Radium MiniBay Enclosure Installation Manual Radium MiniBay Effective: June 2006 Alpha Technologies
Power Alpha Technologies ®
Radium MiniBay Enclosure Installation Manual 044-001-C0-003, Rev. C Effective Date: June 2006 Copyright© 2006 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 Important Safety Instructions.................................................................................................. 6 1.0 Overview and Specifications..................................................................................... 10 1.1 Standard Cordex Configurations.................................................................... 15 1.2 Enclosure Specifications................................................................................. 18 1.3 MiniBay Accessories.
List of Figures 1.0 Overview.................................................................................................................... 10 Fig. 1-1, MiniBay Cabinet.................................................................................................................................. 10 Fig. 1-2, Typical MiniBay Cabinet Configuration, with Side Chamber................................................................11 Fig. 1-3, Interior View of the MiniBay Side Chamber...................
Important Safety Instructions 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.
General Safety Precautions CAUTION! This enclosure and its associated hardware (power supply, batteries, cabling) may contain equipment, batteries or parts that have hazardous voltage or currents. To avoid injury: • This enclosure and its associated hardware must be serviced only by authorized personnel. • Enclosure must remain locked at all times, except when authorized service personnel are present.
Battery Safety Notes WARNING! Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery installation, maintenance, service and replacement must be performed only by authorized personnel. Chemical Hazards To avoid injury: • Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all metallic objects from hands and neck.
Battery Maintenance Guidelines The battery maintenance instructions listed below are for reference only. Battery manufacturer’s instructions for transportation, installation, storage or maintenance take precedence over these instructions. • To prevent damage, inspect batteries every 3 months for signs of: Battery cracking, leaking or swelling. The battery should be replaced immediately by authorized personnel using a battery of the identical type and rating. Battery cable damage.
1.0 Overview and Specifications The MiniBay’s modular design allows the flexible configuration necessary to meet a wide range of applications, including traditional and advanced hybrid fiber coax (HFC), FTTx fiber deep, Wi-Max networks, wireless outdoor base stations, wireless IP access, and bulk power. The MiniBay is comprised of a set of CSA listed assemblies that allow new agency approved configurations to be rapidly constructed.
1.0 Overview and Specifications, continued Lifting Ear Viewing Window Lockable Door Air Conditioning Unit Battery Storage Unit (lockable) Fig. 1-2, Typical MiniBay Cabinet Configuration, with Side Chamber 044-001-C0-003, Rev.
1.
1.0 Overview and Specifications, continued DC Air Conditioning Unit Air Conditioner Controller Board GFCI Convenience Outlet Insulating Material (used on front/rear doors and interior of cabinets equipped with air conditioning) Fig. 1-4, Equipment Bay Detail Door-activated Switches (tamper alarm and service light) Rectifier Shelf (Cordex 48-650W shown) Fig. 1-5, Electronic Components (typical) 044-001-C0-003, Rev.
1.0 Overview and Specifications, continued Front Service Light Equipment Rack (23" shown) 19" Rear Swing Rack GFCI Convenience Outlet Door-activated Switches (tamper alarm and service light) Front Access Circuit Breaker Distribution Center with Integrated Cordex Controller (shown) 48-1.8kW Rectifier Shelf (shown) Lockable Battery Module Fig.
1.0 Overview and Specifications, continued 1.1 Standard Cordex Configurations The Radium MiniBay may be equipped with Cordex 48-650W, 48-1kW, or 48-1.8kW AC/DC rectifiers. Previous models were equipped with RSM 48/10 AC/DC rectifiers. Due to customer requirements, the following illustrations may not resemble your model exactly. RMB DC Power & Distribution Standard Configuration #1 • • • • • • Cordex 48-650W 19" shelf with two rectifier modules with load LVD Provides 13.
1.0 Overview and Specifications, continued 1.1 Standard Cordex Configurations, continued RMB DC Power & Distribution Standard Configuration #2 • • • • • • Cordex 1.8kW 19" Shelf, with two Cordex 48-1.8kW rectifier modules Provides 37.5A @ 48VDC, N+1 Fully equipped shelf provides 7.
