Wireless Transport Enclosure (wte) Technical Manual

Transcript

Wireless Transport Enclosure (WTE) Technical Manual Effective: December 2009 Alpha Technologies Power Alpha Technologies ® Wireless Transport Enclosure (WTE) Technical Manual 021-517-B0-001, Rev. A Effective Date: December 2009 Copyright© 2009 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. 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. Contacting Alpha Technologies: www.alpha.com or For general product information and customer service (7 AM to 5 PM, Pacific Time) call, 1-800-863-3930 For complete technical support, call 1-800-863-3364 7 AM to 5 PM, Pacific Time or 24/7 emergency support 021-517-B0-001, Rev. A 3 Contents Important Safety Instructions................................................................................................. 6 Battery Safety Notes.............................................................................................................. 8 Chemical Hazards.................................................................................................................. 8 Battery Maintenance Guidelines............................................................................................ 9 Recycling and Disposal.......................................................................................................... 9 Electrical Safety..................................................................................................................... 9 Mechanical Safety.................................................................................................................. 9 1.0 Overview.................................................................................................................... 10 1.1 Introduction .................................................................................................... 10 1.2 Enclosure Specifications................................................................................. 12 1.3 Accessories..................................................................................................... 12 1.4 Equipment Section Cooling System............................................................... 13 1.4.1 Heat Exchanger Shut-down/Start-Up Sequence................................. 13 1.4.2 Recommended Maintenance and Operational Notes.......................... 14 1.5 Battery Section Cooling/Heating System........................................................ 15 1.5.1 Cooler Shut-down/Start-Up Sequence................................................. 15 1.5.2 Recommended Maintenance and Operational Notes.......................... 16 2.0 3.0 Site Preparation......................................................................................................... 17 2.1 Site Selection.................................................................................................. 17 2.2 Precast Pad.................................................................................................... 18 2.3 Sweep Openings............................................................................................ 19 2.4 Cable Sweep Sealing..................................................................................... 19 2.5 Site Arrangement............................................................................................ 20 2.6 Enclosure Grounding...................................................................................... 21 Installation................................................................................................................. 22 3.1 Plinth Installation . .......................................................................................... 23 3.2 Installing the Cabinet ..................................................................................... 24 3.3 Connecting to Utility Power............................................................................. 26 3.4 Thermal Electric Cooler (TEC) Condensate Hose Mounting ......................... 29 3.5 Initial Turn Up — Placing the unit in Service................................................... 29 Appendix A, Agency Compliance......................................................................................... 30 Appendix B, Connecting Auxiliary Generator....................................................................... 31 4 021-517-B0-001, Rev. A Figures Fig. 1-1, Exterior view........................................................................................................... 10 Fig. 1-2, Interior view.............................................................................................................11 Fig. 2-1, Precast Pad Dimensions........................................................................................ 