Alpha PWE-SG Series User Manual
PWE-SG Series
Pole Mount Battery Expansion Enclosure
Installation Manual
Pole Mount Battery Expansion Enclosure
Effective: April 2006
Alpha Technologies
Alpha Technologies
Power
®
PWE-SG Series
Battery Expansion Pole Mount Enclosure
Installation Manual
Effective Date: April 2006
Copyright© 2006
Alpha Technologies, Inc.
member of The Group
NOTE:
Photographs contained in this manual are for illustrative purposes only. These photographs may not match
your installation.
NOTE:
Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding. If
there are questions regarding the safe operation of this product, please contact Alpha Technologies or your
nearest Alpha representative.
NOTE:
Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators,
batteries, or other hardware if used or operated in any manner or subject to any condition not consistent with
its intended purpose, or is installed or operated in an unapproved manner, or improperly maintained.
TM
Contacting Alpha Technologies: www.alpha.com
or
For general product information and customer service (7 AM to 5 PM, Pacic Time), call
033-090-C0-001, Rev. A
1-800-863-3930,
For complete technical support, call
1-800-863-3364
7 AM to 5 PM, Pacic Time or 24/7 emergency support
3
Table of Contents
Safety Notes........................................................................................................................................................6
1.0 Introduction ............................................................................................................................................ 8
1.1 PWE-SG Enclosure Description ............................................................................................... 8
1.2 Enclosure Specications .......................................................................................................... 9
1.3 Accessing the Enclosure ........................................................................................................ 10
1.3.1 Removing the Enclosure Lid ...................................................................................... 10
1.3.2 Operating the Optional Battery Trays ........................................................................ 10
1.4 Optional Features ....................................................................................................................11
2.0 Installation ........................................................................................................................................... 12
2.1 Wooden Pole Installation, Attaching the Brackets .................................................................. 12
2.1.1 Using Optional Brackets ............................................................................................ 14
2.2 Steel/Concrete Pole Installation ............................................................................................. 14
2.3 Grounding the Enclosure ........................................................................................................ 15
2.4 Assembling the Conduit .......................................................................................................... 16
2.5 Connecting to the Legacy (Upper) Enclosure ......................................................................... 19
2.6 Installing PWE-SG Enclosure Batteries .................................................................................. 20
2.6.1 Battery Terminal Connections .................................................................................... 20
2.6.2 Battery Assembly for Vertical Battery Posts .............................................................. 21
2.6.3 Installation Procedure ................................................................................................ 21
2.6.4 Battery Assembly for Front Terminal Battery Posts ................................................... 22
2.6.5 Battery Installation for Front Terminal Batteries ......................................................... 22
2.6.6 Battery Installation Wiring Diagrams ......................................................................... 23
2.7 Installing Optional Features .................................................................................................... 25
2.7.1 Installing the Tamper Switch ...................................................................................... 25
2.7.2 Installing the Battery Heater Mat to the PWE-SG Enclosure ..................................... 26
3.0 Maintenance ........................................................................................................................................ 27
4
033-090-C0-001, Rev.A
Figures
Fig. 1-1, PWE-SG Dimensions .............................................................................................................. 8
Fig. 1-2, Removing the Enclosure Lid ................................................................................................. 10
Fig. 1-3, Operating the Optional Battery Trays .................................................................................... 10
Fig. 2-1, Insert Brackert into Mounting Strap ....................................................................................... 13
Fig. 2-2, Secure Upper Bracket ........................................................................................................... 13
Fig. 2-3, Positioning the Enclosure on the Pole ................................................................................... 13
Fig. 2-4, The Two Point Bracket for Both Concrete and Wooden Poles .............................................. 14
