (with mounting tabs) wide by 3.45  
inches high and is designed so the four mounting tab screw holes align to threaded screw  
holes on the ADTRAN battery pack housing. This procedure assumes that the battery pack is  
mounted in the designated 19-inch or 23-inch rack. Hardware for mounting the PS/BC to the  
battery pack is included. To mount the PS/BC, perform the following steps:  
1. Ensure a 120 VAC wall outlet is within reach of the PS/BC 10-foot power cord.  
2. Determine the most convenient direction to view the status LEDs and position the PS/BC  
accordingly.  
3. Align the mounting tabs to the threaded mounting holes on the battery pack.  
4. Using the included “sems” screws with star washer, mount the PS/BC to the battery pack.  
Tighten fasteners firmly.  
See Figure 2 for a representative example of the PS/BC mounted to the battery.  
B A  
T T E R  
1
Y
1
7 5 0 4 4 L 1  
B A C K U P  
S
M
C
A
R
Y
E
P
W
U
L E  
N
T
C
N
T U  
W
G
R
A R N I N G :  
H
E
S
B
E
A
X
T
C
T
R
E
I E  
G
E
D
S
I N  
.
3 / 8 "  
SMTYPENDRA  
SKOFI,REPLA  
FCOTINUEDPR  
CA  
UITON:  
FSUE:  
TNIGOFUSE  
CEONL  
O
T
E
FF  
S
S
A1/25V  
E E  
YWITHE  
G
ANIST  
.
10843L2  
Figure 2. PS/BC Mounted On Battery Pack  
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Wiring Descriptions  
Alternate Mounting  
Two alternate mounting methods include mounting directly to a wall using customer supplied  
wood screws, or to a 16-gauge steel bracket (P/N 3265555) that mounts in the cabinet.  
Bracket mount location is normally at the battery position when batteries are mounted  
external to the cabinet. The bracket has threaded mounting holes that align to the PS/BC  
mounting tabs. The PS/BC can be mounted to either side of the bracket, or two PS/BCs can  
be mounted, one on each side. Openings in the bracket allow for wire management. Hardware  
for bracket mounting is purchased from ADTRAN. When determining the alternate mounting  
location, ensure supplied cabling reaches the designated termination point including dressing  
and lacing.  
Provisioning  
Aside from various PS/BC and battery mounting and wiring configurations, there are no end  
user controls, adjustments, or options associated with the PS/BC.  
WIRING DESCRIPTIONS  
The wiring required for the single PS/BC and dual battery configuration is included.  
CAUTION  
All grounds must terminate at a known ground location. Check  
metal-to-metal contact on all ground connections. Do not stack or  
combine grounds. Ensure ground circuit continuity.  
Ground  
A ground post adjacent to the PS/BC fuse is available for frame ground.  
WARNING  
Do not connect AC power or make battery connections until all  
other connections have been made for the designated installation  
and protective covers and shields have been installed.  
120 VAC Power Input  
AC input is through a 10-foot wire with a three prong grounded plug on the end. The line is  
hardwired to the PS/BC.  
NOTE  
In the optional two PS/BC configuration, a fully redundant system  
requires that each PS/BC have an independent AC source.  
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Total Access Rackmount 6-Amp Power Supply Battery Charger Installation and Maintenance Practice  
DC Power Output  
The 4-foot long, three conductor PS/BC power output wire originates at the –54V 6A OUTPUT  
modular connector and terminates at three #6 ring lugs for customer designated connection.  
Wire color-code is as follows:  
• Red = –54 VDC  
• Black = Return  
• Green = Ground  
PS/BC to Battery Configurations  
The basic design configuration consists of one PS/BC with two batteries. A variety of other  
configurations are possible with more (or less) redundant capability, see Figure 3 for standard  
configurations I and II.  
Configuration I, Ia, Ib  
I. PS/BC, no battery.  
A
Load  
B
Ia. PS/BC + 1 battery string.  
Ib. PS/BC + 2 battery strings.  
PS/BC  
A
I
Ia  
Ib  
Batt  
Batt  
Configuration II, IIa, IIb, IIc, IId  
II. 2 PS/BC, no battery.  
A
Load  
B
IIa. 2 PS/BC + 1 battery string.  
IIb. 2 PS/BC + 2 battery strings.  
IIc. 2 PS/BC + 3 battery strings.  
IId. 2 PS/BC + 4 battery strings.  
PS/BC  
A
PS/BC  
B
II  
II  
This configuration shows adding battery  
strings alternately to PS/BC A and B.  
Other wiring configurations are optional.  
