Alpha Underground Battery Vault User Manual
Underground Battery Vault
Site Preparation and Installation
Effective: August 2006
Alpha Technologies
Alpha Technologies
Power
®
Underground Battery Vault
Site Preparation and Installation
031-040-B0-002 Rev. B
Effective Date: August 2006
Copyright
© 2006
Alpha Technologies, Inc.
member of The Group
NOTE:
Photographs contained in this manual are for illustrative purposes only. These photographs may not match
your installation.
NOTE:
Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding. If
there are questions regarding the safe operation of this 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.
TM
For general product information and customer service (7 AM to 5 PM, Pacifi c Time), call
031-040-B0-002 Rev. B
Contacting Alpha Technologies: www.alpha.com
or
1-800-863-3930
For complete technical support, call
1-800-863-3364
7 AM to 5 PM, Pacifi c Time and24/7 emergency support
3
Contents
Safety Notes ..........................................................................................................................5
Battery Safety Notes..............................................................................................................6
Mechanical Safety ................................................................................................................. 6
1. INTRODUCTION ...............................................................................................................8
1.1 Underground Battery Vault .......................................................................................................8
2. INSTALLATION .................................................................................................................9
2.1 Site Prep and Installation ..........................................................................................................9
2.2 Battery Placement .................................................................................................................. 10
2.3 Battery Connection ................................................................................................................. 12
2.4 Battery Covers ........................................................................................................................ 18
2.4.1 Installing the Battery covers ............................................................................................. 19
2.5 Temperature Sensor ............................................................................................................... 21
List of Figures
Fig. 1-1 Underground Battery Vault (UBV) ............................................................................................ 8
Fig. 2-1 Typical Site for UBV ................................................................................................................. 9
Fig. 2-2 Terminal Connection without Battery Sense Wiring ...............................................................12
Fig. 2-3 Terminal Connection with Battery Sense Wiring ....................................................................13
Fig. 2-4 AG-CMT-3SC Wiring for Single 36V Battery String ................................................................ 14
Fig. 2-5 AG-CMT-3SC Wiring for Dual 36V Battery String ..................................................................15
Fig. 2-6 AG-CMT-4SC Wiring for Single 48V Battery String ................................................................ 16
Fig. 2-7 AG-CMT-4SC Wiring for Dual 48V Battery String ..................................................................17
Fig. 2-8 165 GXL Battery Cover .......................................................................................................... 18
Fig. 2-9 180 GXL Battery Cover .......................................................................................................... 18
Fig. 2-10 165 AGM Battery with Cover in Place ..................................................................................20
Fig. 2- 11 180 GXL Battery with Cover in Place .................................................................................. 20
Fig. 2-12 Location of Temperature Probe on Battery ........................................................................... 21
Fig. 2-13 Temp Probe Connector ........................................................................................................ 21
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031-040-B0-002 Rev. B
Safety Notes
Review the drawings and illustrations contained in this manual before proceeding. If there are any questions
regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha
representative. Save this document for future reference.
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following
symbols have been placed throughout this manual. Where these symbols appear, use extra care and
attention.
WARNING!
Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contains dilute sulfuric acid,
which is harmful to the skin and eyes. Emissions are electrolytic and are electrically conductive and corrosive.
Chemical Hazards
To avoid injury:
Servicing and connection of batteries shall 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. To avoid
•
battery contact, remove all metallic objects, (such as rings or watches), from your person.
Batteries produce explosive gases. Keep all open fl ames and sparks away from batteries.
•
Use tools with insulated handles, do not rest any 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).
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 a 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.
•
Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have
•
developed on your body.
Use special caution when connecting or adjusting battery cabling. An improperly or unconnected battery
•
cable can make contact with an unintended surface that can result in arcing, fi re, or a 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.
031-040-B0-002 Rev. B
5
Safety Precautions, continued
• Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can result in a fi re
or possible explosion.
