Alpha Radium MiniBay User Manual

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Radium MiniBay

Enclosure Installation Manual

Radium MiniBay

Effective: June 2006

Alpha Technologies

Power

Radium MiniBay

Enclosure Installation Manual

044-001-C0-003, Rev. C

Effective Date: June 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 powering system, 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.

Contacting Alpha Technologies: www.alpha.com

For general product information and customer service (7 AM to 5 PM, Pacic Time) call,

1-800-863-3930

For complete technical support, call

1-800-863-3364

7 AM to 5 PM, Pacic Time or 24/7 emergency support

Table of Contents

Important Safety Instructions ................................................................................................. 6

1.0 Overview and Specications..................................................................................... 10

1.1 Standard Cordex Congurations.................................................................... 15

1.2 Enclosure Specications ................................................................................ 18

1.3 MiniBay Accessories ...................................................................................... 18

1.4 Enclosure Cooling Options ............................................................................ 19

1.5 Enclosure Heating Options ............................................................................ 20

1.6 Storage Unit Cooling Options ........................................................................ 21

1.7 Battery Storage Unit Battery Options ............................................................. 22

2.0 DC Air Conditioner .................................................................................................... 23

2.1 Overview and Theory of Operation ................................................................ 23

2.2 DC Air Conditioner Specications .................................................................. 24

2.3 Temperature Control Board............................................................................ 25

2.4 Air Conditioner Installation and Removal ....................................................... 27

2.5 48/24VDC Power Connection ........................................................................ 28

2.6 Alarm Connector ............................................................................................ 29

2.7 Function Test .................................................................................................. 29

2.8 Jumpers ......................................................................................................... 30

2.9 DC Air Conditioner Preventative Maintenance .............................................. 31

2.10 DC Air Conditioner Trouble Shooting ............................................................ 32

2.11 DC Air Conditioner Parts List ......................................................................... 33

3.0 AC Air Conditioner .................................................................................................... 34

3.1 Verifying Default Settings for the IceQube Air Conditioner ............................ 35

3.2 AC Air Conditioner Specications .................................................................. 36

3.3 AC Air Conditioner Condensate Hose Mounting ........................................... 37

3.4 AC Air Conditioner Preventative Maintenance ............................................... 38

3.5 AC Air Conditioner Troubleshooting ............................................................... 38

3.6 Replacement or Spare 2400 AC Air Conditioner............................................ 38

4.0 Site Preparation ........................................................................................................ 39

4.1 Site Selection ................................................................................................. 39

4.2 Precast Pads.................................................................................................. 40

4.3 Pour-in-place Concrete Pads ......................................................................... 42

4.4 Site Conguration .......................................................................................... 45

4.5 Enclosure Grounding ..................................................................................... 47

5.0 Installation................................................................................................................. 48

5.1 Lifting ............................................................................................................ 49

5.2 Special Instructions for Double-wide Installation ........................................... 51

5.3 Battery Connection ........................................................................................ 52

5.4 Connecting to Utility Power ............................................................................ 53

Appendix A........................................................................................................................... 55

044-001-C0-003, Rev. C

List of Figures

1.0 Overview ................................................................................................................... 10

Fig. 1-1, MiniBay Cabinet ................................................................................................................................. 10

Fig. 1-2, Typical MiniBay Cabinet Conguration, with Side Chamber ...............................................................11

Fig. 1-3, Interior View of the MiniBay Side Chamber ........................................................................................ 12

Fig. 1-4, Equipment Bay Detail ......................................................................................................................... 13

Fig. 1-5, Electronic Components (typical)......................................................................................................... 13

Fig. 1-6, Equipment Bay, Front View ................................................................................................................ 14

Fig. 1-7, Equipment Bay, Rear View ................................................................................................................. 14

Fig. 1-8, Radium MiniBay Standard Conguration #1 ...................................................................................... 15

Fig. 1-8, Radium MiniBay Standard Conguration #2 ...................................................................................... 16

Fig. 1-9, Radium MiniBay Equipment Rack View ............................................................................................. 17

2.0 DC Air Conditioner .................................................................................................... 23

Fig. 2-1, DC Air Conditioner Basic Block Diagram ........................................................................................... 23

Fig. 2-2, Temperature Control Board ................................................................................................................ 25

Fig. 2-3, Wiring Diagram................................................................................................................................... 26

Fig. 2-4, Shroud and Air Conditioner Bolts ....................................................................................................... 27

Fig. 2-5, Power Connections ............................................................................................................................ 28

Fig. 2-6, Alarm Connections ............................................................................................................................. 29

Fig. 2-7, Setpoint Jumper ................................................................................................................................. 29

3.0 AC Air Conditioner .................................................................................................... 34

Fig. 3-1, AC Air Conditioner ............................................................................................................................. 34

Fig. 3-2, AC Air Front Panel Display ................................................................................................................. 35

Fig. 3-3, Condensate Hose Mounting ............................................................................................................... 37

4.0 Site Preparation ........................................................................................................ 39

Fig. 4-1, Conduit Seal Location ........................................................................................................................ 39

Fig. 4-2, Precast Pad Dimensions for Single-wide Enclosure ......................................................................... 40

Fig. 4-3, Precast Pad Dimensions for Single-wide Enclosure with Side Chamber ........................................... 41

Fig. 4-4, Pad Frame Template for Single MiniBay Cabinet .............................................................................. 42

Fig. 4-5, Isometric View, Pad Frame Template, Single MiniBay ....................................................................... 42

Fig. 4-6, Isometric View, Pad Frame Template, Single MiniBay with Side Chamber ....................................... 43

Fig. 4-7, Isometric View, Pad Frame Template, Dual MiniBay with Side Chamber ......................................... 43

Fig. 4-8, Footprint of Dual Enclosure, Dual Side Chamber System ................................................................. 44

Fig. 4-9, Typical Site Arrangement, (cabinet with optional side chamber) ....................................................... 45

Fig. 4-10, Typical Site Arrangement, (stand-alone cabinet) .............................................................................. 46

Fig. 4-11, Suggested Grounding ....................................................................................................................... 47

5.0 Installation................................................................................................................. 48

Fig. 5-1, Enclosure Lifting Arrangement (without side chamber) ...................................................................... 49

Fig. 5-2, Enclosure Lifting Arrangement (with optional side chamber in place) ................................................ 49

Fig. 5-3, Rear View of Enclosure, (showing ladder bar) .................................................................................. 50

Fig. 5-4, Dual Enclosure Installation ................................................................................................................. 51

Fig. 5-5, Battery Terminal Connections ............................................................................................................ 52

Fig. 5-6, Service Entrance Wiring ..................................................................................................................... 54

5044-001-C0-003, Rev. C

Important Safety Instructions

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.

Symbols in this Manual

ATTENTION:

The use of ATTENTION indicates regulatory/code requirements that may affect the placement of equipment or installation procedures.

NOTE:

A NOTE provides additional information to help complete a specic task or procedure.

CAUTION!

A CAUTION presents safety information to PREVENT DAMAGED EQUIPMENT.

WARNING!

A WARNING presents safety information to PREVENT INJURY OR DEATH to the technician/user.

ATTENTION:

Alpha Technologies’ products are subject to change through continual improvement processes. Therefore,

specications or design layouts may vary slightly from the descriptions included in this manual. Updates to the manual are issued when changes affect form, t or function.

044-001-C0-003, Rev. C

General Safety Precautions

CAUTION!

This enclosure and its associated hardware (power supply, batteries, cabling) may contain

equipment, batteries or parts that have hazardous voltage or currents.

To avoid injury:

• This enclosure and its associated hardware must be serviced only by authorized personnel.

• Enclosure 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 enclosure, 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. Battery cables that are either

improperly or unconnected can result in arcing, a re, 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 contain 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.

• Under certain overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas that is explosive. Proper venting of the enclosure is required.

• Follow the battery manufacturer’s approved transportation and storage instructions.

CAUTION!

Enclosure, equipment or parts may be damaged or cause damage if used or installed improperly.

To avoid damage:

• Prior to installation, verify that the AC input voltage to the enclosure and its equipment match with respect to voltage and frequency.

• Prior to installation, verify that the output voltage from the enclosure or its equipment match the voltage

requirements of the connected equipment (load).

• Prior to installation, verify that the enclosure’s utility service panel is equipped with a properly rated circuit breaker for use with the equipment inside. Refer to manufacturer’s recommendations.

• Review and upgrade utility service panel circuit breaker requirements whenever the equipment within the enclosure is changed.

• Prior to installation, contact local utilities, local building maintenance departments, and cable/piping locator services to ensure that installation will not interfere with existing utility or building cables/piping.

• Do not exceed the output rating of equipment. Verify load requirements prior and during connection process.

• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have developed in your body.