Fig. 2-5, The Two Point Extended Bracket for Wooden Pole Mount Enclosures................................. 14
Fig. 2-6, Enclosure Grounding ............................................................................................................. 15
Fig. 2-7, Conduit Placement, Interior View .......................................................................................... 16
Fig. 2-8, Conduit Connector ................................................................................................................ 17
Fig. 2-9, Attaching Anderson Connectors to Battery Cables ............................................................... 18
Fig. 2-10, Receptacle for Battery Heater Mat Line Cord ..................................................................... 18
Fig. 2-11, Attaching Connector ............................................................................................................ 18
Fig. 2-12, Conduit in Place .................................................................................................................. 18
Fig. 2-13, Legacy Enclosure Battery Wiring ........................................................................................ 19
Fig. 2-14, Date Code for Alpha Batteries after September 2001 ......................................................... 20
Fig. 2-15, In-line Fuse Link Mounting .................................................................................................. 20
Fig. 2-16, Vertically Mounted Battery Post .......................................................................................... 21
Fig. 2-17, Typical Ring Lug Assembly for Front Terminal Batteries, Single Lug .................................. 22
Fig. 2-18, 36V Battery Wiring Diagram ................................................................................................ 23
Fig. 2-19, 48V Battery Wiring Diagram ................................................................................................ 23
Fig. 2-20, 2X 36VFT Battery Wiring Diagram ...................................................................................... 24
Fig. 2-21, 1X 48VFT Battery Wiring Diagram ...................................................................................... 24
Fig. 2-22, Tamper Switch Jumper Board, Legacy Enclosure ............................................................... 25
Fig. 2-23, Tamper Switch Installation ................................................................................................... 26
Fig. 2-24, Attaching Battery Heating Mat Line Cord to Side of Enclosure ........................................... 26
Table 1-2, Enclosure Specications ....................................................................................................... 9
033-090-C0-001, Rev. A
Tables
5
Safety Notes
Review the drawings and illustrations contained in this manual before proceeding. If there are any questions
regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha
representative. Save this document for future reference.
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following
symbols have been placed throughout this manual. Where these symbols appear, use extra care and
attention.
ATTENTION:
The use of ATTENTION is only for specic regulatory/code requirements that may affect the placement of
equipment and installation procedures.
NOTE:
A NOTE gives readers additional information to help them complete a specic task or procedure.
CAUTION!
The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment.
WARNING!
A WARNING presents safety information to PREVENT INJURY OR DEATH to the
technician or user.
6
033-090-C0-001, Rev.A
Important Safety Instructions
WARNING!
The temperature of the batteries located in the PWE-SG may differ from those located in the •
legacy enclosure containing the power supply. The design of the PWE-SG minimizes this
difference when the two enclosures are subjected to the same ambient. Always place the battery
temperature sensor, ocntrolling the battery temperature charge compensation, on the hottest
battery. This is typically the center battery located directly below the power supply in the legacy
enclosure.
Lead-acid batteries generate explosive gases. To prevent arcing or burning near batteries, do •
not disconnect DC charging cord from batteries when the charger is operating. Switch the AC
breaker and the DC breaker to the "OFF" position before disconnecting the DC output cord from
the batteries.
Always shield eyes when working near batteries. Do not put wrenches or other metal objects •
across the battery terminal or battery top. Arcing or explosion of the battery can result.
Batteries produce hydrogen gas, which explodes if ignited. Never smoke, use an open ame, •
or create sparks near the battery. Ventilate the area when the battery is charging in an enclosed
place.
Lead-acid batteries contain sulfuric acid, which may cause burns. Do not get acid in eyes, on •
skin, or clothing. If contact with the eyes occur, ush immediately with clean water for 15 minutes
and seek medical attention.
033-090-C0-001, Rev. A
7
1.0 Introduction
The PWE-SG is a stand-alone pole mount battery enclosure that supports several battery
congurations and increases the capacity of your existing enclosure systems.
The PWE-SG is a exible and complementary addition to your legacy enclosure and comes with a full
range of options, including a battery drawer, battery heater mat, and a tamper switch.
1.1 PWE-SG Enclosure Description
The enclosure specications vary depending on the battery congurations used in the PWE-
SG. See Table 1-2.
