GEM Generator Expansion Module Technical Manual Effective: April 2008 Alpha Technologies
Power Alpha Technologies ®
Generator Expansion Module (GEM) Technical Manual 745-872-C0-002, Rev. B Effective Date: April 2008 Copyright© 2008 Alpha Technologies, Inc. member of The GroupTM 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.
Table of Contents Safety Notes .......................................................................................................................... 6 1.0 Introduction ................................................................................................................. 8 2.0 Installing the GEM Enclosure ..................................................................................... 9 3.0 4.0 4 2.1 Installing the Enclosure Ground Wire ...........................................
Figures and Tables Fig. 1-1, Generator Expansion Module.................................................................................. 8 Fig. 2-1, Mounting Hole Location........................................................................................... 9 Fig. 2-2, Ground Wire Hardware Installation ........................................................................11 Fig. 2-3, Drilling Locations for Legacy Enclosures .............................................................. 14 Fig.
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 this product, 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.
General Safety Precautions To avoid injury: • This enclosure and its hardware must only be serviced by authorized personnel. • The 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.
1.0 Introduction The Generator Expansion Module (GEM) extends runtime for PWE-3 and PWE-6 pole-mount enclosures. The GEM installs to the base of a PWE enclosure, and shelters and safeguards a lightweight portable generator. Once the mounting hardware is in place, the GEM can be quickly removed or re-installed without tools.
2.0 Installing the GEM Enclosure The GEM enclosure mounts underneath existing PWE-3 pole-mounted enclosures, and provides for secure deployment of an AC generator. Tools and Materials: • • • • Drill with 3/16" and 1/4" bits Two 1/4"-20 Nylok nuts (provided) #2 Phillips screw driver 7/16" open end wrench • • • • • Rivet gun Four .188" rivets (provided) Center punch (for some enclosures) Tin Snips (for some enclosures) Tape measure (for some enclosures) 1.
2.0 Installation, continued 2. Position the bracket so both .2" half shears are equally spaced and hanging below the bottom of the enclosure. Using the mounting bracket as a template, use a 3/16" (.188") drill bit to drill two holes in each side of the enclosure wall. Rivet the bracket in place using the provided .188" rivets. Ensure equal spacing of half shears. Drill. Rivet in place. 3. Open the PWE enclosure and secure the door open. Slide the GEM into the bracket grooves.
2.0 Installation, continued 2.1 Installing the Enclosure Ground Wire 1. Slide the battery slide tray out and verify the area behind the drilling location is clear of wiring or equipment. Drill a 1/4" hole in the side of the PWE enclosure and collect metal shavings. CAUTION! Before drilling, verify the area behind is free from batteries, wiring, or equipment. Enclosure Wall 2. Slide the battery tray back in. Install the mounting hardware and ground wire as shown below.
2.0 Installation, continued 2.2 Installing the Generator Place the generator in the enclosure with its feet inside the foot recesses. Secure the generator handle with the provided safety lanyard. Safety Lanyard WARNING! The generator must be secured inside the enclosure with the supplied safety lanyard. Failure to do so could result in injury or death. 12 745-872-C0-002, Rev.
3.0 Operation Using the Line Transfer Switch (LTS) Alpha's recommended configuration of the GEM enclosure uses a line transfer switch. The LTS automatically switches the power supply's power source back to AC line on resumption of utility power. In cases of intermittent power, the LTS will alternate from generator to AC line power as available. 3.1 Installing the LTS 1. Clean the area where the Line Transfer Switch (LTS) will be installed.
3.0 Operation Using the Line Transfer Switch (LTS), continued 3.1 Installing the LTS, continued 3. If the enclosure does not have a generator door, drill a 2-1/2" hole in the side of the enclosure as shown in Fig. 2-3. Alpha recommends using a 2-1/2" Punch Kit (Alpha P/N 745-131-20) and a grommet with plug (Alpha P/N 745-131-21) with this modification. CAUTION! Before drilling, verify the areas behind the drilling locations are free from batteries, wiring, or equipment.
3.0 Operation Using the Line Transfer Switch (LTS), continued 3.1 Installing the LTS, continued 4. Route the cord into the GEM enclosure through the generator access door and connect to the generator output. Secure with the rubber grommet. Rubber Grommet 5. Connect the Primary Utility plug from the LTS into the utility outlet and plug the power supply power cord into the LTS. Power Supply Power Cord To Primary Utility Outlet To Generator NOTE: Configuration of components in PWE enclosures will vary.
3.0 Operation Using the Line Transfer Switch (LTS), continued 3.2 Operation 1. Refer to the generator's operation manual and start the generator. 2. Check operation of the power supply. Ensure input current to the power supply does not exceed the generator's rating. • Kipor (IG2000)= 12A (derated @ 1400W) • Honda (EU2000i) = 13.3A (rated @ 1600W) 3. When proper operation is verified, close the PWE and GEM enclosures.
4.0 Operation Without Line Transfer Switch The following procedure is for operating a generator in the GEM enclosure without a line transfer switch. Alpha recommends using an LTS for efficient operation of the powering system. 1. Connect a ground wire from the generator ground screw to the ground stud on the back wall of the GEM enclosure. 2. Using a 10' outdoor rated (SJW) extension cord (minimum wire gauge for 120Vac is 12AWG), connect the generator to the power supply's input line cord.
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