7044-001-C0-003, Rev. C

Battery Safety Notes

WARNING!

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

Chemical Hazards

To avoid injury:

• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all metallic objects from hands and neck.

• Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel knowledgeable of batteries and the required safety precautions.

• All gelled or liquid emissions from a valve-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.

• Batteries produce explosive gases. Keep all open ames and sparks away from batteries.

• Use tools with insulated handles, do not place tools on top of batteries.

• Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Battery post terminals and related accessories contain lead and lead

compounds. Wash hands after handling. (California Proposition 65)

• 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.

• Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with a solution of one pound Bicarbonate of soda to one gallon 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.

• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have developed on your body.

• 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 make contact with an unintended surface that can result in arcing,

re, or possible explosion.

• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by Authorized Personnel using a battery of identical type and rating.

• Under extreme overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas which is explosive.

• All battery compartments must have adequate ventilation to prevent accumulation of potentially dangerous gas. Ventilation should prevent trapped hydrogen gas pockets from exceeding a one percent

concentration as per regulation 70E of the National Fire Protection Agency (NFPA).

044-001-C0-003, Rev. C

Battery Maintenance Guidelines

The battery maintenance instructions listed below are for reference only. Battery manufacturer’s instructions for transportation, installation, storage or maintenance take precedence over these instructions.

• To prevent damage, inspect batteries every 3 months for signs of:

Battery cracking, leaking or swelling. The battery should be replaced immediately by authorized

personnel using a battery of the identical type and rating.

Battery cable damage. Battery cable should be replaced immediately by authorized personnel using

replacement parts specied by vendor.

Loose battery connection hardware. Refer to battery manufacturer’s documentation for the correct

torque and connection hardware for the application.

• Apply battery manufacturer’s specied antioxidant compound on all exposed connections.

• Verify battery terminals and/or exposed connection hardware is not within two inches of a conductive

surface. Reposition batteries as necessary to maintain adequate clearance.

• Clean up any electrolyte (battery emission) in accordance with all federal, state, and local regulations or

codes.

• Proper venting of the enclosure is recommended. Follow the Battery Manufacturer’s approved

transportation and storage instructions.

• 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.

Recycling and Disposal Instructions

Spent or damaged batteries are considered environmentally unsafe. Always recycle used batteries or dispose of the batteries in accordance with all federal, state and local regulations.

Electrical Safety

• Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical

connection or conductor is not energized. Check the circuit with a volt meter with respect to the grounded

portion of the enclosure (both AC and DC) prior to any installation or removal procedure.

• Always use the buddy system when working under hazardous conditions.

• A licensed electrician is required to install permanently wired equipment.

• Input voltages can range up to 240VAC. Ensure that utility power is disabled before beginning installation

or removal.

• Ensure no liquids or wet clothes contact internal components.

• Hazardous electrically live parts inside this unit are energized from batteries even when the AC input

power is disconnected from the MiniBay.

Mechanical Safety

• Keep hands and tools clear of fans. Fans are thermostatically controlled and will turn on automatically.

• Power supplies can reach extreme temperatures under load.

• Use caution around sheet metal components and sharp edges.

9044-001-C0-003, Rev. C

1.0 OverviewandSpecications

The MiniBay’s modular design allows the exible conguration necessary to meet a wide range of applications, including traditional and advanced hybrid ber coax (HFC), FTTx ber deep, Wi-Max

networks, wireless outdoor base stations, wireless IP access, and bulk power.

The MiniBay is comprised of a set of CSA listed assemblies that allow new agency approved

congurations to be rapidly constructed. The equipment section can be congured to 19" or 23" wide rack units (RU), consisting of 23 RU in the front and 23 RU in the rear. An optional “swing rack”

provides 17 RU of additional equipment space.

Thermal management options include conformal-coated fans with electrostatic lters, heat exchangers, and two high efciency air conditioning systems.

Each battery storage unit is isolated from the equipment section and can house a variety of battery types, including a 48V string of GNB M12V155FT batteries that can support a 19.4A load for 8 hours. A second battery storage module can be added to provide additional capacity or redundancy.

The MiniBay integrates Alpha’s comprehensive line of power solutions for today’s complex

communications powering requirements, including the Cordex series of high efciency hot swappable switch mode 48VDC rectiers and the AlphaGen series of telephony grade DC generators.

NOTE:

For MiniBay wiring diagrams and alarm information, see Radium MiniBay System Schematics, Alpha P/N 044-001-C2.

Air Conditioning Unit

(optional)

Lifting Ear

Pin Allen Telecom

Security Locks

Battery Storage Unit

(lockable)

Fig. 1-1, MiniBay Cabinet

044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

Viewing Window

Lifting Ear

Lockable Door

Air Conditioning

Unit

Battery Storage Unit

(lockable)

Fig. 1-2, Typical MiniBay Cabinet Conguration, with Side Chamber

11044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

MiniBayconguredwiththefollowingoptions:

Side Chamber (designed to NEMA 4X specications) 60A Internal AC Service (Square D QO Series) EUSERC Meter Base (240VAC with Test Bypass Blocks) Fusible Service Entrance Disconnect (100,000 AIC rating) Side Chamber Door Viewing Window TVSS (Transient Voltage Surge Suppression) Module Cable Entry Seals Master Ground Bar Telcom 3-point Door Latch Door Activated Light and Tamper Switch

Also shown on this unit:

3,000 BTU DC Air Conditioner Battery Storage Unit Pin Allen Telecom Locks

Viewing Window

Fused Disconnect

Door-activated Tamper Switch

and Light.

Pin Allen 3-point

Door Latch

Ground Bar

Meter Base

EUSERC

Meter Base

AC Distribution

Breaker Panel

Cable Entry Port Seals

Fig. 1-3, Interior View of the MiniBay Side Chamber

044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

DC Air Conditioning Unit

Insulating Material (used on front/rear

doors and interior of

cabinets equipped with

air conditioning)

Fig. 1-4, Equipment Bay Detail

Air Conditioner

Controller Board

GFCI

Convenience

Outlet

Door-activated Switches

(tamper alarm and service light)

Rectier Shelf

(Cordex 48-650W

shown)

Fig. 1-5, Electronic Components (typical)

13044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

Front Service Light

Equipment Rack

(23" shown)

GFCI Convenience Outlet

Door-activated

Switches

(tamper alarm and

service light)

48-1.8kW Rectier Shelf

(shown)

19" Rear Swing Rack

Front Access Circuit Breaker

Distribution Center with

Integrated Cordex Controller

(shown)

Lockable Battery

Module

Fig. 1-6, Equipment Bay, Front View

GFCI Convenience Outlet

Door-activated Switches

(tamper alarm and

service light)

Cable Entry Port Seals

Lockable Battery

Compartment

Fig. 1-7, Equipment Bay, Rear View

044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

1.1 StandardCordexCongurations

The Radium MiniBay may be equipped with Cordex 48-650W, 48-1kW, or 48-1.8kW AC/DC

rectiers. Previous models were equipped with RSM 48/10 AC/DC rectiers. Due to customer

requirements, the following illustrations may not resemble your model exactly.

RMB DC Power & Distribution Standard Conguration #1

• Cordex 48-650W 19" shelf with two rectier modules with load LVD

• Provides 13.5A @ 48VDC, N+1

• Fully equipped shelf provides 2.6kW (54A @ 48VDC), N+0

• 2RU shelf needs 1RU above and below, convection cooled

• Heat dissipation <221 BTU/hr, per rectier module

• Comnet GMT fuse panel, 10A/10B position -48VDC

GMT Fuse Panel

2 RU P/N C016-111-10 10A/10B -48VDC

(Rack Units)

Load Breakers (qty 4)

Available Sized 1-100A

19" or 23" Heat Deector

1 RU

CDX 19/23" 48-650W Shelf

2 RU

P/N 030-728-20-A010

208/240AC CXCI, Load LVD

(Battery LVD available)

CXRC 48-650W Rectier Modules (qty 2-4)

2 RU

P/N 010-570-20-A002

19" Rack

23" Rack

HEAT DEFLECTOR

Blank Plate

P/N 030-728-20-A005

Fig. 1-8, Radium MiniBay Standard Conguration #1

NOTE:

For units equipped with a Battery LVD, a manual reset of the battery contactor is required after the low voltage disconnect has been tripped, if there is no resumption of AC power, and DC power is applied to the unit using

an alternate power source (DC generator).