• Always replace batteries with those of an identical type and rating. Never install old or untested batteries.
• Avoid using uninsulated tools or other conductive materials when handling batteries or working inside the
enclosure.
• Remove all rings, watches and other jewelry before servicing batteries.
• Spent or damaged batteries are environmentally unsafe. Always recycle used batteries. Refer to
local codes for proper disposition of batteries
Battery Safety Notes
• Always refer to the battery manufacturer’s recommendation for selecting correct “FLOAT” and “ACCEPT”
charge voltages. Failure to do so can damage the batteries.
• Verify the Power Supply’s battery charger “FLOAT” and “ACCEPT” charger voltage settings.
• Batteries are temperature sensitive. During extremely cold conditions, a battery’s charge acceptance is
reduced and requires a higher charge voltage; during extremely hot conditions, a battery’s charge
acceptance is increased and requires a lower charge voltage. To compensate for changes in temperature,
the battery charger used in the power supply is temperature compensating. Refer to Section 2.5 for
instructions on connecting the Remote Temperature Sensor (RTS).
• If the batteries appear to be overcharged or undercharged, fi rst check for defective batteries and then
verify the correct charger voltage settings.
• To ensure optimum performance, inspect batteries every three to six months for signs of cracking,
leaking, or unusual swelling (note that some swelling is normal).
• Check battery terminals and connecting wires. Clean battery terminal connectors periodically and
retighten to approximately 50 inch-pounds. Spray the terminals with an approved battery terminal
coating such as NCP-2.
Mechanical Safety
Power supplies can reach extreme temperatures under load.
•
Use caution around sheet metal components, especially sharp edges.
•
Depending on the model, batteries can weigh anywhere from 25 to 100 pounds. Exercise care when
•
handling and moving batteries. Use proper handling equipment.
6
031-040-B0-002 Rev. B
IMPORTANT INSTALLATION NOTES
THE SYSTEM SHOULD BE INSTALLED ONLY BY QUALIFIED SERVICE PERSONNEL.
ALWAYS CONSULT LOCAL CODES FOR CONCRETE PAD REQUIREMENTS.
CONSULT LOCAL UTILITY CODES FOR ADDITIONAL CABINET GROUNDING AND UTILITY REQUIREMENTS.
CONSULT THE LOCAL GAS COMPANY FOR CORRECT METER TYPE AND RISER LOCATION.
THE ENCLOSURE SHOULD BE INSTALLED ABOVE FLOOD ZONES WHENEVER POSSIBLE.
THE PAD MUST BE AT LEAST 6” THICK AND CAPABLE OF HOLDING 4,000 LBS (MINIMUM). REBAR SHOULD
BE PLACED IN A CROSSHATCH PATTERN FOR PAD REINFORCEMENT.
IF THE PAD IS TO BE LOCATED IN AN AREA WITH A DEEP FROST LINE OR UNSTABLE SOIL, CONCRETE
PYLON FOOTINGS (4” DIA. X 4’ DEEP, OR 1’ DEEPER THAN THE REGIONAL FROST LINE) SHOULD BE
PLACED BELOW THE CONCRETE PAD, IN FRONT OF AND BELOW THE (6) MOUNTING FEATURES.
THE HEIGHT OF THE PAD MUST BE AT LEAST 4” ABOVE GRADE TO REDUCE THE BUILDUP OF DEBRIS
AROUND THE BASE OF THE CABINET.
ADEQUATE SPACE SHOULD BE ALLOWED FOR CABLE TV INPUT / OUTPUT CONDUIT; PLANT GROUNDING
ELECTRODE CONDUCTOR(S); RF CABLE ENTRANCE VIA (1) 4”, (2) 3” OR (3) 2 1/2” RIGID CONDUIT
SWEEP(S) WITH 2’ BEND RADIUS (MINIMUM); AND FIBER OPTIC CABLE ENTRANCE (REFER TO FIBER
MANUFACTURER’S SPECIFICATION FOR MINIMUM BEND RADIUS REQUIREMENTS).
