Alpha Te45 User Manual

Te45, 72" Auxiliary Outdoor Enclosure

Installation & Operation Manual

Equipment #: 057-106-20-203

Alpha Technologies Ltd. 057-106-B0 RevF

Printed in Canada. © 2010 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved.

Te45, 72" Auxiliary Outdoor Enclosure w/4k BTU AC, w/ LC

Equipment #: 057-106-20-203
Document #: 057-106-B0

The following documents and drawings are included in this manual to provide the necessary information
required for routine operation and fault diagnosis of the system:

 Safety and Installation Instructions: 057-106-C0
 Specifications: 029-039-B1
 Schematic: 747-666-05
 Outline drawing 057-106-06
 Schematic Interface Kit 747-670-05
 Customer Connection Kit 747-670-08
 CSA/NRTL Equivalence 048-554-10

Manuals included in this package:

 DCP03 300A Distribution Center 020-702-B2
 Cordex 48-1.8kW 23" Shelf 030-807-B2
 Cordex Controller Software 034-136-B2
 Quick Reference Card for Controller 954-472-10

Alpha Technologies Ltd. 057-106-B0 RevF

Printed in Canada. © 2010 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved.

Important Safety Instructions

Save These Instructions

This section contains important instructions that must be followed during the installation and maintenance of the
equipment and batteries. Read all of the instructions before operating the equipment, and save this manual for
future reference.

All electrical connections must be performed by licensed electricians only. Installation of the power supply and
batteries must be performed by, or under the direct supervision of, service personnel knowledgeable of the required
electrical and battery safety procedures.

If instructions in this manual conflict with the local electrical codes, follow the local codes.
The following safety symbols are found throughout this manual. Carefully read all information and abide by the

instructions:

DANGEROUS VOLTAGE
This symbol indicates a dangerous voltage
exists in this area of the product.

GAS HAZARD
This symbol indicates a gas hazard
exists in the area of vented batteries.

NO MATCHES OR OPEN FLAMES
This symbol indicates a fire or explosive hazard
exists in the area of the product.

The following warning levels are used in conjunction with the symbols:

DANGER: You WILL be KILLED or SERIOUSLY INJURED if instructions are not followed closely.
WARNING: You CAN be KILLED or SERIOUSLY INJURED if instructions are not followed closely.
CAUTION: You CAN be INJURED or equipment can be DAMAGED if instructions are not followed closely.

Mechanical safety

Keep hands and tools clear of fans. Fans are thermostatically controlled and switch on automatically.
Power supplies can reach extreme temperatures under load.
Use caution around sheet metal components and sharp edges.

Electrical safety

WARNING: Hazardous voltages are present at the input of power systems. The DC output from
rectifiers and batteries, though not dangerous in voltage, has a high short-circuit current capacity
that may cause severe burns and electrical arcing.

Before working with any live battery or power system, follow these precautions:

 Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.
 Wear safety glasses with side shields at all times during installation.
 Use OSHA approved insulated hand tools.

DANGER: Lethal voltages are present within a power system. Always assume that an electrical
connection or conductor is energized. Check the circuit with a voltmeter with respect to the
grounded portion of the enclosure (both AC and DC) before performing any installation or removal
procedure.

Do not work alone under hazardous conditions.

A licensed electrician is required to install permanently wired equipment. Input voltages can range up to
240 Vac. Ensure that the utility power is disconnected and locked out performing any installation or
removal procedure.

Ensure that no liquids or wet clothes come into contact with internal components.
Hazardous electrically live parts inside this unit are energized from the batteries even when the AC input power is

disconnected.

Battery safety

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

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

Use OSHA approved insulated hand tools. Do not rest tools on top of batteries.
Batteries contain or emit chemicals known to cause cancer and birth defects or other reproductive harm. Battery

post terminals and related accessories contain lead and lead compounds. Wash your hands after handling
batteries.

WARNING: Follow battery manufacturer’s safety recommendations when working around battery
systems.

WARNING: Do not smoke or introduce an open flame when batteries (especially vented batteries)
are charging. Batteries vent hydrogen gas when charging, which creates an explosion hazard.