30 1/4"
16 1/4"
17"
Fig. 1-1, PWE-SG Dimensions
30 3/4"
8
033-090-C0-001, Rev.A
1.0 Introduction, continued
1.2 EnclosureSpecications
PWE-SG Component Description
Enclosure
Material
Hardware
Color
Tamper Switch
Safety Ground
Lid
Doors
Sliding Battery Drawer
Enclosure Mounting
Gem Lock Kit
Conduit Collocation Kit
Enclosure Environmental
Ratings
Battery Congurations
Battery Retaining Bar
Battery Cable Kits
Battery Heater Mats
Regulatory
PWE-SG: 30.25” (76.83cm) W x 16.25” (41.27cm) H x 17.0” (43.18cm) D, Weight: 31.0 lbs (14.1 Kg)
(Alpha P/N 033-090-20)
Powder-coated aluminum
Stainless steel (excluding optional GemLocks)
Gray (Custom colors available)
Optional
NC, with Printed Circuit Board (PCB) jumper (Alpha P/N 745-851-20)•
NO, with PCB jumper (Alpha P/N 745-851-21)•
Bronze stud (Alpha P/N 744-422-20). Optional stainless steel ground available
Removable lift off
Hinged lift-off removable with stainless steel spring latch. Available with optional door-open prop rod
(Alpha P/N 745-857-20); Gemlock options
Aluminum. Two available options with lock in and lock out slides
Standard option (Alpha P/N 745-088-24) Select if battery weight is less than 300 lbs.•
Heavy duty option (Alpha P/N 745-088-23) Select if battery weight is more than 300 lbs and •
less than 420 lbs.
Galvanized steel brackets for wall, wood and concrete pole mount.
2 Pole mount brackets (PMB) concrete (Alpha P/N 591-557-20)•
Single 2-point PMB (Alpha P/N 605-352-N2)•
8 inch extension 2-point PMB (Alpha P/N 605-360-N2) •
2 PMB wooden (Alpha P/N 744-670-20)•
2 Wall mount brackets (Alpha P/N 744-800-20)•
Provides additional security for enclosure (Alpha P/N 744-229-20)
6" to 24" separation, 48" uncut length of conduit (Alpha P/N 745-853-20)
NEMA 3R
165/185/210 AlphaCell (3 or 4 with or without sliding drawer)•
195/255 AlphaCell FT (3, 4 or 6 without sliding drawer)•
Tel12-125 (3 or 4 with or without sliding drawer)•
Other congurations can be supported•
All AlphaGuard battery congurations•
Secures batteries within the enclosure. (Alpha P/N 745-154-20)
Optional
7' extension with all Battery Cable Kits (BCK) (Alpha P/N 875-584-20)•
Heavy Duty (HD), Fused (F), 1 x 36/1 x 48 AlphaCell FT (195/225) 3 or 4 batteries installed •
(Alpha P/N 745-759-20)
HD/F 2 x 36 AlphaCell FT (195/22) (Alpha P/N 745-759-21)•
HD 1 x 36 AlphaCell (165/180/210) (Alpha P/N 874-202-20)•
HD/F 1 x 36 AlphaCell (165/180/210) (Alpha P/N 874-202-21)•
HD/F 1 x 48 AlphaCell (165/180/210) (Alpha P/N 874-845-20)•
HD 1 x 48 AlphaCell (165/180/210) (Alpha P/N 874-845-21)•
Optional
120VAC with slide tray (Alpha P/N 189-031-10)•
240VAC with slide tray (Alpha P/N 189-031-11)•
120VAC no slide tray (Alpha P/N 189-072-10)•
240VAC no slide tray (Alpha P/N 189-072-11)•
8' line cord extension for 120VAC battery heater mat (BHM) (Alpha P/N 745-854-20)•
8' line cord extension for 240VAC BHM (Alpha P/N 745-854-21)•
CSA C22.2 No. 107.1-01, CSA C22.2 No. 0-M91, CSA C22.2 No. 0.4-04,
CSA C22.2 No. 94-M91, UL 50, UL 1778
033-090-C0-001, Rev. A
Table 1-2, Enclosure Specications
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