1.0 Overview and Specifications, continued 1.1 Standard Cordex Configurations, continued NOTE: Rack height is shown in Rack Units (RU). One RU is equal to 1.75 inches. Equipment Rack Front View Equipment Rack Side View 15.0" 20 15 Leave 1RU Space ARGUS TECHNOLOGIES P/N 020-584-20 SM 03 Front Door 10 17 RU Available for Equipment 5 19" Rear Equipment Rack (fixed) 19" Rear Equipment Rack (swing) 0 Installed in fourth hole position 2 .5" 2.0" Fig.
1.0 Overview and Specifications, continued 1.2 Enclosure Specifications Equipment Enclosure 19" or 23" wide Fixed Relay Rack tapped or with Tinnerman nuts 19" Swing Rack (tapped only) Battery Storage Unit Slide Tray, Alpha P/N 033-083-20, will hold four GNB M12V155FT batteries Weight: 195 lbs (88.
1.0 Overview and Specifications, continued 1.4 Enclosure Cooling Options NOTE: Consultation with Alpha Applications Engineering is required. Provisions must be made for adequate air flow in the cabinet, equipment total heat dissipation load inside the cabinet, equipment min/max operating temperatures, equipment over-temp fail safe shutdown capability, environmental outdoor design conditions, and battery back up run times.
1.0 Overview and Specifications, continued 1.4 Enclosure Cooling Options, continued Air Conditioner Door, 48VDC, right or left hinged: Alpha P/N 745-204-50 (R) or 745-204-51 (L) • Cooling capacity 878W dissipated at 43ºC outdoor ambient and maximum internal ambient temperature of 40ºC. • Variable speed compressor temperature control and low voltage disconnect. • Adjustable enclosure temperature set point jumper, factory set to 25ºC.
1.0 Overview and Specifications, continued 1.6 Storage Unit Cooling Options Fan, 120VAC: Alpha P/N 745-214-21 One 64CFM fan powered from 875-075-20 line cord with designated in-line 5A fuse and bimetal thermostat control. Thermostat set point is fixed to close at 29ºC and open at 19ºC. Fan, 48VDC: Alpha P/N 745-214-20 • • One 110CFM fan, turns off below 25ºC. Turns on at 25ºC and increases from 40% to 100% full speed with increased enclosure temperature from 25ºC to 45ºC.
1.0 Overview and Specifications, continued 1.
2.0 DC Air Conditioner 2.1 Overview and Theory of Operation The MiniBay DC Air Conditioner comes in 24V and 48V models and uses a brushless compressor and variable speed controller. A temperature control board varies capacity by varying compressor speed depending on the enclosure internal setpoint temperature. The compressor runs between 50% and 100% of full speed depending on the load and enclosure set point temperature.
2.0 DC Air Conditioner, continued 2.2 DC Air Conditioner Specifications Capacity: 3,000 BTU @ 110°F (43ºC) See chart below External Amb. Operating Range: -40°C (-104°F) to +50°C (+122°F) RH 13% Max Internal Amb.
2.0 DC Air Conditioner, continued 2.3 Temperature Control Board The temperature control board monitors the compressor, condenser fan, and alarm control. Its remote temperature sensors monitor compressor discharge and evaporator suction line temperature. A board-mounted temperature sensor monitors enclosure temperature. An optional remote temperature sensor can monitor a specific area in the enclosure.
2.0 DC Air Conditioner, continued 2.
2.0 DC Air Conditioner, continued 2.4 Air Conditioner Installation and Removal Allow 20 minutes for completion of procedure. Tools required: 7/16" deep-well socket and ratchet handle Removal: 1. Disconnect power to the air conditioner. 2. Disconnect input and alarm wires from the control board (see Fig. 2-2). 3. From the inside of the door, remove the 5 bolts (labeled S below) holding the shroud to the door. Remove the shroud. Remove grounding lug. 4.
