Overviewi
About this Manuali
Table of Contentsii
List of Figuresiii
Safety Informationiv
Installation Notesv
Battery Safety Notesvi
Preface
Overview:The purpose of the CE-G Enclosure Installation Manual is to
provide an overview of the system and to detail the
enclosure installation procedure.
Audience:This manual intended for the installers and operators of the
system.
Contents:Section 1, System Overview. This section describes the
CE-G Series Enclosure.
Section 2, Pre-Installation. This section describes
site selection and pad layout.
Section 3, Installation. This section describes the
procedures for installing the cabinet.
Section 4, Operation. This section describes the preparation of
the cabinet for initial turn-up and the conversion of the APU fuel
source from Natural Gas to Propane.
To reduce the risk of electrical shock, injury or death caused by explosion of
fuel or moving parts, and to 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
This symbol indicates a dangerous voltage exists in this area of the
product. Use caution whenever working in the area to prevent
electrical shock.
iv
INHALATION HAZARD - DONT BREATHE VAPORS
This symbol indicates an inhalation hazard exists in this area of the
product. Use caution whenever working in the area to prevent possible
inhalation of harmful (fuel or exhaust) vapors.
NO MATCHES OR OPEN FLAMES
This symbol indicates a fire or explosive hazard exists in this area of
the product. Use caution whenever working in the area to prevent
possible combustion fuel vapors.
MECHANICAL OR MOVING PARTS HAZARD
These symbols indicate the presence of a mechanical or moving parts
hazard in this area of the product. Use caution whenever working in
the area to prevent possible injury to the operator or servicepersonnel.
LEAK HAZARD
This symbol indicates a leak hazard exists in this area of the product.
Use caution whenever working in the area to prevent and correct any
leaks detected.
ATTENTION
This symbol indicates important installation, operation or maintenance
instructions. Always follow these instructions closely.
SAVE THESE INSTRUCTIONS
NOTE:
continual improvement processes. Therefore, specifications and/or
design layouts may vary slightly from descriptions included in this
manual. Updates to the manual will be issued when changes affect
form, fit or function.
Alpha Technologies products are subject to change through
Page 7
IMPORTANT INSTALLATION NOTES
It is important that the installation procedures be followed as outlined in this
manual. The procedures have been developed to facilitate the installation of
the equipment and for the safety of the installation and service personnel.
Read the documentation thoroughly before proceeding with the installation.
The system should be installed ONLY by qualified service personnel.
Consult local utility codes for additional cabinet grounding and utility
requirements.
ALPHA TECHNOLOGIES is not responsible for broken welds of other damage to
the cabinet caused by improper installation.
All dimensions are given in inches.
For further information regarding this installation, contact ALPHA
TECHNOLOGIES or your nearest ALPHA representative.
1. Never overfill your LP-gas container. LPgas containers not
containing a fixed liquid level gauge must be filled by
weight to 80% of their total capacity. Propane expands
1.5% for each 10 °F increase in temperature. 20% of the
container must remain available for expansion. Some tanks
supplied by Alpha Technologies come equipped with automatic stop fill valves. Tanks must be filled in accordance
with manufactures, D.O.T, NFPA Code 58, state and local
regulations.
2. Do not use pliers to close the POL valve on your tank.
These valves are designed to be closed leak tight by hand or
screwdriver as appropriate. If pliers are needed to stop a
vi
leak , the valve needs replacement.
3. When tightening the POL Nut (left-hand thread) on the
service valve, draw it up snug with a proper wrench do not
jam it. No thread sealant is necessary. Check for leaks
after connecting, by using a leak detection solution or soapy
water.
4. If you take your LP-gas tank to a LP-gas dealer for filling,
transport it in the proper position in which it is used (vertical for all Alpha Technologies supplied tanks), with the
valves closed and the POL plug inserted. Secure the tank
against falling or rolling.
5. The outside of the tank should be kept corrosion free by
periodic checks and a coat of paint should be used if needed
(light reflective color).
6. Do not store LP-gas tanks indoors or in enclosed areas. Do
not expose the tanks to heat, relief valve may open. Always store with the service valve closed tight and plugged.
7. Do not attempt to repair LP-gas containers or valves or
regulators.
8. When using make sure that the tank is level, securely fastened down, and vertical.
9. Check all tank and line connections periodically to be sure
they are tight. When testing for leaks use soapy water or a
leak detect solution. Do not use any open flame for leak
testing.
The CE-X series of enclosures from Alpha Technologies has been
designed to meet the needs of todays outside plant powering requirements.
