CE-G Series Propane Enclosures CE-3G / CE-9G Installation Manual 031-093-C0-001 © 3/99
031-093-C0-001 © 3/99
Preface CE-G Series Enclosure Installation Manual Preface Topic page Overview About this Manual Table of Contents List of Figures Safety Information Installation Notes Battery Safety Notes i i ii iii iv v vi Overview: The purpose of the CE-G Enclosure Installation Manual is to provide an overview of the system and to detail the enclosure installation procedure. Audience: This manual intended for the installers and operators of the system. Contents: Section 1, System Overview.
Preface CE-G Series Enclosure Installation Manual Table of Contents Section 1, System Overview 1.1 Overview .................................................................................. 1-1 1.2 Block Diagram ............................................................................... 1-2 Section 2, Pre-Installation 2.1 Site Preparation ............................................................................ 2-1 2.1.1 Site considerations ........................................................
Preface List of Figures Section 1, Introduction Figure 1.1 Figure 1.2 Colocated CE-X, CE-G enclosures .................................... 1-1 System Block Diagram .................................................... 1-2 Section 2, Pre-Installation Figure 2.1 Figure 2.2 Concrete Pad Layout ..................................................... 2-2 Impact post arrangement .............................................. 2-3 Section 3, Installation Figure 3.1 Figure 3.2 Gas Utility Box cutout .............
Preface IMPORTANT SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL CAUTION HAZARDOUS CONDITION To reduce the risk of electrical shock, injury or death caused by explosion of fuel or moving parts, and to ensure the safe operation of this unit, the following symbols have been placed throughout the manual. Where these symbols appear, servicing should be performed only by qualified personnel. DANGEROUS VOLTAGE This symbol indicates a dangerous voltage exists in this area of the product.
Preface IMPORTANT INSTALLATION NOTES It is important that the installation procedures be followed as outlined in this manual. The procedures have been developed to facilitate the installation of the equipment and for the safety of the installation and service personnel. Read the documentation thoroughly before proceeding with the installation. The system should be installed ONLY by qualified service personnel. Consult local utility codes for additional cabinet grounding and utility requirements.
Preface Propane Safety Notes vi 1. Never overfill your LP-gas container. LPgas containers not containing a fixed liquid level gauge must be filled by weight to 80% of their total capacity. Propane expands 1.5% for each 10 °F increase in temperature. 20% of the container must remain available for expansion. Some tanks supplied by Alpha Technologies come equipped with automatic stop fill valves. Tanks must be filled in accordance with manufactures, D.O.T, NFPA Code 58, state and local regulations. 2.
Preface Propane Safety Notes 6. Do not store LP-gas tanks indoors or in enclosed areas. Do not expose the tanks to heat, relief valve may open. Always store with the service valve closed tight and plugged. 7. Do not attempt to repair LP-gas containers or valves or regulators. 8. When using make sure that the tank is level, securely fastened down, and vertical. 9. Check all tank and line connections periodically to be sure they are tight. When testing for leaks use soapy water or a leak detect solution.
Preface viii 031-093-C0-001 © 3/99
1. System Overview 1.1 Overview The CE-X series of enclosures from Alpha Technologies has been designed to meet the needs of todays outside plant powering requirements. When an alternate fuel source is not available, the CEG propane natural gas option can provide up to 16 hours of continuous operation. The procedures described in this document describe the installation of a CE-G Series Propane Enclosure. The installation procedures are identical for the CE-3G and the CE-9G.
1. System Overview 1.2 Block Diagram The block diagram shown illustrates the overall system interconnection between the CE-X enclosure with Auxiliary Power Unit, and the CE-G enclosure with supplemental propane supply. LP PROPANE - VAPOR WITHDRAWAL BLOCK DIAGRAM ENGINE DEMAND CONTROLS LOW PRESSURE REGULATOR 8oz MAX SOLENOID S LOW FUEL ALM 11"WC APU ENCLOSURE LOW FUEL PRESSURE SWITCH SENSOR 1-2 11"WC OUTLET AUTO/MANUAL DUAL TANK VALVE PROPANE ENCLOSURE PROPANE Fig. 1.
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2. Pre-Installation 2.1 Site Preparation 2.1.1 Site considerations The site for the collocated CE-G will be predetermined by the location of the CE-X enclosure. The site for the remotely located CE-G should be planned so that the enclosure will receive good air flow. If possible, in areas of extreme heat, the enclosure should be positioned so that it will be shaded from the afternoon sun.
2. Pre-Installation 2.1 Site Preparation, continued 2.1.2 Concrete Pad Layout The illustration below shows the general dimensions for a poured in place concrete pad. When placing the pad, allow at least 36 inches of clearance to allow the front and rear doors to fully open. 1 1 2 1 1 2-2 Fig.2-1, Concrete pad layout (all dimensions shown in inches) 1 3/8" diameter (4 places) bolts (which should extend 1"-1 1/2" above the surface of the pad).