Batteries are hazardous to the environment and should be disposed of safely at a recycling facility. Consult the
battery manufacturer for recommended local authorized recyclers.

Post installation weather proofing

After installing the conduits and removing any knockouts to accommodate conduit locations, ensure that any gaps
between the conduit fittings and the shroud are sealed. Apply a weatherproof caulking to gaps to prevent wind
driven rain from reaching the electrical equipment.

Contents

1 Introduction ............................................................................................................. 7

1.1 Scope of manual......................................................................................................... 7

2 Product overview .................................................................................................... 2

2.1 Typical power configuration ........................................................................................ 3

2.2 Typical battery configuration ................................ ....................................................... 4

2.3 Air conditioning and heating ....................................................................................... 5

2.4 AC panel board and generator connector ................................................................... 6

2.5 Equipment mounting rails ........................................................................................... 6

2.6 Battery trays and battery retaining brackets ................................................................ 6

2.7 T1 surge suppression ................................................................................................. 6

2.8 Fiber cable slack box ................................ .................................................................. 7

2.9 Emergency ventilation system (EVS) .......................................................................... 8

2.10 Doors and access panels ........................................................................................... 8

2.11 Rear access panel ...................................................................................................... 9

2.12 Removable solar shield and hatch plate ..................................................................... 10

2.13 DC power equipment .................................................................................................. 11

2.13.1 Distribution panel ............................................................................................... 11

2.14 Rectifier and shelf ....................................................................................................... 11

2.15 Controller .................................................................................................................... 12

2.15.1 GMT fuse block ................................................................................................. 12

3 Transportation and storage .................................................................................... 13

3.1 Packaging................................................................................................................... 13

3.2 Storage ....................................................................................................................... 13

3.3 Inspection ................................................................................................................... 13

4 Installation .............................................................................................................. 14

4.1 Pre-installation considerations .................................................................................... 14

4.2 Power system ............................................................................................................. 14

4.3 HVAC system ............................................................................................................. 14

4.4 Site selection .............................................................................................................. 14

4.5 Enclosure support ....................................................................................................... 14

4.5.1 Base layout dimensions ..................................................................................... 15

4.5.2 Concrete slab .................................................................................................... 16

4.5.3 AC connections with concrete slab mounting ..................................................... 17

4.5.4 Steel platform .................................................................................................... 17

4.6 Multiple enclosure installations ................................................................................... 18

4.7 Installation component requirements .......................................................................... 19

4.8 Installation tools and equipment ................................................................................. 20

4.8.1 Tools Required .................................................................................................. 20

4.8.2 Lifting equipment requirements.......................................................................... 20

4.9 Enclosure installation .................................................................................................. 21

4.9.1 Enclosure preparation ....................................................................................... 21

4.9.2 Lifting preparation .............................................................................................. 21

4.10 Mounting the enclosure .............................................................................................. 22

4.10.1 Concrete slab .................................................................................................... 22

4.10.2 Steel platform .................................................................................................... 22

4.10.3 Roof mounting ................................................................................................ ... 22

4.10.4 Installing multiple enclosures side-by-side ......................................................... 22

4.11 Grounding................................................................................................................... 23

4.11.1 Site ground wire entry ........................................................................................ 23

4.11.2 Master ground bus (MGB) ................................................................................. 23

4.11.3 Enclosure chassis ground .................................................................................. 23

4.12 Wiring, cable management, and connections ............................................................. 24

4.12.1 Alarm connections ............................................................................................. 24

4.13 Utility connections ....................................................................................................... 26

4.13.1 AC conduit installations ..................................................................................... 26

4.13.2 Procedure .......................................................................................................... 27

4.14 Other cable connections ............................................................................................. 27

4.15 Internal cable routing .................................................................................................. 28

4.16 Battery installation ...................................................................................................... 29

4.16.1 Preparation/mounting ........................................................................................ 29

4.16.2 Battery installation in Alpha Tempest power systems ........................................ 29

5 System startup ........................................................................................................ 31