PRIOR TO POURING CONCRETE, ANY WIRE RUNNING THROUGH THE PAD MUST HAVE A THERMAL
EXPANSION JACKET (I.E., PVC) TO PREVENT CRACKING OF THE CONCRETE DURING LIGHTNING
STRIKES.
ALPHA TECHNOLOGIES IS NOT RESPONSIBLE FOR BROKEN WELDS OR OTHER DAMAGE TO THE
CABINET CAUSED BY IMPROPER INSTALLATION.
A BEAD OF SILICONE MUST BE PLACED AROUND THE OUTSIDE PERIMETER OF CABINET’S BASE TO
SEAL OUT RAIN. A 25 YEAR VAPOR BARRIER MUST BE USED BETWEEN THE CONCRETE PAD AND THE
BASE OF THE ENCLOSURE TO FURTHER INHIBIT THE INGRESS OF MOISTURE. ALPHA TECHNOLOGIES
IS NOT RESPONSIBLE FOR WATER DAMAGE OR MOISTURE DAMAGE RESULTING FROM IMPROPER
INSTALLATION.
CONCRETE FILLED, 6” DIAMETER STEEL POSTS (OR EQUIVALENT) SHOULD BE PLACED AT THE
CORNERS OF THE PAD TO REDUCE EXPOSURE TO ACCIDENTAL TRAFFIC DAMAGE. POSTS MUST ALSO
BE PLACED IN FRONT OF THE GAS UTILITY RISER TO PROTECT THE GAS REGULATOR FROM IMPACT
AND / OR DAMAGE FROM LAWN EQUIPMENT.
ALL DIMENSIONS ARE GIVEN IN INCHES.
FOR FURTHER INFORMATION REGARDING THIS INSTALLATION, CONTACT APLHA TECHNOLOGIES OR
YOUR NEAREST ALPHA REPRESENTATIVE.
031-040-B0-002 Rev. B
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1. INTRODUCTION
1.1 Underground Battery Vault
Alpha’s UBV Series Underground Battery Vaults and BVE enclosures meet municipal and
state regulations involving line of sight restrictions. These utility approved vaults are manufactured from high density polyethylene (HDPE) and can house up to eight batteries. Several options are available including combinations with ground and pole mount power supply
enclosures.
UBV Underground Battery Vaults
Standard Features
HDPE Vault
(in): 43.5L x 31.75W x 18H
(mm): 105L x 806W x 457H
HDPE Lid
(in): 35.6L x 24.1W
(mm): 904L x 612W
Accommodates up to 8 batteries
Hex-head bolts (standard)
Penta-head hardware optional)
Cover
Optional Features
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BCK-UBV3 Fused Battery Cable Kit - 3 batteries
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BCK-UBV4 Fused Battery Cable Kit - 4 batteries
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BCK-UBV6 Fused Battery Cable Kit - 6 batteries
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BCK-UBV8 Fused Battery Cable Kit - 8 batteries
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BCK-EXT 15 BCK extension - 5' for XM2 Series
•
BCK-EXT 20 BCK extension - 20' for XM2 Series
•
BCK-EXT 25 BCK extension - 25' for XM2 Series
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UBV-SH Tamper-proof Security Hardware
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UBV-ST Security Tool
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UBV-BT Battery Tray & Hardware (max. 6 AlphaCell
batteries)
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UBV-BG Battery Grate for Vault
•
UBV-BC Individual Battery Cover - Protects battery from
water, dirt & corrosion
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RTS-4 Remote Temperature Sensor 4'
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RTS-25 Remote Temperature Sensor 25'
™
Batteries
Box, High density
polyethelyne
1” thick grate
2.5” PVC Conduit
Fig. 1-1 Underground Battery Vault (UBV)
2 x 48VDC battery string confi guration (maximum capacity)
8
031-040-B0-002 Rev. B
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