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

Preface

Important Installation Notes

The system must be installed ONL Y by qualified service personnel.
Consult local utility codes for additional cabinet grounding and utility requirements.
ALPHA TECHNOLOGIES is not responsible for broken welds or 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.

NOTE:

Alpha T echnologies’ products are subject to change
through 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.

Save these instructions for future reference

8 031-106-C1-001 Rev. A

1. Introduction

1.1 Enclosure Introductions

The CESC enclosure is a cost effective 'all in one' power system. The side car provides for a
single power module, batteries, and generator in a low profile minimum footprint design.

This procedure describes the installation of a side car to an AlphaGen generator, PN-3B or
CE3X2B enclosure.

Fig. 1 Sidecar and Generator Enclosure

9 031-106-C1-001 Rev . A

2. Installation

2.1 Concrete Pad Preparation

Pads can either be poured on site, or precast by Alpha T echnologies. The mounting holes on
the bottom of the high security PN-3 will fit both a standard PN-3 pad, and a CE3X pad.
Precast pad model number PCC-SC-3X, Alpha P/N 641-061-10 or PCD-SC-3X, Alpha P/N
641-064-10 (east coast) are available for this system.

19.5

5

5.5

9.2

3.5

CESC

6

22.0

14.7

Generator

or PN3/4

1

3.5

6.8

10.25

4

Fig. 2 Pad Layout

All measurements are indexed to the front left generator mounting stud.

1

Indicates outline of enclosure.

2

2

3

All Measurments

in Inches

Alpha standard; recommended distance (6" minimum) between edge of pad and cabinet.

3

Four inch diameter hole for AC power IN (non-metered installation).

4

All mounting hardware must be stainless, galvanized, or better to prevent corrosion.

5

5" x 8" rectangular cutout for all internal connections including: generator power and/or coax

6

cable conduit sweeps. Position between mounting studs not critical.

A 25+ year continuous vapor barrier must be used between the enclosure and the pad to
prevent moisture ingress and possible corrosion caused by metal to concrete contact.
The vapor barrier material (such as 30 lb felt, neoprene pond liner, or heavy grade t ar
paper) must be initially extended at least 6" in all directions around the perimeter of the
enclosure. Af ter the enclosure is secured to the pad, the material can be cut closer to
the enclosure, using the appropriate knife or cutting tool.

10 031-106-C1-001 Rev. A

2. Installation

2.2 Utility Power Connection

CAUTION: The “Utility Power Connection” procedure must ONLY be performed by qualified

service personnel and in compliance with local electrical codes and common safety
practices. Connection to utility power must be approved by the local utility before
installing the power supply .

NOTE: UL and NEC require that a service disconnect switch (UL listed) be provided by the

installer and be connected between the power source and the ALPHA power supply .
Connection to the power supply must include an appropriate service entrance weather
head.

Wiring the Utility Service

NOTE: A “high-magnetic” trip circuit breaker must be used in order to accommodate the

high-inrush currents normally associated with the start-up of ferroresonant
transformers (400 Amp, no-trip, first half cycle). Do not replace this circuit breaker
with a conventional service entrance circuit breaker. Alpha recommends Square D
circuit breakers ONL Y , because of increased reliability in this powering application.

Alpha Technologies offers a high-magnetic Square D circuit breaker and a BBX option (a UL Listed

service entrance). Contact your local sales representative for more information.

Description

240V Installation — HACR (15A)

120V Installation — High-magnetic (20A)

120V Installation — High-Magnetic (15A)

BBX — External Service Disconnect

Alpha Part Number Square D Part Number

470-224-10

470-017-10

470-017-10

470-013-10

020-085-10

QO215

QO120HM

QO115HM

QO2-4L70RB

QO8-16L100RBBBX — External Service Disconnect 020-141-10

Table 2-1 Service Entrance Circuit Breaker Requirements

In most cases, the following configurations (see next page) qualify for service
entrance use, however, other codes may apply. Always contact your local utility to
verify that the wiring conforms to applicable codes.