15044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

1.1 StandardCordexCongurations,continued

RMB DC Power & Distribution Standard Conguration #2

• Cordex 1.8kW 19" Shelf, with two Cordex 48-1.8kW rectier modules

• Provides 37.5A @ 48VDC, N+1

• Fully equipped shelf provides 7.2kW (150A @ 48VDC), N+0

• 2 RU shelf, fan cooled

• Heat dissipation <350 BTU/hr, per rectier module

• 584 Distribution Center with Cordex Controller, load LVD, eight load breakers, and shunt

Front ACS Distribution Center

5 RU

P/N 020-584-20-A012

19/23" 48VDC 400A

8 position Circuit Breaker

Sized 1-100A with Load LVD

2 to 4 (qty) CXCM 48-1.8kW Rectier Modules

2 RU

P/N 010-580-20-A001

ARGUS

TECHNOLOGIES

P/N 020-584-20

19" Rack

23" Rack

Leave 1RU Space

SM03

Blank Plate

P/N 030-749-20-A002

(Rack Units)

CDX 19" Shelf

2 RU

48-1.8kW

P/N 030-749-20-A001

208/240VAC

Fig. 1-9, Radium MiniBay Standard Conguration #2

044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

1.1 StandardCordexCongurations,continued

NOTE:

Rack height is shown in Rack Units (RU). One RU is equal to 1.75 inches.

Equipment Rack Side ViewEquipment Rack Front View

15.0"

P/N 020-584-20

ARGUS

CHNOLOGIES

Leave 1RU Space

SM03

Front Door

19" Rear Equipment Rack (xed)

Installed in fourth

hole position

23.5"

32.0

Fig. 1-10, Radium MiniBay Equipment Rack View

17 RU Available

for Equipment

19" Rear Equipment Rack (swing)

NOTE:

For wiring diagrams and alarm information, see Radium MiniBay System Schematics, Alpha P/N 044-001-05.

Contact Alpha Application Engineering for information on Cordex congurations.

17044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

1.2 EnclosureSpecications

Equipment Enclosure Weight: 195 lbs (88.5kg)

19" or 23" wide Fixed Relay Rack

tapped or with Tinnerman nuts

19" Swing Rack (tapped only)

Battery Storage Unit Weight (without batteries): 130 lbs (59kg)

Slide Tray, Alpha P/N 033-083-20, will hold four GNB M12V155FT batteries

Fixed Tray, Alpha P/N 033-083-23, will hold three Avestor batteries.

Riser Module

14" Riser Alpha P/N 033-083-21 7" Skirt/Riser Alpha P/N 033-084-20 7" C-channel Riser Alpha P/N 745-650-20

Side Chamber SC1 Weight: 100 lbs (45.4kg)

Side Chamber SC2 Weight: 89 lbs (40.4kg)

Dimensions (in/mm): 44H x 30W x 32D (1067 x 762 x 813)

Material: High Strength Corrosion Resistant Aluminum Finish: Almond Color Powdercoat Finish

Dimensions (in/mm):

14.0H x 30W x 32D (356 x 762 x 813)

Weight: 102 lbs (46.3kg) Dimensions (in/mm): 14H x 30W x 32D (356 x 762 x 813)

Dimensions (in/mm): 72H x 32W x12D (813 x 1829 x 305)

Dimensions (in/mm): 58H x 32W x 12D (813 x 1321 x 305)

1.3 MiniBay Accessories

Precast Polymer Concrete Padfor Single Radium MiniBay P/N 641-110-10

Precast Polymer Concrete Pad for Single Radium MiniBay + Side Chamber

Pour-in-place Pad Template P/N 604-039-N1

Pour-in-place Pad Template Tie-bars (spacers for 2 template kits) P/N 745-332-20

Pour-in-place Side Chamber Template P/N 745-333-20

Vapor Barrier for MiniBay (die cut template matches MiniBay) P/N 564-990-10

SRG PROT, 5-pin, Gas Tube, 3B1E P/N 162-016-10

Touch-up Spray Paint, Almond P/N 972-056-10

Pad Mounting Hardware Kit (4 Hilti KBII sleeve anchors 1/2 x 3-3/4) P/N 745-592-21

Pad Mounting Hardware (4 Hilti HSLG M12/0 *60 heavy duty sleeve

anchors) requires 12mm metric drill Kit for Zone 4

P/N 641-114-10

P/N 745-592-20

044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

1.4 Enclosure Cooling Options

NOTE:

Consultation with Alpha Applications Engineering is required. Provisions must be made for adequate air

ow in the cabinet, equipment total heat dissipation load inside the cabinet, equipment min/max operating

temperatures, equipment over-temp fail safe shutdown capability, environmental outdoor design conditions, and battery back up run times.

FanFilterCoolingDoor,48VDC,rightorlefthinged:AlphaP/N745-204-20(R)or745-204-21(L)

• Cooling capacity 1000W dissipated with 15ºC rise over ambient.

• Two 150 CFM fans with variable speed temperature control and low voltage disconnect, hysteresis xed

at 42VDC.

• Inline 5A fuse.

• Fans run continuously below 25ºC at 40% speed. Fans increase from 40% to 100% with increased enclosure temperature from 25ºC to 55ºC.

• Form C dry contact alarm, fan fail, open on alarm.

• Maximum power draw 32W.

FanFilterCoolingDoor,120VAC,rightorlefthinged:Alpha745-204-25(R)or745-204-24(L)

• Cooling capacity 750W dissipated with 15ºC rise over ambient.

• Two 115 CFM fans are powered from the included line cord with designated inline 5A fuse and bimetal

thermostat control (Alpha P/N 875-075-20).

• Fixed thermostat set point, close at 29ºC and open at 19ºC.

• Included adjustable enclosure over-temp alarm (Alpha P/N 745-338-20).

• Form C dry contact, open on alarm. Factory setting is 40ºC.

• Maximum power draw 30W.

HeatExchangerDoor,48VDC,rightorlefthinged:AlphaP/N745-204-45(R)or745-204-46(L)

• Cooling capacity 690W dissipated with 15ºC rise over ambient.

• Variable speed fan temperature control and low voltage disconnect. Fans off below 23ºC. Fans turn on at 25ºC and run from 25% to 100% with increased enclosure temperature from 25ºC to 45ºC.

• Two Form C dry contact alarms (Minor: Fan fail, open on alarm and Major: Enclosure over-temp xed at 60ºC, open on alarm).

• Maximum power draw 120W.

HeatExchangerCoolingDoor,120VAC, rightorlefthinged:AlphaP/N745-204-40(R)or745-204-41(L)

• Cooling capacity 690W dissipated with 15ºC rise over ambient

• Heat exchanger fans are powered from included line cord with designated inline 5A fuse and bimetal

thermostat control (Alpha P/N 875-075-20)

• Fixed thermostat set point, close at 29ºC and open at 19ºC

• Included adjustable enclosure over-temp alarm (Alpha P/N 745-338-20). Form C dry contact, open on

alarm. Factory setting is 40ºC.

• Maximum power draw 115W.

19044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

1.4 EnclosureCoolingOptions,continued

AirConditionerDoor,48VDC,rightorlefthinged:AlphaP/N745-204-50(R)or745-204-51(L)

• Cooling capacity 878W dissipated at 43ºC outdoor ambient and maximum internal ambient temperature of 40ºC.

• Variable speed compressor temperature control and low voltage disconnect.

• Adjustable enclosure temperature set point jumper, factory set to 25ºC.

• Two Form C dry contact alarms (Minor: High condensing temp and/or enclosure over-temp, open on

alarm and Major: cooling system failed, open on alarm). See DC air conditioner operation section for

details.

• Maximum power draw 500W.

AirConditionerDoor,24VDC,rightorlefthinged:AlphaP/N745-204-52(R)or745-204-53(L)

• Cooling Capacity 878W dissipated at 43ºC outdoor ambient and maximum internal ambient temperature of 40ºC.

• Variable speed compressor temperature control and low voltage disconnect. Adjustable enclosure temperature set point jumper factory set to 25ºC.

• Two Form C dry contact alarms (Minor: High condensing temp and/or enclosure over-temp, open on

alarm and Major: cooling system failed, open on alarm). See DC air conditioner operation section for

more details.

• Maximum power draw 500W.

AirConditionerDoor,240VAC,rightorlefthinged:AlphaP/N745-204-58(R)or745-204-59(L)

• Cooling capacity 1464W dissipated at 43ºC outdoor ambient and maximum internal ambient of 40ºC.

• Digital display with programmable set points.

• Included adjustable enclosure over-temp alarm (Alpha P/N 745-338-20).

• Form C dry contact, open on alarm. Factory setting is 40ºC. See AC air conditioner operation section for more details.

• Maximum power draw 989W.

1.5 Enclosure Heating Options

Heater,450W,48VDC:AlphaP/N745-588-22or745-588-21

• PCBA thermistor temperature control and low voltage disconnect.

• Heater turns on when enclosure temperature drops below 6ºC.

• Functional test button.

• Model 745-588-22 includes 20A circuit breaker.