When an alternate fuel source is not available, the CEG propane natural gas
option can provide up to 16 hours of continuous operation.
The procedures described in this document describe the installation of a
CE-G Series Propane Enclosure. The installation procedures are identical for
the CE-3G and the CE-9G. The cabinet footprint (and mounting hole location)
is identical for each enclosure. The only physical difference between the
enclosures is that the CE-3G is 44 tall and the CE-9G is 52 tall.
The block diagram shown illustrates the overall system interconnection
between the CE-X enclosure with Auxiliary Power Unit, and the CE-G enclosure
with supplemental propane supply.
The site for the collocated CE-G will be predetermined by
the location of the CE-X enclosure.
The site for the remotely located CE-G should be planned so
that the enclosure will receive good air flow. If possible, in areas
of extreme heat, the enclosure should be positioned so that it
will be shaded from the afternoon sun. In areas of prevailing
winds, the enclosure should be located so that the side of the
cabinet face into the direction of the prevailing wind. This will
greatly reduce the amount of wind borne matter (dirt, snow, and
debris) which may enter the enclosure through the louvers or
vents.
In areas of flooding, the geographical site and concrete pad
should be located above the flood plane.
Place the front of the enclosure facing the street, where
component access will be curbside. In most instances,
landscaping such trees, shrubs, or wooden fences serve to
provide a more acceptable appearance in keeping with
surrounding neighborhood designs.
The enclosure should be placed where it will be free of
obstructions.
The illustration below shows the general dimensions for a poured
in place concrete pad. When placing the pad, allow at least 36
inches of clearance to allow the front and rear doors to fully
open.
2.1.2 Concrete Pad Layout
2-2
1
2
1
Fig.2-1, Concrete pad layout (all dimensions shown in inches)
3/8" diameter (4 places) bolts (which should extend
1"-1 1/2" above the surface of the pad). All mounting hardware
must be stainless steel to prevent corrosion.
A 25+ year continuous vapor barrier must be used between the
2
enclosure and pad to prevent moisture ingress and corrosion
caused by metal-to-concrete contact. The vapor barrier material
(such as 30 lb. felt, neoprene pond liner, or heavy grade tar
paper) should initially extend at least 6" in all directions around
the perimeter of the enclosure. After the enclosure is in place, the
material should be cut closer to the enclosure, using the
appropriate knife or cutting tool.
Page 17
2. Pre-Installation
2.1Site Preparation, continued
2.1.3 Enclosure Impact Protection
As described in the NFPA Technical Compliance Statement,
the cabinet must be protected by impact posts, placed in
strategic locations according to traffic patterns. The illustration
below shows the general arrangement of the 6 diameter,
concrete-filled posts. The actual positioning of the posts may
vary by location.
The following procedure will allow for installation of the Collocated CE-G with
the CE-X/ CE-X2. The CE-G enclosure re is bolted to the concrete pad using
7/16 bolts and to the CE-X APU enclosure by carriage bolts. Also this
procedure will explain step by step how to install the two 40 LB propane tanks
and the regulator /control valve.
Tools:
(2) Pipe wrench 10
7/8 combination box and open ended wrench
Straight slot screw driver
Multimeter
Adjustable crescent wrench 10
1/2 open ended wrench
Materials
QTY
(1)Regulator hold down bracket assembly
(2)40 pound DOT approved propane tanks
(1)CE-G Enclosure
transported, loaded, and unloaded while bolted to the shipping pallet. A safe
means of transportation to the site and unloading the enclosure must be
considered. Do not transport, lift, or place the unit on any surface unable to
fully support its weight.
The enclosure is shipped bolted to a shipping pallet. It should be
3-2
NOTE:
The enclosure should only be transported, lifted, and
installed as shipped from the factory. Do not install the
propane tanks until the enclosure is installed on the pad.
1.Install the CE-G enclosure so that the gas utility box of the CE-X
enclosure fits into the gas utility box cutout on the CE-G (dashed line) as
pictured below. Ensure the two cabinets are placed flush against each
other.
2.With the two cabinets sitting flush against each other, mark the anchor
bolt pattern onto the concrete pad using the four slotted anchor bolt
holes found in the corners of the base plate of the CE-G enclosure as an
template.
3.Also, mark the hole which will be used to bolt the cabinets together
(located at the lower left corner of the gas utility box cutout).
1
3
Fig. 3.1, Gas utility box cutout, connection bolt location
3.Slide the CE-G enclosure away from the CE-X enclosure.
4.Drill with a 1/4 hole through the wall of the CE-X enclosure where
previously marked.