11 031-106-C1-001 Rev . A

2. Installation

2.2 Utility Power Connection, continued

240V AC Service (XM Series 2 915-240 Power Supply; XM Series 2 922-

120V AC 20A Service (XM Series 2 915-120 Power Supply): Enclosures used

48 for UPE-4 and UPE-8): Enclosures used with the XM
Series 2 915-240 or 922-48 are equipped with a 240V AC
duplex receptacle to provide power to the power supply
and peripheral equipment. The receptacle, NEMA 6-15R,
is protected by a single, 2-pole, common trip 15
Amp circuit breaker located inside the service entrance.
Wiring is typically 14AWG per NEC code, a grounding
clamp, located on the enclosure, facilitates dedicated

grounding.

with the XM Series 2 915-120 are equipped with a
120V AC duplex receptacle to provide power to the
power supply and peripheral equipment. The receptacle,
NEMA 5-20R, is protected by a single, 2-pole, common
trip 20 Amp circuit breaker located inside the service
entrance. Wiring is typically 12AWG per NEC code, a
grounding clamp, located on the enclosure, facilitates

dedicated grounding.

120V AC 15A Service (XM Series 2 615): Enclosures used with the XM Series

2 615 are equipped with a 120V AC duplex receptacle
to provide power to the power supply and peripheral
equipment. The receptacle, NEMA 5-15R, is protected
by a single-pole, 15 Amp High Magnetic circuit breaker
located inside the service entrance. Wiring is typically
14AWG per NEC code, a grounding clamp, located on

the enclosure, facilitates dedicated grounding.

NOTE: Alpha recommends wiring with 12AWG, in case the enclosure

is to be upgraded to use 90V power supplies in the future.

12 031-106-C1-001 Rev. A

2.2 Utility Power Connection, continued

2. Installation

Ground

120 VAC

Service Entrance

From Utility

NeutralLine 1

ON

OFF

To EnclosureTo Ground Rod

240 VAC

Service Entrance

NeutralLine 1Line 2Ground From Utility

ON

OFFONOFF

To EnclosureTo Ground Rod

031-106-C1-001 Rev. A

Fig. 3 Service Entrance Wiring

13

2. Installation

2.2 Utility Power Connection, continued

GroundNeutralline 1

ON

OFF

120 VAC Meter Base

ON

20

OFF

GroundLine 2Neutralline 1

240 VAC Meter Base

Fig. 4 Meter Base Wiring

14 031-106-C1-001 Rev. A

2.3 Generator / Sidecar Inter-connecting Cables

The following cables must be routed either through a 3" sweep or coupling:

#4 A WG DC Output from the generator
120 V AC power from the CESC sidecar service entrance
ECM or ACU Interface cable (status monitoring)

2. Installation

Sidecar
Enclosure
Back Wall

Generator
Enclosure
Side Wall

3" PVC

Coupling

ECM Interface (status monitoring)

Line
Neutral

120 VAC From Service Entrance

Ground

Positive

DC Output From Generator

Negative

031-106-C1-001 Rev . A

Fig. 5 Interconnection Wiring

15

2. Installation

2.4 Internal Components

The Sidecar enclosure contains an Input Power Panel (IPP), one or two Service Power Inserters
(SPI),and the Enclosure Grounding Rail. The Power Supply rests on the upper shelf, and a
36 or 48 VDC battery pack on the lower two shelves.

A cooling fan is required any time a Power Supply is housed in the side car. The
fan is thermostatically controlled to turn on at ~140 deg F and off at ~110 deg
F. The fan cable has a 'T' connector that attaches to the Power Supply output
connection. Replace fuse only with a 1/4” X 1-1/4”, 5 Amp, 250 Volt

(Alpha P/N 460-025-10).

