CESC Sidecar Installation Manual Effective: March, 2004 ®
Power Alpha Technologies ®
CE Sidecar Enclosure Installation Manual 031-106-C1-001, Rev. A Effective Date: March, 2004 Copyright© 2004 Alpha Technologies, Inc. NOTE: Alpha denies responsibility for any damage or injury involving its enclosures, power supplies, generators, batteries, or other hardware when used for an unintended purpose, installed or operated in an unapproved manner, or improperly maintained. NOTE: Photographs contained in this manual are for illustrative purposes only.
TM Table of Contents 1. Introduction .......................................................................... 9 2. Installation ......................................................................... 10 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Concrete Pad Preparation ...................................... 10 Utility Power Connection ....................................... 11 Generator / Sidecar Inter-connecting Cables ............ 15 Internal Components ............................................
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 A “Warning” identifies conditions and actions that pose a hazard to the user. A “Caution” identifies conditions and actions that may damage the power supply or associated equipment. Warnings NOTE: This power supply and its associated hardware (enclosure, batteries, cabling) may contain equipment, batteries or parts which have accessible hazardous voltage or currents. To avoid injury: 6 • This power supply and its associated hardware must be serviced by authorized personnel only.
Preface Battery Safety Notes Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery installation, maintenance, service and replacement must be performed by authorized personnel only. Chemical Hazards NOTE: Any 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.
Preface Important Installation Notes The system must be installed ONLY by qualified service personnel. Consult local utility codes for additional cabinet grounding and utility requirements. ALPHA TECHNOLOGIES is not responsible for broken welds or other damage to the cabinet caused by improper installation. All dimensions are given in inches. For further information regarding this installation, contact ALPHA TECHNOLOGIES or your nearest ALPHA representative.
1. Introduction 1.1 Enclosure Introductions The CESC enclosure is a cost effective 'all in one' power system. The side car provides for a single power module, batteries, and generator in a low profile minimum footprint design. This procedure describes the installation of a side car to an AlphaGen generator, PN-3B or CE3X2B enclosure. Fig. 1 Sidecar and Generator Enclosure 031-106-C1-001 Rev.
2. Installation 2.1 Concrete Pad Preparation Pads can either be poured on site, or precast by Alpha Technologies. The mounting holes on the bottom of the high security PN-3 will fit both a standard PN-3 pad, and a CE3X pad. Precast pad model number PCC-SC-3X, Alpha P/N 641-061-10 or PCD-SC-3X, Alpha P/N 641-064-10 (east coast) are available for this system. 2 19.5 5 Generator or PN3/4 5.5 3.5 9.2 14.7 1 CESC 3 3.5 6.8 6 22.0 10.25 4 All Measurments in Inches Fig.
2. Installation 2.2 Utility Power Connection CAUTION: The “Utility Power Connection” procedure must ONLY be performed by qualified service personnel and in compliance with local electrical codes and common safety practices. Connection to utility power must be approved by the local utility before installing the power supply. NOTE: UL and NEC require that a service disconnect switch (UL listed) be provided by the installer and be connected between the power source and the ALPHA power supply.
2. Installation 2.2 240VAC Service (XM Series 2 915-240 Power Supply; XM Series 2 92248 for UPE-4 and UPE-8): Enclosures used with the XM Series 2 915-240 or 922-48 are equipped with a 240VAC duplex receptacle to provide power to the power supply and peripheral equipment. The receptacle, NEMA 6-15R, is protected by a single, 2-pole, common trip 15 Amp circuit breaker located inside the service entrance.
2. Installation 2.2 Utility Power Connection, continued Ground From Utility Line 1 Neutral ON 120 VAC OFF Service Entrance To Ground Rod Ground 240 VAC Line 2 To Enclosure From Utility ON ON OFF OFF Line 1 Neutral Service Entrance To Ground Rod To Enclosure Fig. 3 Service Entrance Wiring 031-106-C1-001 Rev.
2. Installation 2.2 Utility Power Connection, continued line 1 Neutral Ground ON OFF 120 VAC Meter Base line 1 Neutral Line 2 Ground ON 20 OFF 240 VAC Meter Base Fig. 4 Meter Base Wiring 14 031-106-C1-001 Rev.
2. Installation 2.3 Generator / Sidecar Inter-connecting Cables The following cables must be routed either through a 3" sweep or coupling: #4 AWG DC Output from the generator 120 VAC power from the CESC sidecar service entrance ECM or ACU Interface cable (status monitoring) Sidecar Enclosure Back Wall Generator Enclosure Side Wall 3" PVC Coupling ECM Interface (status monitoring) Line Neutral Ground 120 VAC From Service Entrance Positive Negative DC Output From Generator Fig.
2. Installation 2.4 Internal Components The Sidecar enclosure contains an Input Power Panel (IPP), one or two Service Power Inserters (SPI),and the Enclosure Grounding Rail. The Power Supply rests on the upper shelf, and a 36 or 48 VDC battery pack on the lower two shelves. A cooling fan is required any time a Power Supply is housed in the side car. The fan is thermostatically controlled to turn on at ~140 deg F and off at ~110 deg F.
2. Installation 2.5 Battery Pack Wiring 4 3 Upper Shelf 1 3 1 Lower Sheff 2 48 Volt Battery Pack BCK P/N 874-665-20 2 36 Volt Battery Pack BCK P/N 874-664-20 Fig. 8 36- & 48-Volt Battery String Wiring 031-106-C1-001 Rev.
2. Installation 2.6 Power Supply Placement 1. Place the XM2 power supply onto the top shelf of the side car. 2. Verify that the AC Input Breaker in the service entrance is in the OFF position. 3. Verify that the Battery Breaker on the front of the power supply is in the OFF position. 4. Plug the AC power cord into the Input Power Panel on the side of the enclosure. 5. Plug the Battery Input Cable from the battery pack into the Battery Input connection on the front of the power supply. 6.
2. Installation 2.7 Battery Remote Temperature Sensor (RTS) Tools Needed: Adhesive Tape Procedure: For enclosures with multiple battery strings, the RTS must be located with the WARMEST battery string. This ensures proper operation of the battery charger’s temperature compensation circuit. Failure to locate the RTS with the warmest battery string could result in overcharging and premature battery failure. In this application, the RTS MUST be attached to a battery in the upper tray of the side-car. 1.
2. Installation 2.8 Service Power Inserter 1. The SPI box(es) are mounted on the shelf support bracket. 2. Remove the two screws on the face of the SPI and lift off the cover to gain access to the Seizure Screw Assembly. Loosen the seizure Screw several turns so that the stinger will pass through the clamp. (Fig 2-3) 3, Insert the Coaxial Termination into the output port on the bottom of the SPI. Ensure that the stinger goes through the Seizure Screw Assembly. Tighten the Coaxial Termination. 4.
Power ® Alpha Technologies Alpha Technologies 3767 Alpha Way Bellingham, WA 98226 USA Tel: (360) 647-2360 Fax: (360) 671-4936 Web: www.alpha.com Alpha Technologies Ltd. 4084 McConnell Court Burnaby, BC, V5A 3N7 CANADA Tel: (604) 430-1476 Fax: (604) 430-8908 Alpha Technologies Europe Ltd.