IIa  
IIb  
IIc  
IId  
Batt  
Batt  
Batt  
Batt  
Figure 3. Wiring Block Diagrams  
These would include one or two PS/BCs, none, one, or two batteries, or some combination of  
PS/BC and battery. The most reliable configuration would be two PS/BCs with two batteries  
each and with independent AC sources. The two PS/BC outputs would terminate at a single  
load that has primary and secondary power sharing terminals.  
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Operation  
Battery Charge/Discharge  
CAUTION  
To prevent battery discharge prior to system operation, do not con-  
nect the battery to the PS/BC until the AC power is connected or  
imminent.  
Each battery has a hardwired 6-foot battery charge/discharge wire that originates at the  
battery housing and terminates at a modular connector. The PS/BC has two mating  
connector ports each labeled –48V 3A INPUT. It does not matter which battery connects to  
which port.  
To prevent heat buildup the battery charge current is limited to 1 amp per battery. This elimi-  
nates the need for temperature compensation.  
Alarm Wiring  
The alarm relay output originates at a modular connector with a 6-foot wire stub. Wiring  
termination of the output is customer designated. The alarm outputs: AC Fail, Battery Low  
Voltage, are assigned the following wire color-codes:  
• ACF = orange, orange/white  
• BV = blue, blue/white  
OPERATION  
The PS/BC starts operation when AC or battery power is applied. During operation ambient  
temperature can increase up to 50°C without affecting output. If ambient temperature  
increases beyond 50°C, output must be derated. At 70°C ambient, output load is limited to 5  
amps.  
CAUTION  
External PS/BC surfaces can become hot during operation above  
50°C ambient temperature.  
MAINTENANCE  
The Total Access PS/BC does not require routine maintenance for normal operation.  
ADTRAN does not recommend that repairs be attempted in the field. Repair services may be  
obtained by returning the defective unit to ADTRAN. Refer to “Appendix A, Warranty” for  
further information.  
Fuse  
If the fuse fails, replace with a fuse of identical type and rating.  
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Total Access Rackmount 6-Amp Power Supply Battery Charger Installation and Maintenance Practice  
SPECIFICATIONS  
Power Factor specifications for the Total Access PS/BC are listed in Table 2. PS/BC specifica-  
tions are listed in Table 3.  
Table 2. Power Factor and Efficiency  
Power Output vs. Efficiency  
Power Output  
50 watts  
Power Factor  
> 98%  
Efficiency  
> 81%  
Power Dissipation  
11 watts  
150 watts  
> 99%  
> 89%  
18 watts  
325 watts  
> 99%  
> 91%  
29 watts  
Table 3. PS/BC Specifications  
Specification  
Description  
Environmental  
Operating Temperature: –40°C to 50°C  
Derated Operation,  
Linear: 50°C to 70°C (0.05 amp/°C)  
Storage Temperature: –40°C to 85°C  
Relative Humidity: 95 percent noncondensing  
Max Heat Dissipation: 29 watts at 325 watts output  
50 watts maximum during overload  
Physical  
Height: 3.45 inches  
Width: 15.35 inches (with mounting tabs)  
Depth: 2.92 inches  
Weight: 5.5 pounds  
Electrical  
AC Input: 120 Volts, 3.75 amps max, 60 Hz  
DC Output: –54 Volts, 6 amps  
Max power up to 50°C: 6 amps  
Max power @ 70°C: 5 amps  
Power Output: 325 watts  
Compliance  
NEBS: Level 3+  
UL: 60950  
ETL: Listed  
FCC: Part 15, Class A  
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Appendix A  
Warranty  
WARRANTY AND CUSTOMER SERVICE  
ADTRAN will replace or repair this product within the warranty period if it does not meet its  
published specifications or fails while in service. Warranty information can be found at  
Refer to the following subsections for sales, support, Customer and Product Service (CAPS)  
requests, or further information.  
ADTRAN Sales  
Pricing/Availability:  
800-827-0807  
ADTRAN Technical Support  
Pre-Sales Applications/Post-Sales Technical Assistance:  
800-726-8663  
Standard hours: Monday - Friday, 7 a.m. - 7 p.m. CST  
Emergency hours: 7 days/week, 24 hours/day  
ADTRAN Repair/CAPS  
Return for Repair/Upgrade:  
(256) 963-8722  
Repair and Return Address  
Contact CAPS prior to returning equipment to ADTRAN.  
ADTRAN, Inc.  
CAPS Department  
901 Explorer Boulevard  
Huntsville, Alabama 35806-2807  
61180043L2-5D  
A-1  
 
                 
®
Carrier Networks Division  
901 Explorer Blvd.  
Huntsville, AL 35806  
 

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