• Model 745-588-21 does not include circuit breaker, but has a piggyback connector that allows it to share input power from the DC air conditioner 20A circuit breaker.

Heater,450W,120VAC:AlphaP/N745-589-21

Line cord with bimetal thermostat control. Thermostat set point is xed to close at 4ºC and open at 15ºC.

Plugs into GFCI outlet.

044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

1.6 Storage Unit Cooling Options

Fan,120VAC:AlphaP/N745-214-21

One 64CFM fan powered from 875-075-20 line cord with designated in-line 5A fuse and bimetal thermostat

control. Thermostat set point is xed to close at 29ºC and open at 19ºC.

Fan,48VDC:AlphaP/N745-214-20

• One 110CFM fan, turns off below 25ºC. Turns on at 25ºC and increases from 40% to 100% full speed with

increased enclosure temperature from 25ºC to 45ºC.

• Form C dry contact alarm, fan fail, open on alarm.

Fan,24VDC, AlphaP/N745-214-22

• One 110CFM fan, turns off below 25ºC. Turns on at 25ºC and increases from 40% to 100% full speed with

increased enclosure temp from 25ºC to 45ºC.

• Form C dry contact alarm, fan fail, open on alarm.

21044-001-C0-003, Rev. C

1.0 OverviewandSpecications,continued

1.7 BatteryStorageUnitBatteryOptions

The Battery Storage Unit (slide tray), Alpha P/N 033-083-20, and Battery Storage Unit (xed tray), Alpha P/N 033-031-21, accommodates four of the following battery types:

• C&D TEL 12-45

• C&D TEL 12-70

• AlphaCell 85GXL-HP

• AlphaCell 165GXL

• AlphaCell 185GXL

• AlphaCell 195GXL-3FTG

• AlphaCell 225AGM-3FTA

• C&D TEL 12-105F

• GNB Marathon M12V155FT

• AlphaCell SMU12V 155F

The Battery Storage Unit (xed tray) also accommodates three Avestor SE48S63 48VDC

batteries.

Fig. 1-11, Battery Storage Unit

The MiniBay equipment enclosure can house a maximum of four batteries on the oor of enclosure when the fan ltered cooling door or roof vent option is used. The roof vent must have a minimum of four .375" vent holes to provide adequate hydrogen venting (Alpha P/N 745-669-20 or equivalent). The following batteries may be used in the battery compartment or

equipment enclosure:

• C&D TEL 12-45

• C&D TEL 12-70

• AlphaCell 85GXL-HP

• AlphaCell 195GXL-3FTG

• AlphaCell 225AGM-3FTA

044-001-C0-003, Rev. C

2.0 DC Air Conditioner

2.1 Overview and Theory of Operation

The MiniBay DC Air Conditioner comes in 24V and 48V models and uses a brushless compressor and variable speed controller. A temperature control board varies capacity by varying compressor speed depending on the enclosure internal setpoint temperature. The compressor runs between 50% and 100% of full speed depending on the load and enclosure set point temperature. When the temperature drops more than 4°C below the set point, the compressor and condenser fans shut off. The evaporator fans run continuously regardless of the set point to maintain an even temperature inside the enclosure.

Theory of Operation:

1. Low pressure gas is drawn into the compressor.

2. The high pressure gas is sent through a condenser where air is blown over it, cooling the gas into a liquid.

3. The high pressure liquid passes through an expansion valve, where the liquid is allowed to expand and boil off into a gas. As the gas expands, it cools.

4. The cool saturated low pressure gas is sent through the evaporator. Warm interior air is blown over the evaporator and back into the interior, several degrees cooler.

5. The low pressure gas is then drawn into the compressor, where the cycle starts over.

Thermostatic

Expansion Valve

-48VDC Bus Ground

Return Bar

Minor Alarm Connect Major Alarm Connect

Evaporator

Liquid is allowed to expand at

low pressure back into gas,

cooling interior air.

20A

Temp

Control

Board

Speed Control

Board

Evaporator Fans

(always on)

Suction Line

Liquid Line

Sight Glass

Discharge Line

Variable Speed

Compressor

Condenser Fans

(thermostatically controlled)

Condenser

Hot gas is cooled by outside

ambient air and condensed

into a high pressure liquid.

Fig. 2-1, DC Air Conditioner Basic Block Diagram

23044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.2 DCAirConditionerSpecications

Capacity: 3,000 BTU @ 110°F (43ºC) See chart below

External Amb. Operating Range: -40°C (-104°F) to +50°C (+122°F) RH 13%

Max Internal Amb. Temperature: +40°C (+104°F) RH 25%

Maximum Internal Hysteresis: 10°C (50°F)

Maximum Operational Power Draw: 500W ±10% (see chart)

DC Operation @ 48VDC: 42VDC to 60VDC range with LVD xed at 42V

DC Operation @ 24VDC: 21VDC to 30VDC range with LVD xed at 21V

Cooling System Control: Low current DC or dry contact on/off

Major Alarm: Compressor/controller system fail

Minor alarm: High condensing temperature, Low evaporator

Refrigerant Type: R134a

Fan Life: >50,000 Hours

Color: Almond semigloss (other colors available)

External Dimensions (in/mm): 19.50 W x 38.25 H x 7.50 D (495 x 972 x 191)

Agency: CSA

Enclosure Rating: IP55 - Weather tight hose directed spray

Noise Level: 60 dBA at one meter

Materials: Corrosion and salt-fog resistant (including fans)

circuit breaker, magnetic short delay 15A

circuit breaker, magnetic short delay 30A

temperature, Enclosure over-temp

1400

1200

1000

800

600

Capacity Wattage

400

200

10 20 30 40 50

Ambient Temp (C)

Capacity (watt/hr)

Total Unit Watts

NOTE:

The chart above table illustrates air conditioner capacity under controlled conditions. A safety factor should

be used depending on cabinet insulation and outside air ltration. To calculate capacity in BTUs at a given outdoor ambient temperature multiply 3.413 x (capacity watt/hr).

044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.3 Temperature Control Board

The temperature control board monitors the compressor, condenser fan, and alarm control. Its remote temperature sensors monitor compressor discharge and evaporator suction line temperature. A board-mounted temperature sensor monitors enclosure temperature. An

optional remote temperature sensor can monitor a specic area in the enclosure. The board incorporates a low-voltage shutdown xed at 42V for the 48VDC air conditioner, and 21V for

the 24VDC air conditioner.

A temperature sensor on the discharge line of the compressor regulates the condenser fans. At low outdoor ambient temperatures, the condenser fans cycle on or off to maintain pressure across the expansion valve.

A temperature sensor on the suction line exiting the evaporator monitors low evaporator

temperature, which can result from blocked evaporator air ow or faulty evaporator fans. This

condition sends out a minor alarm and shuts down the compressor until the suction lines warm up again.

704-713-

Temperature Set Point Jumper

Local-Remote Temp Sensor Jumper

DC Power

Input

DC Aux

Output

+ -

Major/Minor

Alarm Output

Under Temp Shutdown Jumper

Enclosure Over Temp Jumper

Minor Alarm LED and N/C - N/O Jumper

Major Alarm LED and N/C - N/O Jumper

Remote Enclosure

Temp Probe

Fig. 2-2, Temperature Control Board

25044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.3 TemperatureControlBoard,continued

AIR COND TEMP CONTROL

SHDOWN

Evap temp

MINOR

J10

ALARM

SETPOINT

18C 23C

MAJO

N0NC

MAJOR4MAJOR3MINOR2MINOR

28C 33C 38C

N0NC

PWR (+)1PWR (-)

(-)

J11

J12

(+)

Evap Temp Sensor

LOCAL

RMT

Remote T

em p

SPEED CONTROL BOARD

PWR (-)

PWR (+)

Cond Temp Sensor

(BREAKER IS INSTALLED ON THE UNGROUNDED LEAD)

BLACK

RED

YELLOW

48 or 24VDC

MAJOR ALARM CONNECT

MINOR ALARM CONNECT

EVAP FANS

COMPRESSOR

A B C

COND FANS

Fig. 2-3, Wiring Diagram

044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.4 Air Conditioner Installation and Removal

Allow 20 minutes for completion of procedure.

Tools required: 7/16" deep-well socket and ratchet handle

Removal:

1. Disconnect power to the air conditioner.

2. Disconnect input and alarm wires from the control board (see Fig. 2-2).

3. From the inside of the door, remove the 5 bolts (labeled S below) holding the shroud to

the door. Remove the shroud. Remove grounding lug.

4. While another installer supports the air conditioner on the outside of the door, remove the

10 remaining bolts (labeled A below). Remove the air conditioner.

5. Reverse order for installation. Replace PORON washers if they are damaged (Alpha P/N

684-020-10).