3-4
NOTE:
5.With the anchor bolt pattern marked, drill holes for the installation of
anchor studs.
Tools required:
Stainless steel wedge-type stud anchor , 3/8" dia., 3-3/4" in length (4).
4 each, 3/8 flat washer, 3/8 lock washer, and hex nut.
Hand Drill or Rotary Hammer
3/8 Concrete or Masonry bit(s)
Hammer
Mounting bolt installation procedure:
1.At the points located in step 3 above, drill holes for the anchor studs.
Each hole should be at least 1-3/4 deep to properly secure the
enclosure to the pad.
2.With the hammer, tap the anchor studs into their respective holes.
3.Brush away any debris from the drilling prior to proceeding.
Before drilling through the CE-X cabinet wall,
ensure that the area behind the wall is clear
of any wires, gas hoses, or pipes.
5.Lay down the vapor barrier material. With a utility knife, make small
cutouts in the material through which the anchor studs protrude.
6.Place the CE-G enclosure back into place over the mounting studs.
7.With CE-G enclosure in place and flush against the CE-X enclosure,
install the mounting hardware (flat washers, lock washers, and 3/8
nuts) on each mounting bolt. Do not tighten at this time.
8.Install the 1 x 1/4 x 20 bolt through the lower left side bolt hole of the
gas utility box cutout (drilled in Step 4). Secure the bolt using a lock
washer, flat washer and nut.
9.Once the two cabinets have been secured together, evenly tighten the
anchor stud mounting hardware.
NOTE:
ALPHA TECHNOLOGIES is not responsible for
broken welds of other damage to the cabinet
caused by improper installation.
As described in the NFPA Technical Compliance Statement, the cabinet must
be protected by impact posts, placed in strategic location according to traffic
patterns.
3-6
FRONT
TRAFFIC
TRAFFIC
PROPANEAPU
POSTS
SIDEWALKSIDEWALK
CURB
STREET
CE-XCE-G
PAD
Fig.3.2, Impact post arrangement (typical)
Once the impact posts (Concrete-filled, 6 diameter, steel) have been
placed, proceed to the next section for the Propane Tank Installation procedure.
4.1Installation of the propane tanks and regulator assembly
4.1.1Installation of tanks
1.Place the rear tank into the enclosure through the rear access and the
front tank through the front access. Ensure that the base of each tank
fits into the tabs of the base plate, as shown below.
Figure 4.1, Tank base locator tabs
2.The tanks' vapor outlets should be facing towards the gas utility box (the
front left of the enclosure).
1.On tank hold down rod adjust stop nut so that the tank hold down
bracket aligns with the bottom edge of the tank valve guard / handle, as
shown below.
4-2
Figure 4.3, Stopnut
2.Slide regulator / hold down bracket assembly onto the hold down rod.
Ensure regulator assembly is facing same direction of tank valve vapor
ports, and that the hold down brackets outermost grooves fits onto the
bottom edge of the valve guard.
4.4Converting APU From Natural Gas To Propane Gas, cont.
9.Reconnect the APU exhaust and Fuel Hose
Procedure:
1.Install new gasket at the exhaust Flex pipe flange.
2.Apply antiseize compound to the flange bolts and install into flange
3.Torque the exhaust pipe flange bolts, bolt to bolt, to 7-ft/pounds.
4-10
Figure 4.15, Exhaust pipe flange gasket
4. Reconnect the fuel hose with cable ties to the proper anchor points (see
below). Verify the chafe guard is properly seated in the cut out before the
APU drawer is closed.
5. Once the fuel hose is securely fastened, slide the APU drawer back in the
enclosure and re-fasten the retaining bolts.
NOTE:
Verify fuel hose
is completely
wrapped in
chafe guard
material and
fully seated in
cutout.
2.Install the Low fuel pressure Switch package on to the gas inlet elbow
fitting.
NOTE:
The switch package is joined to the input pipe with a
compression fitting. DO NOT overtighten this fitting,
as that will cause it not to be leak tight.
The collocated CEG enclosure can be converted to be a remotely located
enclosure at distances of no more than 25 feet from the APU. This remote
operation requires the use of interconnecting buried gas pipe, between the
APU cabinet and the CEG cabinet. All pipe and pipe fittings running from the
CEX to the CEG will be installed in accordance with local code. All materials
used must meet approval of all local codes.
4-14
CAUTION
3" SWEEP
:Due to the Low Pressure Output of the CEG,
(1"), all interconnecting gas pipe must be 1"
to 3/4" inch diameter to ensure proper flow.