Installation: Alpha Technologies AlphaCap-665 Instruction Manual

Overview

The AlphaCap-665 is a short-duration backup supply module designed for 48 Vdc remote power applications such as xDSL and FTTx equipment. It acts like a battery-connected hold-up device on a -48 Vdc bus, using ultra-capacitor storage and a DC-DC converter to keep critical loads running through brief interruptions.

This model is well suited to telecom sites and other remote installations that need ride-through power during transients, ground-fault resets, or brief input loss. It is also a practical option for battery-eliminated systems that still need a burst of backup power.

Specifications

• Model: AlphaCap-665, part number 013-015-20
• Input voltage: -48 to -56 Vdc
• Charge current: 160 mA maximum
• Output voltage: -46 Vdc ±3%
• Power: 665 W nominal, 750 W maximum
• Backup duration: 4.5 seconds at 665 W under nominal conditions
• Backup duration: at least 3 seconds at 665 W down to -40°C
• Backup duration: up to 30 seconds at 130 W under nominal conditions
• Backup duration: 3.8 seconds at 750 W under normal operating conditions
• Operating temperature: -40°C to +65°C
• Dimensions: 43.1 mm H x 183.4 mm W x 350.5 mm D
• Mounting: wall mount with L-shaped brackets and chassis flange mounting holes
• Power connection: Tyco 193839-1 terminal block
• Ground connection: two #10-32 standoffs, 5/8 inch center
• Alarm connection: Amp 2-1445055-2 relay connector

Detailed Description

The AlphaCap-665 stores energy in an array of ultra-capacitors and releases that energy through a converter board when the main supply is interrupted. Because it parallels the load bus, it behaves similarly to a battery module from the system’s point of view, but it is intended for very short backup intervals rather than long standby runtimes.

The chassis includes two status LEDs and a dry-contact alarm relay for system monitoring. Power and alarm wiring are brought out on the side of the module, and earth grounding is provided through dedicated chassis standoffs. The unit is built for restricted-access installations where qualified personnel handle installation and service.

Safety

Installation and servicing must be done with care because hazardous voltages may be present even when AC input power is disconnected. The module is intended for restricted-access locations and should be handled only by qualified personnel.

• Remove metal jewelry before working on live equipment.
• Wear safety glasses with side shields and use insulated tools approved for electrical work.
• Assume conductors are energized until verified with a voltmeter.
• Do not work alone under hazardous conditions.
• Disconnect and lock out utility power before installation or removal procedures.
• Keep liquids and wet clothing away from internal components.
• Battery work requires eye protection, rubber gloves, and protective clothing.
• Avoid sparks, smoking, and open flames near charging batteries.
• Use proper recycling methods for battery disposal.

The enclosure can contain hot surfaces, sharp metal edges, and moving fans, so hands and tools should be kept clear during operation and maintenance.

Setup and Operation

Before installation, inspect the shipment for container damage and check the module for visible or hidden damage. Keep the original packaging if the unit may need to be returned for service.

The AlphaCap-665 is mounted to a clean, dry wall location using the chassis mounting holes and L-shaped wall brackets. Wiring is accessed from the side of the unit, with separate provisions for power, ground, and alarm wiring.

Power and Connections

• Connect -48 and +RTN using the specified 2-position Tyco terminal block and compatible mating connector.
• Use #12 to #18 AWG TEW 90 wire or equivalent for the power connection.
• Connect chassis earth ground to the provided #10-32 studs.
• Wire the alarm relay through the Amp Mate-N-Lok alarm connector.

The charge circuit is limited to 160 mA, which helps minimize the power drawn from the source during recharge. The unit returns to full capacity in about 30 minutes after discharge, regardless of how deeply it was used.

Status Indications

• Solid green: normal operation
• Flashing green: charging
• Alternating green and amber: backup mode
• Alternating green and red: overcharge or charging circuit failure
• Solid red or no light: module failure

The dry-contact alarm relay is normally closed in alarm logic terms and changes state when a fault is detected. It can signal capacitor discharge, low input shutdown, overcharge shutdown, over-temperature shutdown, internal reference errors, or a blown fuse.

Temperature Performance

The normal operating range is -40°C to +65°C. A shutdown occurs at +65°C, and normal operation resumes after the temperature drops to +60°C. The 5°C hysteresis helps prevent rapid cycling near the trip point.

Backup duration drops as temperature rises, and long-term capacitor life also decreases in hotter environments. For example, at a 350 W load, holdup after 10 years is longer at 25°C than at 45°C or 55°C.

Cleaning and Maintenance

Routine maintenance is limited, but annual inspection is recommended to keep the system performing reliably. Check connections, verify alarm and control settings, and re-torque hardware if needed.

Work inside the unit only when necessary and only by qualified service personnel. The cover should remain closed because there are no user-serviceable parts inside. Static-sensitive components should be handled with proper grounding precautions.

Troubleshooting

Status LEDs and relay behavior provide the main clues for diagnosing AlphaCap-665 faults. A solid red LED or no LED indication points to a module failure, while alternating green and red indicates an overcharge condition or charging circuit problem.

• Backup mode with alarm output active may indicate the module is supplying hold-up power.
• No backup when needed may indicate a fully discharged capacitor state or low-voltage input shutdown.
• Persistent alarm output can also be caused by over-temperature shutdown, internal reference error, or a blown fuse.

Warranty

The standard warranty covers repair, replacement, or credit at the manufacturer’s discretion for covered equipment returned during the warranty period. It does not cover losses such as lost profits, installation or removal costs, consequential damages, or failures caused by outside factors such as environmental conditions, water damage, or power surges.

Shipping and handling are the customer’s responsibility when returning a unit, although return shipping for repaired or replacement products is covered when the item is approved under warranty.

Pros & Cons

• Pros: Compact short-duration backup for 48 Vdc telecom loads; fast recharge; simple single-bus wiring; clear LED and relay status; wide temperature range.
• Cons: Designed for brief hold-up rather than long runtime; performance drops at higher temperatures; requires qualified installation and careful electrical safety practices.