S S

–

Fig. 2-4, Shroud and Air Conditioner Bolts

27044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.5 48/24VDCPowerConnection

Allow 20 minutes for completion of procedure.

Tools required: Assorted wrenches and screwdrivers

1. Install circuit breaker mounting plate in a convenient location near the 48/24VDC source

(see Fig. 2-5 below). Leave circuit breaker IN THE OFF POSITION.

2. Connect black wire leading from circuit breaker to the 48/24VDC Bus.

3. Connect the red wire to the ground/return bar.

The air conditioner can be positively or negatively grounded. The overcurrent protection must be placed in the ‘Hot’ lead.

Circuit

Breaker

To Ground Return Bar

Fig. 2-5, Power Connections

To Circuit Breaker

044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.6 Alarm Connector

1. Set major and minor alarm jumpers to the desired position.

2. Connect yellow wire (minor) and red wire (major) to status monitoring device.

Minor Alarm Jumper

Shown Normaly Closed

2.7 FunctionTest

1. Set the 48VDC Circuit Breaker to the ON position.

2. Remove SETPOINT jumper and verify fans are running. Compressor will start after 10 second delay.

3. Replace SETPOINT jumper and verify AC unit shuts down.

Major Alarm Jumper Shown Normaly Closed

Fig. 2-6, Alarm Connections

SETPOINT Jumper

Fig. 2-7, Setpoint Jumper

29044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.8 Jumpers

Enclosure Temperature Setpoint Jumper

Determines what temperature the system will maintain inside the enclosure. The diagram below details the start and shutdown temperatures for each setting.

104°F/40°C

95°F/35°C

86°F/30°C

77°F/25°C

68°F/20°C

59°F/15°C

50°F/10°C

40° C Maximum Internal Temp.

38° C Startup

38° C Setpoint

34° C Shutdown

33° C Startup

33° C Setpoint

29° C Shutdown

28° C Startup

28° C Setpoint

24° C Shutdown

23° C Startup

23° C Setpoint

19° C Shutdown

18° C Startup

18° C Setpoint

14° C Shutdown

Remote Temperature Sensor Jumper

Determines where the control card gets its temperature information. In the LOCAL position the card receives temperature information from its onboard temperature sensor. In the RMT position, temperature information is received from an optional Remote Temperature Sensor that can be placed anywhere in the enclosure.

Major and Minor Alarm Jumpers

Determines the state of the alarm relays in the non-alarm state. In the NO position, the nonalarm state is OPEN. In the NC position, the non-alarm state is CLOSED.

NOTE:

See Fig. 2-2 for jumper locations.

044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.9 DC Air Conditioner Preventative Maintenance

A preventative maintenance check should be conducted on initial startup, and on a yearly basis thereafter.

1. Check that the evaporator fans, located on the inside of the door, run continuously.

2. Remove temp setpoint jumper. Make sure the compressor comes on after 10 seconds.

3. Check for proper function of the outdoor condenser fans (located under the shroud on the

outside of the door). The outdoor condenser fans are controlled by the temperature of the

outdoor condenser coil. These fans should cycle on and off, or run continuously when the setpoint jumper is removed. They may not turn on unless outdoor ambient is above 70ºF

(21ºC). As the outdoor condenser coil heats up, rst one fan and then the other cycles

on. If the unit is hot already, the fans turn on simultaneously, when the setpoint jumper is removed. After ten seconds the compressor will turn on.

4. Using a DC clamp-on ampere probe, check the input current to the air conditioner while the compressor is running. The 48VDC air conditioner should draw between 6A and

10.4A (10.4 FLA, Full Load Amps), for normal operation. The 24VDC air conditioner should draw between 12A and 20.8A (20.8 FLA).

5. Replace setpoint jumper when functional check is complete.

6. Visually inspect the outdoor condenser coil with a ashlight. It should look clean and clear

of debris. If there is excess dirt build up, turn off circuit breaker, remove shroud and clean

it with soft brush or compressed air (be careful not to damage ns).

7. With a ashlight, visually inspect that the condensate drain is working and clear of debris.

There should be no excess water build up in the pan below the inside evaporator coil. The evaporator coil should be offset far enough so water drips into the drain pan below, and does not bead up on the edge of the door.

8. To complete the check, replace the setpoint jumper and all guards. Turn the circuit breaker on.

31044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.10 DC Air Conditioner Trouble Shooting

ATTENTION:

Contact Alpha Technical Service to determine proper diagnosis. See page 3 for contact information.

1. Check that wire connections and input voltage are correct.

2. Check the evaporator and condenser thermostat wires are not reversed. These are on the inside of the evaporator box and look like telephone jacks. The evaporator sensor is attached to the suction line inside the evaporator box. The condenser sensor goes to the outside and attaches to the discharge line. Look on the front of the PCBA for silkscreen

connector label “EVAP” and “COND”. If these are reversed the condenser fans will not

turn on, and the circuit breaker will trip.

3. When the breaker is turned on, both evaporator fans should run continuously.

4. Verify the compressor comes on 10 seconds after pulling the setpoint jumper.

5. Watch the sight glass for bubbles. Bubbles should go to clear liquid after about a minute.

If there are no bubbles or liquid ow, or the moisture indicator shows wet and the bubbles don't clear, there is low or no charge. This is not eld serviceable, and the unit should be

replaced.

6. Check the discharge line to see if it is warming up. Both condenser fans should come on

(rst one, then the other) when discharge line is above 104ºF (40ºC).

7. If unit control board indicates a yellow LED minor alarm, check for plugged outdoor condenser or bad condenser fan.

8. If the unit control board indicates a red LED major alarm, the compressor may be over heated or overloaded, or there is a bad three-phase connection to the compressor. Check for a plugged outdoor condenser, or compressor overload.

9. Using a DC clamp-on ampere probe, check the input current to the air conditioner while the compressor is running. The 48VDC air conditioner should draw between 6A and

10.4A (10.4 FLA, Full Load Amps), for normal operation. The 24VDC air conditioner should draw between 12A and 20.8A (20.8 FLA).

10. Check the Delta-T across the evaporator coil. It should be between 9ºF and 18ºF (5ºC

and 10ºC).

11. The unit is overloaded if the FLA is too high and evaporator Delta-T is 9ºF (5ºC).

• Check heat dissipation load inside the cabinet.

• Check blocked condenser or bad condenser fans.

12 Check the suction line entering the compressor. It should be getting cooler. If it is not

getting colder, and the sight glass looks full or clear, there may be a refrigerant blockage

at the TX valve screen (this is not eld serviceable). Replace the unit and send it back

for evaluation and repair. To protect the unit from damage during shipping, use proper packing to keep the unit in an upright vertical position.

044-001-C0-003, Rev. C

2.0 DCAirConditioner,continued

2.11 DC Air Conditioner Parts List

Part Number Description

745-289-20 48VDC, 3000BTU replacement air conditioner assembly for Radium MiniBay

745-355-20 48VDC,150CFM outdoor condenser fan with sealed connectors

(qty 2 per unit)

500-074-10 48VDC,126CFM Inside Evaporator fan (qty 2 per unit)

704-713-20 48VDC, temperature control PCBA.

745-356-20 48VDC, controller inside fan assembly (contains 2 evaporator fans,

temperature control board, variable speed controller)

745-289-40 24VDC, 3000BTU replacement air conditioner assembly for Radium MiniBay

745-355-40 24VDC,150CFM outdoor condenser fan with sealed connectors

(qty 2 per unit)

500-087-10 24VDC,126CFM inside evaporator fan (qty 2 per unit)

704-713-21 24VDC, temperature control PCBA.

745-356-40 24VDC, controller inside fan assembly (contains 2 evaporator fans,

temperature control board, variable speed controller)

33044-001-C0-003, Rev. C

3.0 AC Air Conditioner

IceQube AC Air Conditioner Overview, Basic Theory of Refrigeration:

1. The compressor pump draws in and compresses cool, low-pressure gas into a high pressure gas. Compression raises the boiling point of the gas.

2. The hotter, high-pressure gas passes through a coil called a condenser. A fan blows air over the coil which cools the gas into a liquid.

3. This high-pressure liquid passes through an expansion valve, where the liquid expands to boil off as a gas. As the gas expands, it absorbs heat.

4. The cool low-pressure gas is sent through another set of coils called an evaporator or heat exchanger. Warm interior air is blown over the coil and back into the interior, several degrees cooler.

5. The low-pressure gas is then drawn into the compressor, where the cycle starts over. The air conditioning system is actually three systems, which function simultaneously to maintain environmentally friendly conditions for your equipment within the enclosure: The closed-loop cold air system, warm air system, and vapor-compression refrigeration system.

The closed-loop cold air system circulates cold air from the cooling system to the electronics enclosure. This air captures the heat and humidity within the enclosure and carries it through the heat exchanger, the part of the vapor-compression system that removes the heat/humidity.