2. Pre-Installation 2.1 Site Preparation, continued 2.1.3 Enclosure Impact Protection As described in the NFPA Technical Compliance Statement, the cabinet must be protected by impact posts, placed in strategic locations according to traffic patterns. The illustration below shows the general arrangement of the 6 diameter, concrete-filled posts. The actual positioning of the posts may vary by location. APU CE-X PROPANE CE-G PAD POSTS FRONT SIDEWALK SIDEWALK TRAFFIC 2-3 CURB STREET TRAFFIC Fig.
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3. Installation 3.1 Tools and Materials The following procedure will allow for installation of the Collocated CE-G with the CE-X/ CE-X2. The CE-G enclosure re is bolted to the concrete pad using 7/16 bolts and to the CE-X APU enclosure by carriage bolts. Also this procedure will explain step by step how to install the two 40 LB propane tanks and the regulator /control valve.
3. Installation 3.2 Transportation The enclosure is shipped bolted to a shipping pallet. It should be transported, loaded, and unloaded while bolted to the shipping pallet. A safe means of transportation to the site and unloading the enclosure must be considered. Do not transport, lift, or place the unit on any surface unable to fully support its weight. NOTE: The enclosure should only be transported, lifted, and installed as shipped from the factory.
3. Installation 3.3 Installation Procedure 1. Install the CE-G enclosure so that the gas utility box of the CE-X enclosure fits into the gas utility box cutout on the CE-G (dashed line) as pictured below. Ensure the two cabinets are placed flush against each other. 2. With the two cabinets sitting flush against each other, mark the anchor bolt pattern onto the concrete pad using the four slotted anchor bolt holes found in the corners of the base plate of the CE-G enclosure as an template. 3.
3. Installation 3.3 Installation Procedure, continued 3. Slide the CE-G enclosure away from the CE-X enclosure. 4. Drill with a 1/4 hole through the wall of the CE-X enclosure where previously marked. NOTE: 5. Before drilling through the CE-X cabinet wall, ensure that the area behind the wall is clear of any wires, gas hoses, or pipes. With the anchor bolt pattern marked, drill holes for the installation of anchor studs. Tools required: Stainless steel wedge-type stud anchor , 3/8" dia.
3. Installation 3.3 Installation Procedure, continued 5. Lay down the vapor barrier material. With a utility knife, make small cutouts in the material through which the anchor studs protrude. 6. Place the CE-G enclosure back into place over the mounting studs. 7. With CE-G enclosure in place and flush against the CE-X enclosure, install the mounting hardware (flat washers, lock washers, and 3/8 nuts) on each mounting bolt. Do not tighten at this time. 8.
3. Installation 3.4 Enclosure Impact Protection As described in the NFPA Technical Compliance Statement, the cabinet must be protected by impact posts, placed in strategic location according to traffic patterns. APU CE-X PROPANE CE-G PAD POSTS FRONT SIDEWALK SIDEWALK TRAFFIC CURB STREET TRAFFIC 3-6 Fig.3.2, Impact post arrangement (typical) Once the impact posts (Concrete-filled, 6 diameter, steel) have been placed, proceed to the next section for the Propane Tank Installation procedure.
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4. Operation 4.1 4.1.1 1. Installation of the propane tanks and regulator assembly Installation of tanks Place the rear tank into the enclosure through the rear access and the front tank through the front access. Ensure that the base of each tank fits into the tabs of the base plate, as shown below. 4-1 Figure 4.1, Tank base locator tabs 2. The tanks' vapor outlets should be facing towards the gas utility box (the front left of the enclosure). Figure 4.
4. Operation 4.2 1. Installation of Regulator Assembly On tank hold down rod adjust stop nut so that the tank hold down bracket aligns with the bottom edge of the tank valve guard / handle, as shown below. Figure 4.3, Stopnut 4-2 2. Slide regulator / hold down bracket assembly onto the hold down rod. Ensure regulator assembly is facing same direction of tank valve vapor ports, and that the hold down brackets outermost grooves fits onto the bottom edge of the valve guard. Figure 4.
4. Operation 4.2 3. Installation of Regulator Assembly, continued Install the hold down bracket wing nut onto the hold down rod and tighten down. Figure 4.
4. Operation 4.3 Installation of High Pressure and Low Pressure Hoses 4.3.1 Installation of high pressure Hoses 1. Install high pressure hoses into the tanks vapor outlet port with a service loop pointing upward, as shown below. Figure 4.6, High-pressure hose arrangement 4-4 4.3.2Installation of high pressure Hoses 1. Install the Low pressure hose onto the Low fuel pressure switch, located in the gas utility box, as shown below. Figure 4.