5.1 Connecting the batteries ............................................................................................. 31

5.2 Test and commissioning overview .............................................................................. 32

5.2.1 System ................................................................................................ .............. 32

5.2.2 Environmental/intrusion ..................................................................................... 32

5.3 Battery ........................................................................................................................ 32

5.3.1 Documentation ................................ .................................................................. 32

5.4 Air Conditioner/heater factory settings ........................................................................ 33

5.5 EVS (Emergency Ventilation System) factory settings ................................................ 33

5.6 Enclosure temperature alarms .................................................................................... 33

6 Final cleanup .......................................................................................................... 34

7 Maintenance ........................................................................................................... 35

7.1 General maintenance schedule .................................................................................. 35

7.2 Air conditioner ............................................................................................................ 35

7.2.1 Air conditioner settings ................................ ...................................................... 35

7.2.2 Air conditioner filter ............................................................................................ 35

8 Batteries ................................................................................................................. 36

8.1.1 Monthly maintenance ........................................................................................ 36

8.1.2 Semi-annual maintenance ................................................................ ................. 36

8.1.3 Performance/ integrity checks............................................................................ 36

8.1.4 String or cell replacement .................................................................................. 36

8.2 EVS intake and exhaust filter ...................................................................................... 37

9 Alpha conventions .................................................................................................. 38

9.1 Numbering system ...................................................................................................... 38

9.2 Acronyms ................................................................................................................... 38

List of figures

Figure 1 – Tempest outdoor auxiliary enclosure. Rear view. ......................................................... 2

Figure 2 – Tempest outdoor auxiliary enclosure. Front view. ......................................................... 2

Figure 3 – Typical Te45 enclosure power configuration ................................................................ 3

Figure 4 – Typical Te45 Battery Configuration .............................................................................. 4

Figure 5 – Miscellaneous enclosure features ................................................................................ 5

Figure 6 – Surge suppression mounted on rear of fibre slack box bracket .................................... 6

Figure 7 – Fiber slack box mounted on rear rails ........................................................................... 7

Figure 8 – Fiber cable slack box ................................................................................................... 7

Figure 9 – Locking front door ........................................................................................................ 8

Figure 10 – Rear panel latch ......................................................................................................... 9

Figure 11 – Rear panel released ................................................................................................... 9

Figure 12 – Wing nuts retaining lower panels ................................................................................ 9

Figure 13 – Disconnect lanyard and ground strap ......................................................................... 9

Figure 14 – Base layout drawing and mounting hole locations ...................................................... 15

Figure 15 – Concrete anchor bolt fastening detail ......................................................................... 16

Figure 16 – AC conduit outside concrete slab ............................................................................... 17

Figure 17 – Installation on steel platform ....................................................................................... 17

Figure 18 – Multiple enclosure installation ..................................................................................... 18

Figure 19 – Example of an insulated tool kit .................................................................................. 20

Figure 20 – Secure hooks in eyebolts ........................................................................................... 21

Figure 21 – Enclosure ground connections ................................................................................... 23

Figure 22 – Alarm connections ...................................................................................................... 24

Figure 23 – Alarm block ................................................................................................................ 25

Figure 24 – Slab AC conduit installation ........................................................................................ 26

Figure 25 – Underground AC conduit installation. AC panel extends of edge of concrete slab ...... 26

Figure 27 – DC and fibre cable routing at top of enclosure ............................................................ 27

Figure 26 – DC and fibre cable routing at bottom of enclosure ...................................................... 27

Figure 28 – Fiber optic cables must be protected by a loom at the cable entry.............................. 28

Figure 29 – Gasket installation on batteries location Te40panels release ..................................... 29

Figure 30 – Battery fuse kits and battery cabling. See attached drawing for more details ............. 30

Figure 31 – Completed installation ................................................................................................ 34

Figure 32 – Plastic plug - 4 positions ............................................................................................. 37

Figure 33 – Loosen internal nuts ................................................................................................... 37

Figure 34 – Slide cover up and off................................................................................................. 37

Figure 35 – Filter is located inside cover ....................................................................................... 37

1 Introduction

1.1 Scope of manual

This instruction manual covers the features, installation, startup, and maintenance of the Alpha Technologies’

Tempest Te45 Outdoor Auxiliary Enclosure.