The vapor-compression refrigeration system is run by an efcient rotary compressor which circulates NON-CFC refrigerant to transfer heat from the heat exchanger (evaporator) in the closed-loop air

stream to a condenser located in the warm air system. Heat from the enclosure transfers from the warm air heat exchanger and dissipates to the ambient.

Air Filter Access

Fig. 3-1, AC Air Conditioner

044-001-C0-003, Rev. C

3.0 ACAirConditioner,continued

3.1 VerifyingDefaultSettingsfortheIceQubeAirConditioner

Procedure:

1. Remove IceQube controller's access panel on the enclosure door shroud (2 screws).

2. Turn on the AC power.

3. Record the displayed temperature information.

4. Check the STATUS LEDs (On/Off/Blink):

• COOL - On if temperature is above 70ºF

• HEAT - On if temperature is below 32ºF

• ALM - Contact Alpha

• FILT - Turn off lter alarm (if on) and clean lter if needed

5. To enter programming mode, enter the default PIN code in sequence on the front panel display. The code must be entered with less than 2 seconds between keystrokes.

• ADJUST up arrow (1)

• ADJUST down arrow (2)

• SELECT (3)

• EXIT (4)

6. The programming LEDs ashes, and a pattern of boxes appears in the digital display to

indicate program mode has been entered. If no selection is made within one minute, the system returns to normal operating mode.

7. To verify or adjust the AC default parameters use the ADJUST up and down arrows. Press SELECT to accept the current setting and cycle to the next.

8. Pressing the EXIT button saves setting changes and returns the unit to normal operating mode.

Programming LED

Cooling Mode

Heating Mode

Digital Display

General Alarm

LED's Indicate Parameter Displayed

Filter Alarm

Fig. 3-2, AC Air Front Panel Display

Default Settings Parameter Default Setting

HI Temp set point: 72°F LO Temp set point: Set to lowest limit (approx. 40°F) HI Alarm set point: 100°F LO Alarm set point: Set to lowest limit (approx. 33°F) ALL: ON AUD: OFF

-F-: Do not change PIN: Do not change FIL: 0.0 Days Add: 0.0

35044-001-C0-003, Rev. C

3.0, ACAirConditioner,continued

3.2 ACAirConditionerSpecications

Specications

Capacity 5000 BTUH (sensible) @ 43ºC ambient

Maximum Operating Temperature 125º F

Electrical 8.7A @ 120VAC/60HZ maximum

Microprocessor Controller Displays temperature in Fahrenheit and Celsius

Refrigeration System Efcient, long lasting rotary compressor

Evaporator Fan Lustran ABS 633 housing and squirrel cage

Condenser Fan Lustran ABS 633 housing and squirrel cage

4.3A @ 230VAC/60HZ maximum

4.8A @ 220VAC/50HZ maximum UL/CUL recognized per UL50-File#SA12062 CE

Compliant

Programmable heating and cooling set points Standard on/off differential 7º Fahrenheit Programmable high/low temperature alarms Condenser air lter maintenance indicator Security programming access code Integral EMI / RFI protection 24VAC input power Operating status indicators for cooling, heating and alarm conditions

Coil construction: Aluminum n with copper tube Solid core 4 stage lter drier Pressure balancing refrigerant ow control HCFC refrigerant 22, Chlorodiuoromethane

Life lubricated ball bearing system .05 HP shaded pole therm. protected motor

Maximum 247 CFM free air @120VAC/60HZ

Life lubricated ball bearing system .05 HP shaded pole thermal protected motor

Maximum 247 CFM free air @120VAC/60HZ

044-001-C0-003, Rev. C

3.0 ACAirConditioner,continued

3.3 AC Air Conditioner Condensate Hose Mounting

The MiniBay AC air conditioner comes with a condensate hose that must be secured to the mounting pad. The hose may be run out the front or back of the pad, and should extend three inches from the edge.

Tools Required:

• Rotary Hammer Drill with 1/4" bit

• Hammer

Procedure:

1. Locate the hose hardware kit (packaged with the battery cable kits).

2. Extend the hose out in the desired direction and position brackets.

3. Locate the anchor holes so the hose does not interfere with the door opening. Drill two holes for the anchors into the pad.

4. Place anchors in anchor holes.

5. Run the pins through the brackets and hammer into the anchors.

6. Trim the hose to approximately three inches over the edge of the pad.

Washer

Bracket

Anchor

NOTE:

The condensate hose should have a minimum two-inch bend radius and should not kink when the door is opened. Check the hose every six months for blockage or disconnection.

Fig. 3-3, Condensate Hose Mounting

37044-001-C0-003, Rev. C

3.0 ACAirConditioner,continued

3.4 AC Air Conditioner Preventative Maintenance

Inspect the systems lters for replacement or cleaning every six months, depending on time of year or environment. Clean the lters by back ushing with water in the direction indicated and reinstall the lter. See page 3 for contact information.

NOTE:

Some environments may require more frequent inspections to maintain optimum airow.

3.5 AC Air Conditioner Troubleshooting

Contact Alpha Technologies Technical Support for troubleshooting procedures and warranty issues. See page 3 for contact information.

3.6 Replacement or Spare 5000 AC Air Conditioner

Ice Cube 5000BTU AC Air Conditioner congured for Minibay:

KT,AIR COND,5K BTU/HR,230VAC,60HZ,RAD-MB, Alpha P/N 745-636-20

The IceQube Manual can be found on line at http://www.iceqube.com/pdf/manual.pdf

044-001-C0-003, Rev. C

4.0 Site Preparation

4.1 Site Selection

Considerations:

• Where possible, select a site above the 100-year ood plain, and away from houses.

• Place in a shaded location to minimize the effects of solar loading.

• Locate in an area where airow can be maximized.

• Avoid locating the enclosure where it is an obstruction and would inhibit visibility.

• Locate the enclosure away from sprinkler systems or other sources of forced water.

• Locate the enclosure out of the prevailing wind to minimize the buildup of snow or the accumulation of wind-borne dust.

• Evaluate the soil conditions for suitability for the installation of the required grounding system applicable to your particular installation.

• Ensure cabling has been run and terminated at the site.

• Will the enclosure be placed on a precast concrete pad or on a pad poured on site?

• An enclosure with both front and rear doors is required for batteries with terminals located

on top. Allow for at least 36" of front and rear clearance so the door(s) may be opened

adequately for servicing.

• Contact a cable locating service, the local utility, and adjacent building supervisors to ensure installation location and cable routing does not interfere with existing utility connections.

NOTE:

Prior to paving the pad or placing cables and conduit, familiarize yourself with the location of the conduit

seals. The pad should include a rectangular sweep opening lled with drain rock to allow cables and conduit

to be maneuvered into position to enter the seals.

Fig. 4-1, Conduit Seal Location

39044-001-C0-003, Rev. C

4.0 SitePreparation,continued

4.2 Precast Pads

The type of enclosure mounting pad is determined by the size of the enclosure (single bay, single bay with side chamber, dual bay, dual bay with single side chamber, and dual bay

with dual side chambers). Typically, Alpha Technologies recommends using precast polymer

mounting pads. These pads are designed for proper cabinet support and ease of installation. Drilling areas for openings are indicated for coax and service sweeps, and pre-installed threaded inserts for enclosure attachment.

44" SYMM. 32" SYMM.

5-1/2"

27-3/4" SYMM.

4-5/8"

RAD-MB

MM.

" SYMM

42" SYMM.

24" SYMM.

25-7/8

Sweep Opening

8-1/2"

10-3/4"

Front of Pad

IN.

Fig. 4-2, Precast Pad Dimensions for Single Enclosure

(P/N 641-110-10)

044-001-C0-003, Rev. C

4.0 SitePreparation,continued

4.2 PrecastPads,continued

29.88"

28.62"

27.75"

26.48"

23.12"

FAR SIDE

FRONT OF RAD-MB SC

Side Chamber

1.26

.000"

2.12"

4.38"

8.12

54.5"

42.5" SYMM

ENCLOSURE OUTLINE REFERENCE

RAD-MB

SYMM.

Sweep Openings

44.0"

32.0"

Front of Pad

74"

20.59"

8.69

14.59"

0.91"

24.91"

25.82"

000

Front of Pad

N. MI

3.0"

Fig. 4-3, Precast Pad Dimensions for Single Enclosure with Side Chamber

(P/N 641-114-10)

41044-001-C0-003, Rev. C

4.0 SitePreparation,continued

4.3 Pour-in-place Concrete Pads

Pad Frame Templates

NOTE:

The illustrations below show the overall size of the pad frame template for a single MiniBay enclosure. The actual outer dimensions of the pad will be determined by the customer’s requirements. When placing the pad, allow at least 36 inches of clearance for the front and rear doors to open fully.