4. Operation 4.4 4.4.1 Converting APU From Natural Gas To Propane Gas Accessing the APU 1. Remove rear cabinet door. 2. Remove the exhaust pipe access panel, by removing the 6 panel screws. Remove panel screws 4-5 Figure 4.
4. Operation 4.4 Converting APU From Natural Gas To Propane Gas, cont. 4.4.1 3. Accessing the APU, continued Use a 10mm socket and ratchet remove the two flange bolts that connect the flex exhaust pipe to the upper exhaust pipe. Figure 4.9, Exhaust pipe flange bolts 4-6 4. Disconnect fuel hose at the APU 45° fitting. Cut cable ties from hose. Figure 4.
4. Operation 4.4 4.4.1 5. Converting APU From Natural Gas To Propane Gas, cont. Accessing the APU, continued Disconnect the APU connector, Battery Connector, Fuel Solenoid and ACU 12 pin connector from the top panel of the generator enclosure. Figure 4.11,APU housing connetors 4-7 6. Use a 9/16" socket remove the two slide retaining bolts. (picture) Figure 4.
4. Operation 4.4 Converting APU From Natural Gas To Propane Gas, cont. 4.4.1 7. Accessing the APU, continued Slide the APU out. 4-8 Figure 4.
4. Operation 4.4 8. Converting APU From Natural Gas To Propane Gas, cont. Dual Fuel Load Block conversion from Natural Gas to Liquid Propane Gas. Procedure: 1. 2. 3. 4. 5. Remove the blanking plug from the lower outlet port on the load block. Loosen the hose clamp on the fuel supply hose at the load block. Loosen the brass fitting and remove from the upper outlet port (NG port) and install in the lower outlet port (LP port). Retighten the hose clamp. Install the blanking plug into the upper outlet port.
4. Operation 4.4 9. Converting APU From Natural Gas To Propane Gas, cont. Reconnect the APU exhaust and Fuel Hose Procedure: 1. 2. 3. Install new gasket at the exhaust Flex pipe flange. Apply antiseize compound to the flange bolts and install into flange Torque the exhaust pipe flange bolts, bolt to bolt, to 7-ft/pounds. Figure 4.15, Exhaust pipe flange gasket 4-10 4. Reconnect the fuel hose with cable ties to the proper anchor points (see below).
4. Operation 4.5 4.5.1 Pre-Regulator/Low-Fuel Pressure Package Conversion Converting from Natural Gas Pre-regulator Gas Package to LP Gas Low fuel Pressure switch Removal Procedure: 1. 2. 3. 4. Have authorized personnel disconnect the Natural Gas at the manual shutoff valve. De-couple the input piping at a point outside of the gas utility box. In the Gas Utility Box locate the Pre-regulator, disconnect at the coupler fitting. (see picture) Lift pre-regulator up and out of the gas utility box.
4. Operation 4.5 Pre-Regulator/Low-Fuel Pressure Package Conversion, cont. LP Gas low fuel pressure switch Installation procedure 1. Route the low fuel pressure switch wires (connector not installed) located on the back wall of the gas utility box. Figure 4.18, Low fuel pressure switch wire placement 4-12 2. Install the Low fuel pressure Switch package on to the gas inlet elbow fitting. NOTE: The switch package is joined to the input pipe with a compression fitting.
4. Operation 4.5 Pre-Regulator/Low-Fuel Pressure Package Conversion, cont. LP Gas low fuel pressure switch Installation procedure 3. Install the two position connector onto the low fuel pressure switch wire harness, Black wire to Pin 1, White to Pin 2. 4. Connect the switch side wire harness connector to the cabinet side low fuel pressure switch connector. 4-13 Figure 4.
4. Operation 7. CEG Enclosures Used In Remote Applications The collocated CEG enclosure can be converted to be a remotely located enclosure at distances of no more than 25 feet from the APU. This remote operation requires the use of interconnecting buried gas pipe, between the APU cabinet and the CEG cabinet. All pipe and pipe fittings running from the CEX to the CEG will be installed in accordance with local code. All materials used must meet approval of all local codes.
4. Operation 7.1 Converting Collocated CEG Enclosure For Remote Application 1. Locate the gas utility box cut out on the left wall of CEG. 2. Align the Remote Gas Utility Box Assembly with the pre drilled bolt holes surrounding the cut out. 2 4-15 Figure 4.22, Bolt hole locations 3. Use the six carriage bolts and supplied hardware, to mount the remote gas utility box to the outside of the CE-G enclosure wall. Figure 4.
4. Operation 7.1 Converting Collocated CEG Enclosure For Remote Application 3. Install the gas hoses to the brass fitting located on the inside of remote gas utility box. (see picture) 4. Hook up interconnecting gas pipe to the remote utility gas box pipe fixture. 4-16 Figure 4.24,Hose connection End of conversion Procedure 1. 2. 3. Securely fasten all hoses. Open previously-filled gas bottles.
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031-093-C0-001 © 3/99
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