Thermostat

Cooling Fan

Input Power Pane l ( IP P)

AC Power

Connections

Fig. 6 Fan Connections

Fuse

Enclosure

Grounding Rail

Fig. 7

Location of IPP, SPI, and

Ground Rail

SPI

16 031-106-C1-001 Rev. A

2.5 Battery Pack Wiring

2. Installation

4

3

1

2

48 Volt

Battery Pack

BCK P/N 874-665-20

Upper Shelf

3

1

Lower Sheff

2

36 Volt

Battery Pack

BCK P/N 874-664-20

031-106-C1-001 Rev . A

Fig. 8 36- & 48-Volt Battery String Wiring

17

2. Installation

2.6 Power Supply Placement

1. Place the XM2 power supply onto the top shelf of the side car.

2. Verify that the AC Input Breaker in the service entrance is in the OFF position.

3. Verify that the Battery Breaker on the front of the power supply is in the OFF
position.

4. Plug the AC power cord into the Input Power Panel on the side of the enclosure.

5. Plug the Battery Input Cable from the battery pack into the Battery Input
connection on the front of the power supply .

6. Plug the wire leading from the fan into the OUTPUT 1 connection on the front of
the power supply .

7. Plug the wire leading from the top SPI into the other set of plugs on the wire
from the fan.

8. If a second SPI is installed, plug it into the OUTPUT 2 connection on the front of
the power supply .

Fig. 9 Power supply on Shelf

18 031-106-C1-001 Rev. A

2.7 Battery Remote Temperature Sensor (RTS)

Tools Needed:

Adhesive T ape

Procedure:

For enclosures with multiple battery strings, the RTS must be located
with the WARMEST battery string. This ensures proper operation of
the battery charger’s temperature compensation circuit. Failure to
locate the RTS with the warmest battery string could result in
overcharging and premature battery failure. In this application, the RTS
MUST be attached to a battery in the upper tray of the side-car .

1. Attach the RTS Probe to the inner side of one of the batteries
on the upper tray of the side-car with adhesive tape.

2. The other side of the RTS Probe is attached to the front panel of the
XM2 power supply , in the jack labeled TEMP PROBE

2. Installation

031-106-C1-001 Rev . A

Fig. 10 Location of Temperature Sensor

19

2. Installation

2.8 Service Power Inserter

1. The SPI box(es) are mounted on the shelf
support bracket.

2. Remove the two screws on the face of the
SPI and lift off the cover to gain access to
the Seizure Screw Assembly. Loosen the
seizure Screw several turns so that the
stinger will pass through the clamp. (Fig 2-3)

3, Insert the Coaxial T ermination into the output

port on the bottom of the SPI. Ensure that
the stinger goes through the Seizure Screw
Assembly. Tighten the Coaxial T ermination.

4. Tighten the seizure screw to 35.0 Inch-Pounds.
Replace the SPI cover and screws.

Ensure that the switch on the top or the SPI is
in the ON position, the AUX position is used
only when an alternate power source is
connected to the SPI.

Fig. 13 Location of SPI

Seizure Screw

Assembly

Seizure

Screw

Coax

Stinger

Coax

Termination

Fig. 1 1 Seizure Screw Assembly Location

Fig. 12 Cable Connection

20 031-106-C1-001 Rev. A

Alpha Technologies

Power

®

Alpha T echnologies
3767 Alpha Way
Bellingham, WA 98226

USA

Tel: [phone]
Fax: [phone]
Web: www.alpha.com

Alpha Technologies Ltd.
4084 McConnell Court
Burnaby, BC, V5A 3N7

CANADA

Tel: [phone]
Fax: [phone]

Alpha T echnologies
Europe Ltd.
Cartel Business Estate
Edinburgh Way
Harlow, Essex CM20 2TT

UNITED KINGDOM

T el: [phone]
Fax: [phone]

Alpha T echnologies
Hansastrasse 8
D-91126 Schwabach

GERMANY

T el: [phone]
Fax: [phone]

Alphatec
339 St. Andrews Street
Suite 101
Andrea Chambers
Limassol, Cyprus

CYPRUS

T el: [phone]
Fax: [phone]

Alpha T echnologies
Unit R5-R7 Regents Park Estate
Corner Park Rd and Prince’s Rd
East
Regents Park, NSW 2143

AUSTRALIA

T el: [phone]
Fax: [phone]

Copyright © 2004 by Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies. 031-106-C1-001 Rev. A.

Due to continuing product improvements, Alpha reserves the right to change specifications without notice.