29.25"

Front Rear

25.00" Ref.

Front Rear

25.82"

4.0"

(2 places)

4.0"

(2 places)

Fig. 4-4, Pad Frame Template for Single MiniBay Cabinet

Front

Rear

Fig. 4-5, Isometric View, Pad Frame Template, Single MiniBay

(P/N 604-039-N1)

044-001-C0-003, Rev. C

4.0 SitePreparation,continued

4.3 Pour-in-placeConcretePads,continued

Pad Frame Templates

The illustration below shows the various components of the optional modular pourin-place pad template for a dual-cabinet application. Use template to easily and accurately locate the open area for the AC service and TSC conduit as well as the threaded inserts to which the cabinet is attached.

Base Pad Frame Template (P/N 604

-039

-N1)

Side Chamber Conduit Locator P/N 745-333-20

Fig. 4-6, Isometric View, Pad Frame Template, Single MiniBay with Side Chamber

Template for Second Enclosure.

Locator Bar for Second Pad FrameTemplate

Locator Bar for Second Pad Frame Template

Base Pad Frame Templ (P/N 604-039-N1)

P/N 745-332-20

ate

Side Chamber Conduit Locator P/N 745

-333-20

Fig. 4-7, Isometric View, Pad Frame Template, Dual MiniBay with Side Chamber

43044-001-C0-003, Rev. C

4.0 SitePreparation,continued

4.3 Pour-in-PlaceConcretePads,continued

Pad Frame Templates

Figure 4-7 (below) provides the necessary dimensions to layout and pour a concrete

pad on site.

3/4"

1/8"

5-7/8" 2 PL

5-3/4" 2 PL

7/8" 2 PL

SWEEP OPENING

see Section 4.0 Note

Front of MiniBay

TING UN

2 PL

TH TEMPLAT

USED W I ES OL

UND H

OBROUNDS USED FOR STUD MO

24-1/8" 2

7/8" 2 PL 7/8"

SWEEP OPENING

see Section 4.0 Note

4-1/8"

PAD

FRONT OF

30" 30" 12-1/2"

2-1/8" 2 PL 2-1/8" 2 PL

12-1/2"

1/8"

3/8"

Fig. 4-8, Footprint of Dual Enclosure, Dual Side Chamber System

(dimensions in inches)

044-001-C0-003, Rev. C

4.0 SitePreparation,continued

4.4 SiteConguration

Figure 4-9 (below) shows the cable conduit route into the side chamber.

Front

Enclosure

PRE-CAST PAD

Precast Polymer Pad

Compacted Gravel (12" depth recommended

Level Grade

Area of Backlled Soil

Trench for Sweep (sweep enters back of cabinet)

Fig. 4-9, Typical Site Arrangement, (cabinet with optional side chamber)

NOTE:

Verify the conduit is trimmed 1" to 2" above the pad surface (for side chamber), or 1" to 4" for riser.

45044-001-C0-003, Rev. C

4.0 SitePreparation,continued

4.4 SiteConguration,continued

Figure 4-10 (below) shows the cable conduit route into the back of the enclosure.

Back

PRE-CAST PAD

Precast Polymer Pad

Compacted Gravel (12" depth recommended

Level Grade

Front

Area of Backlled Soil

Trench for Sweep (sweep enters back of cabinet)

Fig. 4-10, Typical Site Arrangement, (stand-alone cabinet)

NOTE:

Verify the conduit is trimmed 1" to 2" above the pad surface (for side chamber), or 1" to 4" for riser.

044-001-C0-003, Rev. C

4.0 SitePreparation,continued

4.5 Enclosure Grounding

NOTE:

Alpha Technologies recommends using the grounding method illustrated below. The grounding method for a

particular site is dependant upon soil type, available space, local codes, NEC (National Electric Code), and other site-specic characteristics.

NOTE:

It is the responsibility of the installer to ensure the requirements of all applicable national and local codes are met. Alpha Technologies assumes no responsibility or liability for failure of the installer to comply with the requirements of all applicable local and national codes.

Lightning Protection (Optional)

• 1/2" x 8' copper ground rod, four places, driven about 2 feet (typical) from the corners of

the pad.

• #2 bare copper wire loop terminated to each ground rod and buried a minimum of 30 inches below grade. Corrosion-proof connections (25+ year life-span) and hardware

suitable for direct burial MUST be used.

• #2 bare copper wire from loop to the enclosure.

• When the electrical supply is a primary service (not a secondary or feeder service) a #2 bare copper wire must bond the lightning protection loop to the Grounding Electrode

Conductor where they are closest.

• Service Grounding (required), #6 bare copper wire from Service Neutral/Ground Bar with

2 ground rods located 6' apart.

Connection made with Burndy connector

(P/N YGHR58C2W-3 or equivalent)

)

Enclosure Footprint

Terminate at enclosure ground

#2 AWG

Connection made with Burndy connector

(P/N YGHP58C2W-2TN or equivalent)

Fig. 4-11, Suggested Grounding

47044-001-C0-003, Rev. C

5.0 Installation

This section describes the procedures for installing the enclosure and preparing it for turn-up and test. The procedures are comprised of the following steps:

• Cabinet installation

• Battery installation and connection

• Utility power connection

Before installation verify the following:

• All necessary grounding rods and materials are in place.

• Utility power is onsite in accordance with NEC (National Electric Code).

• Review and comply with all local safety practices for working with high-voltage systems.

• All necessary permits and permissions are granted.

• The lifting/transport path is free of obstructions.

To perform the installation procedures, the installer(s) needs to have the following tools and materials on hand:

• Crane to lift enclosure from shipping pallet and place on pedestal

• Key to enclosure doors (P/N 964-022-10 — Pin Allen type)

• Digital RMS voltmeter

• Torque wrench with insulated handle and 7/16" socket

• 7/16" box-end wrench

• NO-OX or other suitable corrosion inhibiting agent

• Battery Cabling Kit

• Silicone sealant (GE RTV123)

CAUTION!

The enclosure MUST be loosed from the pallet BEFORE lifting the enclosure from the truck and placing it on the pad. Problems such as broken welds, corrosion, etc., resulting from improper installation are not covered under warranty.

044-001-C0-003, Rev. C

5.0 Installation,continued

5.1 Lifting

The enclosure is shipped from Alpha Technologies bolted to a wooden pallet. Follow the procedure below for lifting and positioning the unit.

NOTE:

Remove the lifting ears after installation. The ears are made of steel and may rust over time.

Installation Procedure:

1. Unbolt the enclosure from the pallet. The bolts fastening the enclosure to the pallet are located in the feet of the rack/rail assembly. They can be reached through the front and

rear doors of the enclosure or battery module (if applicable).

2. Remove the side chamber cable entry port seal plate (if equipped).

3. Position the 25-year vapor barrier material over the concrete pad, and make all necessary cutouts.

WARNING!

Do not allow personnel to walk beneath the suspended unit during the lifting operation. Use

steel-toe work shoe protection. Use “hard hats” at all times during this procedure.

CAUTION!

Do not lift the enclosure with the batteries in place.

4. Attach the lifting chain to the lifting ears located in the top of the enclosure. Verify the adjustable chain links are tightened securely. Also verify the length of the cable between

the liftng ears and the lifting hook (2d) is at least twice the distance (d) between the lifting

ears, and that the lifting angle of the chain is greater than or equal to 60 degrees.

Fig. 5-1, Enclosure Lifting Arrangement

(without side chamber)

Fig. 5-2, Enclosure Lifting Arrangement

(with optional side chamber in place)

49044-001-C0-003, Rev. C

5.0 Installation,continued

5.1 Lifting,continued

NOTE:

Verify the length of the cable between the lifting ears and the lifting hook is at least twice the distance between the lifting plates and that the lifting angle of the chain is greater than or equal to 60 degrees.

5. Lift the enclosure off of the truck using a winch capable of supporting approximately

500 lb. (227kg).

6. Verify all cabling passing through the enclosure is bundled and maintained within the cutout area.

7. Position the enclosure above the concrete pad and slowly lower it into position over

the pad’s 1/2" anchor or J-bolts. A 25+ year vapor barrier MUST be used between the

concrete and enclosure base to inhibit moisture ingress and corrosion caused by metalto-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 trimmed close to the enclosure, using the appropriate knife or cutting tool.

8. Secure the enclosure using stainless at washers, lock washers and 1/2" nuts at each

mounting bolt.

NOTE:

To prevent damage, enclosures must be mounted ush with a smooth surface and not over-torqued. The enclosure must be bolted down to a completely at surface. If the concrete pad is uneven or has bumps,

cracks, or other imperfections, the installer is responsible for correcting these defects prior to installing the enclosure. Do not caulk the enclosure bottom. Caulking can lead to condensation inside the enclosure.

