Alpha CESC User Manual

CESC Sidecar Installation Manual

Effective: March, 2004

®

Alpha Technologies

Power

®

CE Sidecar

Enclosure Installation Manual

031-106-C1-001, Rev. A

Effective Date: March, 2004

Copyright© 2004

Alpha Technologies, Inc.

NOTE: Alpha denies responsibility for any damage or injury involving its

enclosures, power supplies, generators, batteries, or other
hardware when used for an unintended purpose, installed or
operated in an unapproved manner, or improperly maint ained.

NOTE: Photographs contained in this manual are for illustrative purposes

only . These photographs may not exactly match your installation.

NOTE: Review the drawings and illustrations contained in this manual

before proceeding. If there are questions regarding the safe
operation of this powering system, please contact Alpha
T echnologies or your nearest Alpha representative.

Contacting Alpha Technologies:

For general product information and customer service

1-800-863-3930

(7:00 AM to 5:00 PM Pacific Time )

For complete technical support

1-800-863-3364

(7:00 AM to 5:00 PM Pacific Time, or 24/7 emergency support)

TM

Table of Contents

1. Introduction .......................................................................... 9

2. Installation ......................................................................... 10

2.1 Concrete Pad Preparation ...................................... 10

2.2 Utility Power Connection .......................................11

2.3 Generator / Sidecar Inter-connecting Cables............15

2.4 Internal Components ............................................ 16

2.5 Battery Pack Wiring .............................................. 17

2.6 Power Supply Placement .......................................18

2.7 Battery Remote Temperature Sensor (RTS).............. 19

2.8 Service Power Inserter .......................................... 20

List of Figures

Fig. 1 Sidecar and generator enclosure ..........................9

Fig. 2 Pad layout....................................................... 10

Fig. 3 Service Entrance wiring ..................................... 13

Fig. 4 Meter base wiring .............................................14

Fig. 5 Interconnection wiring ...................................... 15

Fig. 6 Fan connections ............................................... 16

Fig. 7 Location of IPP, SPI, and ground rail ...................16

Fig. 8 36- & 48-volt battery string wiring ..................... 17

Fig. 9 Power supply on shelf ....................................... 18

Fig. 10 Location of temperature sensor ......................... 19

Fig. 11 Seizure screw assembly location ........................20

Fig. 12 Cable connection..............................................20

Fig. 13 Location of SPI ................................................ 20

List of Tables

Table 2-1 Circuit Breaker Requirements ........................ 11

4 031-106-C1-001 Rev. A

Important Safety Instructions Contained in This

Manual

CAUTION

HAZARDOUS CONDITION

T o 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 VOL TAGE

This symbol indicates a “dangerous voltage” exists in this area of the
product. Use caution whenever working in the area to prevent
electrical shock.

Preface

INHALATION HAZARD - DON’T 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 service personnel.

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.

CRUSH HAZARD

This symbol indicates the presence of crushing hazard in this area.
Keep hands clear of areas under extended battery trays and equipment
drawers.

ATTENTION

This symbol indicates important installation, operation or maintenance
instructions. Always follow these instructions closely.

5 031-106-C1-001 Rev . A

Preface

A “Warning” identifies conditions and actions that pose a hazard to the user.

A “Caution” identifies conditions and actions that may damage the power
supply or associated equipment.

Warnings

NOTE: This power supply and its associated hardware (enclosure, batteries, cabling)

may contain equipment, batteries or parts which have accessible hazardous
voltage or currents.

T o avoid injury:

• This power supply and its associated hardware must be serviced by authorized personnel

only .

• The enclosure which contains the power supply and associated equipment must remain

locked at all times, except when authorized service personnel are present.

• Remove all conductive jewelry or personal equipment prior to servicing equipment, parts,

connectors, wiring, or batteries.

• Read and follow all installation, equipment grounding, usage, and service instructions

included in this manual.

• Use proper lifting techniques whenever handling equipment, parts, or batteries.

• Batteries contain dangerous voltages, currents and corrosive material. Battery installation,

maintenance, service and replacement must be performed by authorized personnel only .

• Never use uninsulated tools or other conductive materials when installing, maintaining,

servicing or replacing batteries.

• Use special caution when connecting or adjusting battery cabling. An improperly connected

battery cable or an unconnected battery cable can result in arcing, a fire, or possible
explosion.

• A battery that shows signs of cracking, leaking or swelling must be replaced immediately by

authorized personnel using a battery of identical type and rating.

• Avoid any contact with gelled or liquid emissions from a valve-regulated lead-acid (VRLA)

battery. Emissions cont ain dilute sulfuric acid which is harmful to the skin and eyes.
Emissions are electrolytic, which are electrically conductive and are corrosive. Follow the
Chemical Hazards notes if contact occurs.

• Do not smoke or introduce sparks in the vicinity of a battery .

6 031-106-C1-001 Rev. A

Battery Safety Notes

Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery
installation, maintenance, service and replacement must be performed by authorized personnel
only.

Chemical Hazards

NOTE: Any gelled or liquid emissions from a V alve-Regulated lead-acid (VRLA)

battery contain dilute sulfuric acid, which is harmful to the skin and eyes.
Emissions are electrolytic, which are electrically conductive and
corrosive.

T o avoid injury:

• Wear protective clothing (insulated gloves, eye protection, etc) whenever installing,

maintaining, servicing, or replacing batteries.

• If any battery emission contacts the skin, wash immediately and thoroughly with water .

Follow your company’s approved chemical exposure procedures.

Preface

• If any battery emission contacts the eye, wash immediately and thoroughly with water for

10 minutes with pure water or a special neutralizing eye wash solution and seek
immediate medical attention. Follow your company’s approved chemical exposure
procedures.

• Neutralize any spilled battery emission with the special solution contained in an approved

spill kit or with a solution of 1 lb. bicarbonate of soda to 1 gal. of water. Report chemical
spill using your company’s spill reporting structure and seek medical attention if
necessary.

• Always replace batteries with those of an identical type and rating. Never install old or

untested batteries.

• Do not charge batteries in a sealed container . Each individual battery should have at least

0.5 inches of space between it and all surrounding surfaces to allow for convection
cooling.

• All battery compartments must have adequate ventilation to prevent an accumulation of

potentially dangerous gas.

7 031-106-C1-001 Rev . A