18 Fig. 2-2, Representative view, cross-section, Precast Pad.................................................. 18 Fig. 2-3, Sweep Routing options.......................................................................................... 19 Fig. 2-4, Representative Site Arrangement.......................................................................... 20 Fig. 2-5, Suggested Grounding Method............................................................................... 21 Fig. 3-1, Placement of Plinth, Corrosion Barrier on Pad...................................................... 23 Fig. 3-2, Placing Enclosure onto Preinstalled Plinth and Pad.............................................. 25 Fig. 3-3, Load Center Wiring................................................................................................ 27 Fig. 3-4, System Schematic................................................................................................. 28 Fig. 3-5, Condensate Hose Mounting................................................................................... 29 Fig. App-1, Auxiliary Generator Connection......................................................................... 31 021-517-B0-001, Rev. A 5 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. Where these symbols appear, use extra care and attention. Symbols in this Manual ATTENTION: The use of ATTENTION indicates regulatory/code requirements that may affect the placement of equipment or installation procedures. NOTE: A NOTE provides additional information to help complete a specific task or procedure. CAUTION! A CAUTION presents safety information to PREVENT DAMAGED EQUIPMENT. WARNING! A WARNING presents safety information to PREVENT INJURY OR DEATH to the technician/user. ATTENTION: Alpha Technologies’ products are subject to change through continual improvement processes. Therefore, specifications or design layouts may vary slightly from the descriptions included in this manual. Updates to the manual are issued when changes affect form, fit or function. The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment. 6 021-517-B0-001, Rev. A 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. • 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. • Use proper lifting techniques whenever handling enclosure, equipment, parts, or batteries. • Batteries contain dangerous voltages, currents and corrosive material. Battery installation, maintenance, service and replacement must be performed by authorized personnel only. • Never use uninsulated tools or other conductive materials when installing, maintaining, servicing or replacing batteries. • Use special caution when connecting or adjusting battery cabling. Battery cables that are either improperly or unconnected can result in arcing, a fire, or possible explosion. • A battery that shows signs of cracking, leaking or swelling must be replaced immediately by authorized personnel using a battery of identical type and rating. • Avoid any contact with gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery. Emissions contain dilute sulfuric acid which is harmful to the skin and eyes. Emissions are electrolytic, which are electrically conductive and are corrosive. Follow the Chemical Hazards notes if contact occurs. • Do not smoke or introduce sparks in the vicinity of a battery. • Under certain overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas that is explosive. Proper venting of the enclosure is required. • Follow the battery manufacturer’s approved transportation and storage instructions. CAUTION! Enclosure, equipment or parts may be damaged or cause damage if used or installed improperly. To avoid damage: • Prior to installation, verify that the AC input voltage to the enclosure and its equipment match with respect to voltage and frequency. • Prior to installation, verify that the output voltage from the enclosure or its equipment match the voltage requirements of the connected equipment (load). • Prior to installation, verify that the enclosure’s utility service panel is equipped with a properly rated circuit breaker for use with the equipment inside. Refer to manufacturer’s recommendations. • Review and upgrade utility service panel circuit breaker requirements whenever the equipment within the enclosure is changed. • Prior to installation, contact local utilities, local building maintenance departments, and cable/piping locator services to ensure that installation will not interfere with existing utility or building cables/piping. • Do not exceed the output rating of equipment. Verify load requirements prior and during connection process. • Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have developed in your body. 021-517-B0-001, Rev. A 7 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. • Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel knowledgeable of batteries and the required safety precautions. • All 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. • Batteries produce explosive gases. Keep all open flames and sparks away from batteries. • Use tools with insulated handles, do not place 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) • Wear protective clothing (insulated gloves, eye protection, etc.) whenever installing, maintaining, servicing, or replacing batteries. • 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 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. • Do not charge batteries in a sealed container. Each individual battery should have at least 0.5 inches of space between it and all surrounding surfaces to allow for convection cooling. • All battery compartments must have adequate ventilation to prevent an accumulation of potentially dangerous gas. • Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have developed on your body. • Never use uninsulated tools or other conductive materials when installing, maintaining, servicing or replacing batteries. • Use special caution when connecting or adjusting battery cabling. An improperly connected battery cable or an unconnected battery cable can make contact with an unintended surface that can result in arcing, fire, or 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. • Under extreme overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas which is explosive. • All battery compartments must have adequate ventilation to prevent accumulation of potentially dangerous gas. Ventilation should prevent trapped hydrogen gas pockets from exceeding a one percent concentration as per regulation 70E of the National Fire Protection Agency (NFPA). 8 021-517-B0-001, Rev. A 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. Battery cable should be replaced immediately by authorized personnel using replacement parts specified by vendor. Loose battery connection hardware. Refer to battery manufacturer’s documentation for the correct torque and connection hardware for the application. Apply battery manufacturer’s specified antioxidant compound on all exposed connections. Verify battery terminals and/or exposed connection hardware is not within two inches of a conductive surface. Reposition batteries as necessary to maintain adequate clearance. Clean up any electrolyte (battery emission) in accordance with all federal, state, and local regulations or codes. Proper venting of the enclosure is recommended. Follow the Battery Manufacturer’s approved transportation and storage instructions. Always replace batteries with those of an identical type and rating. Never install old or untested batteries. Do not charge batteries in a sealed container. Each individual battery should have at least 0.5 inches of space between it and all surrounding surfaces to allow for convection cooling. All battery compartments must have adequate ventilation to prevent an accumulation of potentially dangerous gas. Recycling and Disposal Instructions Spent or damaged batteries are considered environmentally unsafe. Always recycle used batteries or dispose of the batteries in accordance with all federal, state and local regulations. Electrical Safety • • • • • • Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical connection or conductor is not energized. Check the circuit with a volt meter with respect to the grounded portion of the enclosure (both AC and DC) prior to any installation or removal procedure. Always use the buddy system when working under hazardous conditions. A licensed electrician is required to install permanently wired equipment. Input voltages can range up to 240Vac. Ensure that utility power is disabled before beginning installation or removal. Ensure no liquids or wet clothes contact internal components. Hazardous electrically live parts inside this unit are energized from batteries even when the AC input power is disconnected. Mechanical Safety • • • Keep hands and tools clear of fans. Fans are thermostatically controlled and will turn on automatically. Power supplies can reach extreme temperatures under load. Use caution around sheet metal components and sharp edges. 021-517-B0-001, Rev. A 9 1.0 Overview 1.1 Introduction The Wireless Transport Enclosure (WTE) offers a self-contained total power solution for a wide range of applications including wireless outdoor base stations, wireless IP access and bulk power. With a compact 24” x 24” footprint, the WTE features a standard 19" rack mount system which has 17RU (front/rear) of rack space, and an internal Breaker Distribution Panel with GFCI and Surge Protection. Its two compartments share a common door keeping batteries and electronics isolated in operation, but quickly and easily accessible for set-up, maintenance or repairs. Thermal management is provided by a doormounted 48Vdc heat exchanger for the equipment area and a 48Vdc Thermoelectric cooling/heating unit for the battery area. The available 6" Plinth system is well-suited for staged installations, and an internal L14-30P generator inlet plug enables connection with a portable AC generator for backup powering capability. 1 1 48Vdc Heat Exchanger (Alpha p/n 040-017-10) 2 Equipment area 3 48Vdc Thermoelectric Cooling/Heating Unit (Alpha p/n 040-016-10) 4 Battery Area 5 6" Plinth 2 3 4 5 Fig. 1-1, Exterior view 10 021-517-B0-001, Rev. A 1.0 Overview 1.1 Introduction, continued 1 2 10 3 2 4 5 6 9 7 6 8 1 Enclosure light (door switch activated) 6 Battery Shelves 2 Equipment mounting rack 7 Aux Generator Connector L14-30P 3 DBX 8 Space load center 8 Access port for Aux Gen cable 4 Door switches for service lighting and Intrusion alarm 9 48Vdc Thermoelectric Cooling/Heating Unit Insulated Battery area 10 48Vdc Heat Exchanger 5 Fig. 1-2, Interior view 021-517-B0-001, Rev. A 11 1.0 Overview 1.2 Enclosure Specifications Mechanical Weight: 330 lbs (150kg) Dimensions (in/mm): 64H x 24W x 24D (1626 x 610 x 610) Material: High Strength Corrosion Resistant Aluminum Finish: Almond Color Powdercoat Finish Battery Storage Area Two shelves Optional 6" Plinth Alpha P/N 746-080-20 Dimensions (in/mm): 6H x 24W x 24D (152 x 610 x 610) 1.3 Accessories Description Precast Polymer Concrete Pad Pour-in-place Pad Drawing 12 Part Number P/N 641-131-10 TBD Field Installed Right to Left door mounting kit P/N 746-079-20 Concrete-to-Aluminum Corrosion Barrier MSTCD, 3/6" RBR, WTE P/N 648-173-10 Kit. Plinth, 6"T, WTE, 24" x 24" P/N 746-080-20 Touch-up Spray Paint, Almond P/N 972-056-10 Pad Mounting Hardware Kit (4 Hilti KBII sleeve anchors 1/2 x 3-3/4); for pour-in-place pads P/N 745-592-21 Pad Mounting Hardware (4 Hilti HSLG M12/0 *60 heavy duty sleeve anchors) requires 12mm metric drill Kit for Zone 4; for pour-in-place pads P/N 745-592-20 021-517-B0-001, Rev. A 1.0 Overview 1.4 Equipment Section Cooling System Model Alpha Part Number McLean TX33 Heat Exchanger (Almond) 040-017-10 Specifications Cooling capacity 50W/deg C Cooling @ 65° C/149° F Ambient Nominal Voltage 48Vdc (32-60Vdc) FLA (Full Load Amperage) 1.8 Input Power Protection Required 5A Circuit Breaker or Fuse Max Temp 65°C / 150°F 1.4.1 Heat Exchanger Shut-down/Start-Up Sequence WARNING! This procedure MUST be followed to minimize damage to the input power connectors due to arcing resulting from hot-swapping the connectors. 1. Turn off circuit breaker or remove fuse before disconnecting or reconnecting input power connector. 2. Service unit as necessary. 3. Remake input power connections. 4. Close circuit breaker/fuse to reapply power to unit. 5. Once power is applied, the unit will initiate its start-up sequence where the LEDs will flash Red and Green and alarm contacts will open and close. At the end of a successful start-up sequence, the LEDs will be lit Green and the alarm contacts should indicate No Alarm. 021-517-B0-001, Rev. A 13 1.0 Overview 1.4.2 Recommended Maintenance and Operational Notes Yearly: Visual inspection of air intakes is recommended. Remove any obstructions and use compressed air to clean heatsink. As needed: Fan Replacement Procedure: 1. 2. 3. 4. 5. 6. Follow shutdown procedure in 1.4.1 and lock-out power as required. Use a Torx T-25 bit to remove security screws on the external fan cover. Remove cover and set aside. Replace fan. Reinstall cover. Reapply power and return unit to service. General Operation: Enclosure fans: Operate at low speed from -40°C to 20°C (-40°F to 68°F), then ramp linearly up to full speed at 50°C (122°F). Above 50°C (122°F), control is released and ambient fan runs at maximum speed. Maximum speed is a function of load and voltage Ambient fans: OFF below 18°C (64.4°F). At 20°C (68°F) it turns on and ramps linearly up to full speed at 50°C (122°F). Above 50°C (122°F), control is released and ambient fan runs at maximum speed. Maximum speed is a function of load and voltage. Temperature Alarms Hi temp alarm is 70°C (158°F) Low temp alarm is -20°C (-4°F) If the onboard temperature sensor fails, control to the impellers will be released and the impellers will run to their maximum speeds. Maximum impeller speed may be limited during low voltage input Miscellaneous: Quick test / Reset push button switch. Functions tested include: LEDs, customer alarm outputs, enclosure fan, and ambient fan using the following sequence. Press button until LEDs flash Red to start sequence. LED test; 4 seconds. All LEDs blink Red/Green/Red/Green, all customer outputs will alternate LOW/ HIGH, 1 second each. Begin all fans spin-down period of 26 seconds. The ambient fan will spin up to maximum. If the ambient fan is not running in excess of 2000 RPM the ambient fan alarm LED and output will remain Red/HIGH. If the fan does exceed this limit the alarm LED and Output will clear to Green/LOW. LED and Output Green/LOW by the end of this test step indicate acceptable performance. 30 seconds. Ambient fan spins down, and enclosure fan spins up to maximum. If the enclosure fan is not running in excess of 2000 RPM the enclosure fan alarm LED and Output will remain Red/ HIGH. If the enclosure fan does exceed this limit the alarm LED and Output will clear to Green/LOW. LED and Output Green/LOW by the end of this test step indicates acceptable performance. 30 seconds. Operational parameters are reset and normal operation is resumed. Total test time is approximately 90 seconds. See Mclean Manual for more information on operation and trouble shooting. 14 021-517-B0-001, Rev. A 1.0 Overview 1.5 Battery Section Cooling/Heating System Model Alpha Part Number McLean TE16 Thermal Electric Cooler/Heater (Almond) 040-016-10 Specifications Nominal Cooling capacity 130W @ ΔT= 0t (Internal and external air entering unit at the same temperature) Heating mode capacity 80W Nominal Voltage 48Vdc (42 to 60Vdc) FLA (Full Load Amperage) 9.5 amps Input Power Protection Required 15A Circuit Breaker* or Fuse Temperature Range (external ambient) -40°F to 131°F (-40°C to +55°C) Temperature Range (internal enclosure) -4°F to 131°F (-20°C to +55°C) Cooling set point 25° C (77°F) Cooling alarm 40° C (104°F) Heating set point 5° C (41°F) Heating Alarm -5° C (23°F) * The use of a circuit breaker is recommended for ease of service 1.5.1 Cooler Shut-down/Start-Up Sequence WARNING! This procedure MUST be followed to minimize damage to the input power connectors due to arcing resulting from hot-swapping the connectors. 1. Turn off circuit breaker or remove fuse before disconnecting or reconnecting input power connector. 2. Service unit as necessary. 3. Remake input power connections. 4. Close circuit breaker/fuse to reapply power to unit. 5. Once power is applied, the unit will initiate its start-up sequence where the LEDs will flash Red and Green and alarm contacts will open and close. At the end of a successful start-up sequence, the LEDs will be lit Green and the alarm contacts should indicate No Alarm. 021-517-B0-001, Rev. A 15 1.0 Overview 1.5.2 Recommended Maintenance and Operational Notes Yearly: Visual inspection of air intakes is recommended. Remove any obstructions and use compressed air to clean heatsink. As needed: Fan Replacement Procedure: 1. 2. 3. 4. 5. 6. Follow shutdown procedure in 1.5.1 and lock-out power as required. Use a Torx T-25 bit to remove security screws on the external fan cover. Remove cover and set aside. Replace fan. Reinstall cover. Reapply power and return unit to service. NOTE: If a rain hood is used is used with the cooler, the cooling unit must be removed from the door in order to remove the fan cover. General Operation: Internal blower runs at low speed between cooling and heating set points then ramps linearly up to full speed as temp moves away from set points. External fans shut off when external heat sink is at or below normal ambient. Fans then ramp linearly up to full speed as external heat sink increases. Miscellaneous: Green LEDs indicate normal operation. Red LEDs indicate alarm condition. When unit is initially powered up, LEDs will flash on/off through a start up sequence and then normalize with green LED indication.When internal temperature is changed above or below the set point the unit may take up to 50 seconds to react and then up to a minute to go to full operation depending on a stable internal temperature. 16 See Mclean Manual for more information on operation and trouble shooting 021-517-B0-001, Rev. A 2.0 Site Preparation 2.1 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. • Locate the enclosure out of the prevailing wind to minimize the buildup of snow or the accumulation of wind-borne dust. • Evaluate the soil conditions for suitability for the installation of the required grounding system applicable to your particular installation. • Ensure cabling has been run and terminated at the site. • Decide whether the enclosure will be placed on a precast concrete pad or on a pad poured on site. • An enclosure with both front and rear doors is required for batteries with terminals located on top. Allow for at least 36" of front and rear clearance so the door(s) may be opened adequately for servicing. • Contact a cable locating service, the local utility, and adjacent building supervisors to ensure installation location and cable routing does not interfere with existing utility connections. NOTE: Prior to paving the pad or placing cables and conduit, familiarize yourself with the location of the conduit seals. The pad should include a rectangular sweep opening filled with drain rock to allow cables and conduit to be maneuvered into position to enter the seals. 021-517-B0-001, Rev. A 17 2.0 Site Preparation 2.2 Precast Pad The type of enclosure mounting pad is determined by the size of the enclosure. Typically, Alpha Technologies recommends using precast polymer mounting pads. These pads are designed for proper cabinet support and ease of installation. Drilling areas for openings are indicated for coax and service sweeps, and pre-installed threaded inserts for enclosure attachment. 