 Enclosure specifications are found in Alpha document #029-039-B2.
 Operation instructions for the system controller and related modules are provided in separate component

manuals.

 Separate manuals are provided for batteries and other accessory equipment, such as HVAC.
 Images contained in this document are for illustrative purposes only and may not exactly match your unit.

Figure 2 – Tempest outdoor

auxiliary enclosure. Front view.

AC Load center

Generator connector

Removable rear panels (3)

EVS intake

4000 btu air
conditioner w/ heater

EVS exhaust

Figure 1 – Tempest outdoor auxiliary

enclosure. Rear view.

2 Product overview

The Te45 Outdoor Auxiliary Enclosure is a 72" tall enclosure that can be configured for power, battery or auxiliary
applications. Each configuration is designated by a part number that may include separate available options.

A Te45 system typically includes:

 Zone 4 seismic enclosure
 Optional AC distribution or junction box
 DC power components
 Alarm interface
 4000 BTU air conditioner and EVS

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 2 of 38

EVS intake fans

Air Conditioner
return air

Wind latch

DC light

Air conditione/
heater temp
set point

Air conditioner
supply air

Alarm connection
blocks

High/low temp alarms

GFCI plug in
Ground bar

Cordex
power and
distribution
system
(typical)

Battery
retaining
bracket

Battery
shelves

EVS exhaust

Figure 3 – Typical Te45 enclosure power configuration

Door intrusion alarm

2.1 Typical power configuration

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 3 of 38

Ground bar

GFCI outlet

Alarm
termination
blocks

Hi/low temp
alarms

Battery termination bus bars

Battery retaining
bracket

Battery trays

Figure 4 – Typical Te45 Battery Configuration

2.2 Typical battery configuration

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 4 of 38

EVS thermostat

Three­point door
latch

HVAC intake
and exhaust

HVAC controls

Figure 5 – Miscellaneous enclosure features

2.3 Air conditioning and heating

A 4000 BTU air conditioner/500 watt heater package provides cooling or heating to the batteries. It is mounted on
the front door of the enclosure. Refer to the HVAC manual that is supplied with the unit.

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 5 of 38

Figure 6 – Surge suppression mounted on rear of fibre slack box bracket

2.4 AC panel board and generator connector

The AC panel board and generator connector are supplied by Intersect Corporation. The panel includes an
automatic transfer switch, an additional emergency generator connection, and a manual transfer switch. Refer to
the Intersect manual that is supplied with the unit.

2.5 Equipment mounting rails

4 x 23" mounting rails are installed in the enclosure.

2.6 Battery trays and battery retaining brackets

Two battery trays are provided. Battery retaining brackets are supplied for mounting positions both in front and on
top of the batteries.

Battery trays and retaining brackets are designed specifically for GNB155 batteries. Any deviation from this battery
may affect Zone 4 seismic compliance. Call Alpha before changing battery models.

2.7 T1 surge suppression

The enclosure is provided with a rail mounted bracket that accommodates a fiber slack box and two AC data Model
MPM6-TTTTEE-DL “Multi-port Max 6" surge suppression devices.

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 6 of 38

Figure 8 – Fiber cable slack box

Figure 7 – Fiber slack box mounted on rear rails

Fiber cable
slack box

2.8 Fiber cable slack box

A fiber cable slack box is provided on the enclosure.

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 7 of 38

The front door
can be secured
at the handle
via a padlock

Figure 9 – Locking front door

Door mounted
EVS thermostat

2.9 Emergency ventilation system (EVS)

The EVS unit provides ambient cooling when the inside temperature exceeds a predetermined temperature setting
on the EVS control thermostat.

The EVS is a DC system that operates when any one or more of the following conditions is present:

 AC power failure. The air conditioner shuts down.
 Air conditioner compressor failure.
 Extreme ambient temperatures above 45°C.