2.0 DC Air Conditioner, continued 2.5 48/24VDC Power Connection Allow 20 minutes for completion of procedure. Tools required: Assorted wrenches and screwdrivers 1. Install circuit breaker mounting plate in a convenient location near the 48/24VDC source (see Fig. 2-5 below). Leave circuit breaker IN THE OFF POSITION. 2. Connect black wire leading from circuit breaker to the 48/24VDC Bus. 3. Connect the red wire to the ground/return bar. The air conditioner can be positively or negatively grounded.
2.0 DC Air Conditioner, continued 2.6 Alarm Connector 1. Set major and minor alarm jumpers to the desired position. 2. Connect yellow wire (minor) and red wire (major) to status monitoring device. Minor Alarm Jumper Shown Normaly Closed Major Alarm Jumper Shown Normaly Closed Fig. 2-6, Alarm Connections 2.7 Function Test 1. Set the 48VDC Circuit Breaker to the ON position. 2. Remove SETPOINT jumper and verify fans are running. Compressor will start after 10 second delay. 3.
2.0 DC Air Conditioner, continued 2.8 Jumpers Enclosure Temperature Setpoint Jumper Determines what temperature the system will maintain inside the enclosure. The diagram below details the start and shutdown temperatures for each setting. 104°F/40°C 40° C Maximum Internal Temp.
2.0 DC Air Conditioner, continued 2.9 DC Air Conditioner Preventative Maintenance A preventative maintenance check should be conducted on initial startup, and on a yearly basis thereafter. 1. Check that the evaporator fans, located on the inside of the door, run continuously. 2. Remove temp setpoint jumper. Make sure the compressor comes on after 10 seconds. 3. Check for proper function of the outdoor condenser fans (located under the shroud on the outside of the door).
2.0 DC Air Conditioner, continued 2.10 DC Air Conditioner Trouble Shooting ATTENTION: Contact Alpha Technical Service to determine proper diagnosis. See page 3 for contact information. 1. Check that wire connections and input voltage are correct. 2. Check the evaporator and condenser thermostat wires are not reversed. These are on the inside of the evaporator box and look like telephone jacks. The evaporator sensor is attached to the suction line inside the evaporator box.
2.0 DC Air Conditioner, continued 2.11 DC Air Conditioner Parts List Part Number 044-001-C0-003, Rev. C Description 745-289-20 48VDC, 3000BTU replacement air conditioner assembly for Radium MiniBay 745-355-20 48VDC,150CFM outdoor condenser fan with sealed connectors (qty 2 per unit) 500-074-10 48VDC,126CFM Inside Evaporator fan (qty 2 per unit) 704-713-20 48VDC, temperature control PCBA.
3.0 AC Air Conditioner IceQube AC Air Conditioner Overview, Basic Theory of Refrigeration: 1. The compressor pump draws in and compresses cool, low-pressure gas into a high pressure gas. Compression raises the boiling point of the gas. 2. The hotter, high-pressure gas passes through a coil called a condenser. A fan blows air over the coil which cools the gas into a liquid. 3. This high-pressure liquid passes through an expansion valve, where the liquid expands to boil off as a gas.
3.0 AC Air Conditioner, continued 3.1 Verifying Default Settings for the IceQube Air Conditioner Procedure: 1. Remove IceQube controller's access panel on the enclosure door shroud (2 screws). 2. Turn on the AC power. 3. Record the displayed temperature information. 4. Check the STATUS LEDs (On/Off/Blink): • • • • COOL - On if temperature is above 70ºF HEAT - On if temperature is below 32ºF ALM - Contact Alpha FILT - Turn off filter alarm (if on) and clean filter if needed 5.
3.0, AC Air Conditioner, continued 3.2 AC Air Conditioner Specifications Specifications 36 Capacity 5000 BTUH (sensible) @ 43ºC ambient Maximum Operating Temperature 125º F Electrical 8.7A @ 120VAC/60HZ maximum 4.3A @ 230VAC/60HZ maximum 4.