9. Trim sealing cones to proper diameter for a tight t around cables and reassemble seal

plate assembly.

10. Use suitable cable clamps or ties to secure cables to “ladder bar” (see below).

Cable Lashing Bar

Rear of Battery Drawer

Tamper Switch

Fig. 5-3, Rear View of Enclosure (showing lashing bar)

044-001-C0-003, Rev. C

5.0 Installation,continued

5.2 Special Instructions for Double-wide Installation

When installing two MiniBay enclosures side-by-side, the units should be lifted independently

as shown in section 5.1. Position the rst unit and remove the lifting ears. Apply gasket

material supplied in gasket kit, Alpha P/N 745-361-20. The gasket material should be in place

before positioning the second unit in order to maintain 3R rainproof integrity (see Fig. 5-4). When the gasket is in place, position the units together and secure together (8 places) using

the supplied hardware.

Tools Required: 9/16" open-end wrench

9/16" socket and driver

Remove Lifting Ears

Apply Gasket Material

Bolt together using

supplied hardware

Fig. 5-4, Dual Enclosure Installation

51044-001-C0-003, Rev. C

5.0 Installation,continued

5.3 Battery Connection

Battery Identication

Each battery contains a DATE CODE usually located on a sticker near the center of the battery or stamped in white ink near the POS terminal. This date code must be recorded in the battery’s maintenance log. If batteries other than those installed by Alpha are used, consult the battery’s manufacturers’ documentation for date code type and placement.

Battery Date Code

Connections for AlphaCell Batteries

Battery Terminal Connections:

Refer to the accompanying Battery Cable Kit (BCK) instructions for battery wiring

arrangement and terminal assembly procedures. During maintenance procedures, refer to the

manufacturers’ specications for the maintenance torque requirements.

Mounting hardware requirements may vary with battery manufacturers. Use only the hardware recommended by your particular battery manufacturer.

Battery Mounted Fuse Stackup

ForTEL12-105,GNBM12V155,andSMU12-155

Threaded

Battery Post

Fuse

BUSS

Ring Terminal

Isolation Washer

Flat Washer

Lock Washer

Bolt

on fused terminal)

(torque to 75 in-lbs

Inline Fuse Stackup

For AlphaCell–FT

Nut

Flat Washer

Ring Terminal

Fuse

Ring Terminal

BUSS

Isolation Washer

Flat Washer

Lock Washer

Bolt

on fused terminal)

(torque to 75 in-lbs

Fig. 5-5, Battery Terminal Connection

044-001-C0-003, Rev. C

5.0 Installation,continued

5.4 Connecting to Utility Power

ATTENTION:

Verify electrical codes prior to installation. Codes may vary and contain specic conduit and wire sizes for

connection to the load center. Connection to utility power must be approved by the local utility before installing the power supply.

Connection Procedure:

1. Locate the service entrance panel on the enclosure. Remove the cover to access

the circuit breaker assembly. If this service panel is to be used as the primary service entrance, neutral must be bonded to ground by installing the green ground screw

(provided) in the hole in the neutral bus.

2. Remove the knockout located in the service entrance to accept the conduit.

3. Install the conduit nipple into the service entrance via the knockout and secure it using

the appropriate threaded conduit locknut.

4. Locate the two screw terminals (L1 and L2) on the service circuit breaker.

5. Connect one of the incoming Black #6AWG wires to L1 (left terminal). Connect the

remaining Black (or Red) #6AWG wire to L2 (right terminal).

NOTE:

If the wire at L2 is black, place red tape (or label) on it.

NOTE:

The enclosure is equipped with a Square D, rainproof load center box (SUSE rated). The service entrance is

equipped for a 120/240VAC, split phase, 3-wire with ground source.

6. Connect the #6AWG White wire to the neutral (N) bus lug located to the top right of

the circuit breaker assembly.

7. Connect the #2AWG stranded copper ground wire (Earth Ground) to the ground and

neutral bus located to the right side of the circuit breaker assembly.

8. Notify the electrical inspector to approve the service entrance wiring. Once approved,

contact the local power utility for electrical service.

53044-001-C0-003, Rev. C

5.0 Installation,continued

OFF

Optional AC Generator

Enclosure

Load Breakers

Meter

Grounded Conductor

(Neutral)

Ground Bar

Neutral

Line 1

Line 2

OFF

OFFONOFF

Optional AC Generator

Meter

Service Entrance

Enclosure

Load Breakers

Neutral

Ground Bar

Neutral

5.4 ConnectingtoUtilityPower,continued

Enclosure as Service Entrance

Line 1 Line 2 Groun Neutral

Legend

Fig. 5-6, Service Entrance Wiring

Line 1 Line 2 Groun

utra

Legend

044-001-C0-003, Rev. C

Appendix A

CSA Marks

NRTL/C

CSA International (CSA) was established in 1919 as an independent testing laboratory in Canada. In 1994, OSHA granted CSA Nationally Recognized Testing Laboratory (NRTL)

status in the United States of America. This was extended in 1999. When these marks

appear with the indicator “C and US” or “NRTL/C” it means that the product is certied for both the U.S. and Canadian markets to the applicable U.S. and Canadian standards.(1)

ArgusRectierandPowerSystemproductsbearingtheCSANRTL/CMarkare certiedtoCSAC22.2No.950andUL1950.

As part of the reciprocal U.S./Canada agreement regarding testing laboratories, Standards

Council granted Underwriters Laboratories (UL) authority to certify products manufactured

in the U.S. for sale in Canada.

C US

Only Underwriters Laboratories may grant a license for the use of this mark which indicates

compliance with both Canadian and U.S. requirements. (2)

Go to: http://www.osha.gov for more information.

What are NRTLs and what do they do?

NRTL’s are third party organizations recognized by OSHA, U.S. Department of Labor under the NRTL Program.

The testing and certications are based on product safety standards developed by the U.S.-based standards developing organizations and often issued by ANSI.(3)

The NRTL determines that a product meets the requirements of an appropriate consensus based product safety standard either by successfully testing the product itself, or by verifying that a contract laboratory has done so.

The NRTL certies that the product meets the requirements of the product safety standard.(4)

WhenwastheNRTLstarted,andwhogovernsit?

In 1983, in a suit brought on by an independent testing laboratory, OSHA

was court ordered to remove specic references to UL (Underwriters Laboratories) and FRMC (Factory Mutual Research Corporation).

OSHA

In 1988, OSHA revised its regulations to remove those references and the NRTL program was established.

The NRTL program is both national and international in scope with foreign labs permitted. As of Dec. 17, 1998, 17 recognized labs were permitted,

with pending applications from 21 other labs.(5)

References:

Information presented has been developed from the ofcial web sites of the respective organizations. Specic

references are as follows:

(1) www.csa-international.org/english/product_services/index_cert.htm (2) www.ul.com/mark/ulmark.htm (3) www.osha-slc.gov/dts/otpca/nrtl/slide02.html (4) www.osha-slc.gov/dts/optca/nrtl/slide04.html (5) www.osha-slc.gov/dts/optca/nrtl/slide18.html

NRTL

ogram

NRTL/C

15 Others

Dec. 17, 1998

55044-001-C0-003, Rev. C

Alpha Technologies

Power

Due to continuing product improvements, Alpha reserves the right to change specications without notice.

Alpha Technologies 3767 Alpha Way Bellingham, WA 98226

USA

Tel: +1 360 647 2360 Fax: +1 360 671 4936 Web: www.alpha.com

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

CANADA

Tel: +1 604 430 1476 Fax: +1 604 430 8908

Alpha Technologies Europe Ltd. Twyford House Thorley Bishop's Stortford Hertfordshire CM22 7PA

UNITED KINGDOM

Tel: +44 01279 501110 Fax: +44 01279 659870

Alpha Technologies GmbH Hansastrasse 8 D 91126 Schwabach

GERMANY

Tel: +49 9122 79889 0 Fax: +49 9122 79889 21

Alphatec, Ltd P.O. Box 56468 Limassol, Cyprus

CYPRUS

Tel: +357 25 375675 Fax: +357 25 359595

AlphaTEK ooo Khokhlovskiy Pereulok 16 Stroenie 1 109028 Moscow

RUSSIA

Tel: +7 495 916 1854 Fax: +7 495 916 1349

Alphatec Baltics S. Konarskio G. 49 Vilnius 2009

LITHUANIA

Tel: +350 5 210 5291 Fax: +350 5 210 5292

Alpha Technologies 5 Avenue Victor Hugo F 92140 Calmart France

FRANCE

Tel: +33 3 41 90 07 07 Fax: +33 1 41 90 93 12

Alpha Radium MiniBay User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual