Alpha CESC-3X User Manual

© 2002

CESC-3X

Compact AlphaGen System Sidecar

Installation Manual

Effective: March, 2002

®

TM

031-099-C0-001 Rev. A

2

© 2002

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R

TM

CESC-3X Sidecar

Installation Manual

031-099-C1-001 Rev. A

March, 2002

© 2002 Alpha Technologies

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 installation of this
system, please contact Alpha Technologies or your nearest Alpha
representative

© 2002

TM

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031-099-C1-001 Rev. A

1. Introduction

031-099-C0-001 Rev. A

4

© 2002

TM

2. Installation

2.1 Concrete Pad Preparation

Pads can either be poured on site, or precast by Alpha Technologies. The mounting
holes on the bottom of the side car will fit both a standard PN-3 pad, and a CE3X pad.
Precast pad model number PCD-SC-3X, Alpha P/N 641-064-10 is available for this
system.

All measurements indixed to the

1

left-front generator mounting stud

Indicates enclosure mating

2

surface

Alpha standard, recomended distance,

3

between edge of pad and enclosure

4" diameter through-hole for AC Power

4

sweep (non-metered installation)

All mounting hardware must be stainless

5

or galvanized to prevent corrosion

5" X 8" cutout for internal connections

6

to generator, and coaxial cable sweeps

19.5

5.5

2

3.5

6

CESC-3X

9.2

22.0

14.7

Generator

6.8

3.5

4

1

10.25

5

3

All Measurments

in Inches

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 tar paper) must be initially extended at
least 6" in all directions around the perimeter of the enclosure. After the
enclosure is secured to the pad, the material can be cut closer to the
enclosure, using the appropriate knife or cutting tool.

© 2002

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031-099-C1-001 Rev. A

2. Installation

2.2 Utility Power Connection

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

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

Wiring the Utility Service

Utility power enters the enclosure through the side or bottom of the UPE. The
enclosure accepts a standard electrical fitting. The UPE Series can be equipped with an
optional circuit breaker assembly located in the enclosure’s module compartment.

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

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.

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.

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
ONLY, 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.

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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.

rebmuNtraP

031-099-C0-001 Rev. A

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© 2000

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2. Installation

2.2 Utility Power Connection, continued

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

48 for UPE-4 and UPE-8): Enclosures used with the XM
Series 2 915-240 or 922-48 are equipped with a 240VAC
duplex receptacle to provide power to the power supply
and peripheral equipment. The receptacle, NEMA 6­15R, 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.

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

with the XM Series 2 915-120 are equipped with a
120VAC 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.

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

2 615 are equipped with a 120VAC 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.

© 2000

TM

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031-099-C1-001 Rev. A

2. Installation

2.2 Utility Power Connection, continued

ISE 120 VAC 15 Amp

Neutral

Ground

Line

ON

OFF

Neutral

Ground

Line

ISE 120 VAC 20 Amp

Ground

Line 2

Line 1

ISE 240 VAC 15 Amp

ON

OFF

ON

OFF

031-099-C0-001 Rev. A

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© 2000

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2.2 Utility Power Connection, continued

2. Installation

Ground

120 VAC Service
Entrance

From Utility

NeutralLine 1

ON

OFF

To Enclosure

240 VAC Service
Entrance

ON

OFFONOFF

NeutralLine 1Line 2Ground From Utility

To Enclosure

© 2000

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031-099-C1-001 Rev. A

2. Installation

2.2 Utility Power Connection, continued

GroundLine 2Neutralline 1

ON

2
0

OFF

240 VAC Meter Base

GroundNeutralline 1

ON

OFF

031-099-C0-001 Rev. A

120 VAC Meter Base

10

© 2000

TM

2. Installation

2.3 Generator / Sidecar Inter-connecting Cables

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

#4 AWG DC Output from the generator

120 VAC power from the CESC sidecar service entrance

ECM or ACU Interface cable

Sidecar
Enclosure
Back Wall

Generator
Enclosure

Side Wall

3" PVC

Coupling

ECM Interface

Line
Neutral

120 VAC From Service Entrance

Ground

Positive

DC Output From Generator

Negative

© 2000

TM

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031-099-C1-001 Rev. A

2. Installation

2.4 Internal Components

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).

Cooling Fan

Thermostat

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
48 VDC battery pack on the lower two
shelves.

Input Power Panel (IPP)

AC Power Connections

Fuse

Enclosure

Grounding Rail

SPI

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2.5 Battery Pack Wiring

2. Installation

1

2

4

3

48 Volt

Battery Pack

Upper Shelf

1

3

Lower Sheff

2

36 Volt

Battery Pack

© 2000

TM

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031-099-C1-001 Rev. A

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.

Output to SPI

and Fan

XM2 Power Supply

AC Power Cord

Battery Pack Input

031-099-C0-001 Rev. A

14

© 2002

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2. Installation

2.7 Battery Remote Temperature Sensor (RTS)

Tools Needed:

Adhesive Tape

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

© 2002

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031-099-C1-001 Rev. A

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 Termination into the output

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

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 'Jones" connector on the top of the SPI.

031-099-C0-001 Rev. A

Seizure Screw

Assembly

16

Seizure

Screw

© 2002

Coax

Stinger

Coax

Terminati on

TM

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®

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Tel: [phone]
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Copyright © 2000 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies. 031-099-C0-001 Rev. A

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