3.0 AC Air Conditioner, continued 3.3 AC Air Conditioner Condensate Hose Mounting The MiniBay AC air conditioner comes with a condensate hose that must be secured to the mounting pad. The hose may be run out the front or back of the pad, and should extend three inches from the edge. Tools Required: • • Rotary Hammer Drill with 1/4" bit Hammer Procedure: 1. Locate the hose hardware kit (packaged with the battery cable kits). 2. Extend the hose out in the desired direction and position brackets. 3.
3.0 AC Air Conditioner, continued 3.4 AC Air Conditioner Preventative Maintenance Inspect the systems filters for replacement or cleaning every six months, depending on time of year or environment. Clean the filters by back flushing with water in the direction indicated and reinstall the filter. See page 3 for contact information. NOTE: Some environments may require more frequent inspections to maintain optimum airflow. 3.
4.0 Site Preparation 4.1 Site Selection Considerations: • Where possible, select a site above the 100-year flood plain, and away from houses. • Place in a shaded location to minimize the effects of solar loading. • Locate in an area where airflow can be maximized. • Avoid locating the enclosure where it is an obstruction and would inhibit visibility. • Locate the enclosure away from sprinkler systems or other sources of forced water.
4.0 Site Preparation, continued 4.2 Precast Pads The type of enclosure mounting pad is determined by the size of the enclosure (single bay, single bay with side chamber, dual bay, dual bay with single side chamber, and dual bay with dual side chambers). Typically, Alpha Technologies recommends using precast polymer mounting pads. These pads are designed for proper cabinet support and ease of installation.
4.0 Site Preparation, continued 4.2 Precast Pads , continued 54.5" 42.5" 29.88" 28.62" 27.75" 26.48" SYMM. ENCLOSURE OUTLINE REFERENCE A A 2 .12" Sweep Openings 44.0" FRONT OF RAD-MB SC 2.0" FAR SIDE SYMM. Side Chamber RAD-MB Front of Pad .000" 1.26" A 2.12" 4. 8" A B .0" MIN. 25.82" 24.91" 0.91" .000" 2.74" 8.69" 14.59" 20.59" 8.12" Front of Pad Fig. 4-3, Precast Pad Dimensions for Single Enclosure with Side Chamber (P/N 641-114-10) 044-001-C0-003, Rev.
4.0 Site Preparation, continued 4.3 Pour-in-place Concrete Pads Pad Frame Templates NOTE: The illustrations below show the overall size of the pad frame template for a single MiniBay enclosure. The actual outer dimensions of the pad will be determined by the customer’s requirements. When placing the pad, allow at least 36 inches of clearance for the front and rear doors to open fully. 29.25" Front Rear 25.00" Ref. Front Rear 25.82" 4.0" (2 places) 4.0" (2 places) Fig.
4.0 Site Preparation, continued 4.3 Pour-in-place Concrete Pads, continued Pad Frame Templates The illustration below shows the various components of the optional modular pourin-place pad template for a dual-cabinet application. Use template to easily and accurately locate the open area for the AC service and TSC conduit as well as the threaded inserts to which the cabinet is attached. Base Pad Frame Template (P/N 604-0 9-N1) Side Chamber Conduit Locator P/N 745- -20 Fig.
4.0 Site Preparation, continued 4.3 Pour-in-Place Concrete Pads, continued Pad Frame Templates Figure 4-7 (below) provides the necessary dimensions to layout and pour a concrete pad on site. 5-3/4" 2 PL 12-1/2" 2 PL 0" FRONT OF PAD 4-1/8" 2-1/8" 2 PL 7/8" 2 PL 2 PL 2-1/8" SWEEP OPENING see Section 4.0 Note 1-3/8" 32" 1- /8" 12-1/2" 7/8" 2 PL 2-1/8" 2 PL 24-1/8" ROUND HOLES USED WITH TEMPLATE OBROUNDS USED FOR STUD MOUNTING 30" 7/8" 2 PL SWEEP OPENING see Section 4.
4.0 Site Preparation, continued 4.4 Site Configuration Figure 4-9 (below) shows the cable conduit route into the side chamber. Front of Enclosure C B A PRE-CAST PAD D E A Precast Polymer Pad B Compacted Gravel (12" depth recommended C Level Grade D Area of Backfilled Soil E Trench for Sweep (sweep enters back of cabinet) Fig.