2.10 Doors and access panels

The hinged front door is held closed by a 3 position latching system with a pad lockable handle.

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 8 of 38

Remove rear top panel

CAUTION:
The rear panels are

connected by a
ground strap and
release cable, but can
fall upon release.

Pull on handle to
release top rear panel

Remove each set of wing
nuts, one on each side, to
release the lower panel.

To remove rear
panel, disconnect
lanyard and ground
strap once the panel
is released

Figure 10 – Rear panel latch

Figure 11 – Rear panel released

Figure 12 – Wing nuts retaining lower panels

Figure 13 – Disconnect lanyard and ground strap

When installing the rear panels,
first install the lower panel, and
then install the middle panel.
When installing either panel, first
connect the ground strap, then
move the panel into place, and
finally tighten the wing nuts
securely.

On the upper panel, re-install the
ground strap and re-attach the
lanyard as shown

2.11 Rear access panel

There are three rear access panels. The top panel is a slam latch panel. The lower two panels use internal wing­studs that must be removed to lift off the panels. The following procedure explains how to remove the rear panels:

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 9 of 38

Remove eyebolts

Remove solar shield to
expose hatch plate

To release hatch plate, pull the
latch ring toward the rear of the
enclosure in the direction shown
by the large arrow

2.12 Removable solar shield and hatch plate

 To re-install, ensure the slam latch on the hatch plate is fully engaged.
 Re-install the solar shield by re-installing the eyebolts.

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 10 of 38

Distribution
center

Rectifier

2.13 DC power equipment

2.13.1 Distribution panel

 The DCP03, 300 A distribution center in an integrated DC system distribution package designed for small to

mid size power applications.

 The distribution panel takes up three rack units of space.
 The DC system and signal connections are accessible from the front of the panel.
 All distribution wires are connected via two-hole termination lugs.
 Up to 18 plug-in breakers can be installed at up to 100 A per position. Optional multiple pole breaker adapter

kits are available.

 The 4R/8D ADIO Cordex peripheral is installed in the front door, expanding the I/O capability of the controller.

2.14 Rectifier and shelf

 37.5 A @ 48 Vdc is provided to each rectifier.
 Rectifiers are hot swappable.
 2RU ultra compact rectifier design.

The fan cooled 1.8 kW rectifier has extremely high density with a compact 2RU design that allows five rectifiers per
23" shelf and four rectifiers per 19" shelf together with an integrated CXCI controller. An optional CXCM2 controller
with a touch screen display is available.

Local and remote setup, adjustments, and control are a single step process via the controller. By using TCP/IP
technology, complete configuration and monitoring of power equipment can be done through a network web
browser.

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 11 of 38

CXCI Cordex
controller

GMT fuse block
mounted to side
of distribution
center

2.15 Controller

The compact CXCI Cordex controller is an integrated option that fits inside the rectifier shelves and takes up 2RU
of space. The controller includes a complete range of standard software features.

The controller includes a web server interface that provides easy set ups via local or remote IP access using a
standard Internet Explorer browser. The controller features LED indicator lights and an LCD screen that displays
voltage and current.

An integrated logging feature is typically available only with an advanced, standalone, data logging system. It
allows the capture of data from multiple AC/DC voltages, load/battery currents, and cell voltages/temperatures.
Common applications of the logging include power system details, thermal performance of outdoor enclosures,
battery cell specifics, and mains variations captured by an AC voltage watchdog.

The CXCI I/O features can be expanded by adding CXC smart peripherals, such as battery cell monitoring, shunt
multiplexing, or alarm relay expansion.

Cordex CXC controllers are designed to ensure effortless operation of Cordex rectifiers. Otherwise complicated and
time consuming set ups are greatly simplified.

2.15.1 GMT fuse block

An 8-position GMT fuse block is installed in the enclosure to provide additional distribution capability.

Alpha Technologies Ltd. 057-106-C0 Rev D
Burnaby, British Columbia. Telephone: [phone] Fax: [phone]. Page 12 of 38