4.0 Site Preparation, continued 4.4 Site Configuration, continued Figure 4-10 (below) shows the cable conduit route into the back of the enclosure. Back C B Front A PRE-CAST PAD D E A Precast Polymer Pad B Compacted Gravel (12" depth recommended C Level Grade D Area of Backfilled Soil E Trench for Sweep (sweep enters back of cabinet) Fig.
4.0 Site Preparation, continued 4.5 Enclosure Grounding NOTE: Alpha Technologies recommends using the grounding method illustrated below. The grounding method for a particular site is dependant upon soil type, available space, local codes, NEC (National Electric Code), and other site-specific characteristics. NOTE: It is the responsibility of the installer to ensure the requirements of all applicable national and local codes are met.
5.0 Installation This section describes the procedures for installing the enclosure and preparing it for turn-up and test. The procedures are comprised of the following steps: • Cabinet installation • Battery installation and connection • Utility power connection Before installation verify the following: • All necessary grounding rods and materials are in place. • Utility power is onsite in accordance with NEC (National Electric Code).
5.0 Installation, continued 5.1 Lifting The enclosure is shipped from Alpha Technologies bolted to a wooden pallet. Follow the procedure below for lifting and positioning the unit. NOTE: Remove the lifting ears after installation. The ears are made of steel and may rust over time. Installation Procedure: 1. Unbolt the enclosure from the pallet. The bolts fastening the enclosure to the pallet are located in the feet of the rack/rail assembly.
5.0 Installation, continued 5.1 Lifting, continued NOTE: Verify the length of the cable between the lifting ears and the lifting hook is at least twice the distance between the lifting plates and that the lifting angle of the chain is greater than or equal to 60 degrees. 5. Lift the enclosure off of the truck using a winch capable of supporting approximately 500 lb. (227kg). 6. Verify all cabling passing through the enclosure is bundled and maintained within the cutout area. 7.
5.0 Installation, continued 5.2 Special Instructions for Double-wide Installation When installing two MiniBay enclosures side-by-side, the units should be lifted independently as shown in section 5.1. Position the first unit and remove the lifting ears. Apply gasket material supplied in gasket kit, Alpha P/N 745-361-20. The gasket material should be in place before positioning the second unit in order to maintain 3R rainproof integrity (see Fig. 5-4).
5.0 Installation, continued 5.3 Battery Connection Battery Identification Each battery contains a DATE CODE usually located on a sticker near the center of the battery or stamped in white ink near the POS terminal. This date code must be recorded in the battery’s maintenance log. If batteries other than those installed by Alpha are used, consult the battery’s manufacturers’ documentation for date code type and placement.
5.0 Installation, continued 5.4 Connecting to Utility Power ATTENTION: Verify electrical codes prior to installation. Codes may vary and contain specific conduit and wire sizes for connection to the load center. Connection to utility power must be approved by the local utility before installing the power supply. Connection Procedure: 1. Locate the service entrance panel on the enclosure. Remove the cover to access the circuit breaker assembly.
5.0 Installation, continued 5.
Appendix A CSA Marks ® NRTL/C CSA International (CSA) was established in 1919 as an independent testing laboratory in Canada. In 1994, OSHA granted CSA Nationally Recognized Testing Laboratory (NRTL) status in the United States of America. This was extended in 1999. When these marks appear with the indicator “C and US” or “NRTL/C” it means that the product is certified for both the U.S. and Canadian markets to the applicable U.S. and Canadian standards.
Power Alpha Technologies ® Alpha Technologies 3767 Alpha Way Bellingham, WA 98226 USA Tel: +1 360 647 2360 Fax: +1 360 671 4936 Web: www.alpha.com Alpha Technologies Ltd. 4084 McConnell Court Burnaby, BC, V5A 3N7 CANADA Tel: +1 604 430 1476 Fax: +1 604 430 8908 Alpha Technologies Europe Ltd.