24.00 Ref. 21.00 Ref. 36.0 34.0 34.0 [+0.13/-0.00] 28.50 27.0 26.62 21.00 15.00 14.00 13.88 24.00 Ref. 21.00 Ref. 25.063 24.06 22.12 22.00 11.94 10.938 9.38 9.00 7.50 6.00 [+0.00/-0.13] 2.00 38.00 36.00 31.0 [+0.13/-0.00] 29.50 24.90 23.875 14.125 8.50 8.00 [2plcs] 7.00 [+0.00/-0.13] 0 2.00 13.13 [3 plcs] Front of Pad 0 Fig. 2-1, Precast Pad Dimensions (in inches) for Single Enclosure (P/N 641-131-10) 3.0" Fig. 2-2, Representative cross-section of precast pad (P/N 641-131-10) 18 021-517-B0-001, Rev. A 2.0 Site Preparation 2.3 Sweep Openings The opening in the precast pad allows for a number of options for the actual routing of cabling. Sweep routing options through precast pad Front of Pad Fig. 2-3, Sweep routing options 2.4 Cable Sweep Sealing Input and Output cable sweeps are sealed by means of 3MTM Moldable Fire Barrier Putty+ (Lower battery tray has been moved aside for this procedure). 1. Fire Barrier Putty and gloves 2. Divide Fire Barrier Putty in half 4. Pack Putty into opening 021-517-B0-001, Rev. A 3. Wrap putty around cabling 5. Completed seal 19 2.0 Site Preparation 2.5 Site Arrangement The illustration below shows a representative view of the installation site. 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 can enter at back and/or front of cabinet) Fig. 2-4, Representative Site Arrangement NOTE: Verify the conduit is trimmed to an appropriate height to accommodate the use of the plinth. 20 021-517-B0-001, Rev. A 2.0 Site Preparation 2.6 Enclosure Grounding NOTE: • • • Alpha generally recommends using the grounding method illustrated below. However, the grounding method appropriate for a particular site depends on local codes, the NEC (National Electric Code), and other site-specific characteristics. Alpha Technologies recommends 5 ohms minimum ground resistance between enclosure and ground rods, in accordance with IEEE 1100-1999 Powering and Grounding Electronic Equipment. Alpha Technologies assumes no responsibility or liability for failure of the installer to comply with the requirements of all applicable local and national codes. Where allowed, exothermic welding may be used as an alternative to Burndy clamps and connectors. CAUTION! Corrosion-proof, twenty-five-year connections suitable for direct burial must be used. Terminate at Enclosure Ground Point Burndy YGHP58C2W-2TN or Equivalent Burndy YGHP58C2W-3 or Equivalent 1 3 1 Fro nt 2' (m of inimu m) Pa 1 d 2 1 Fig. 2-5, Suggested Grounding Method Site Service Grounding (Minimum Requirement) Low-impedance earth protection from cabinet to earth potential (lightning/transient protection) is provided by #6 bare copper wire connecting enclosure ground point and site grounding system. The site grounding system, at a minimum, must be comprised of two ground rods 1/2" diameter x 8' in length driven into the ground at least 6' apart. Lightning Protection Ground Ring (Recommended installation) 1 Four 1/2" X 8' copper ground rods, driven at least two feet from pad. 2 #6 bare copper wire ring, at least 30" below grade, and terminated at each ground rod. 3 #6 bare copper wire from ring to enclosure ground point. 021-517-B0-001, Rev. A 21 3.0 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: • Plinth Installation • 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 on site in accordance with NEC (National Electric Code). • Review and comply with all local safety practices for working with high-voltage systems. • All necessary permits and permissions are granted. • The lifting/transport path is free of obstructions. To perform the installation procedures, the installer(s) needs to have the following tools and materials on hand: • Crane to lift enclosure from shipping pallet and place on pedestal • Key to enclosure doors (P/N 964-022-10 ­— Pin Allen type) • Digital RMS voltmeter • Torque wrench with insulated handle and 7/16" socket and 3/4" socket • Standard ratchet for 3/4" socket • 7/16" box-end wrench • NO-OX or other suitable corrosion inhibiting agent • Battery Cabling Kit CAUTION! The enclosure MUST be loosened from the pallet BEFORE lifting the enclosure from the truck and placing it on the pad. Problems such as broken welds, corrosion, etc., resulting from improper installation are not covered under warranty. 22 021-517-B0-001, Rev. A 3.0 Installation 3.1 Plinth Installation The Plinth can be installed either ahead of the enclosure installation or at the same time the enclosure is installed. The plinth is separated from the pad by a concrete-to-aluminum corrosion barrier and affixed to the pad by four 1/2" stainless bolts tightened to 50ft•lbs. At this time input and output cabling can be routed through the plinth in preparation for the installation of the enclosure. 6" x 24" x 24" Plinth Kit (optional) Alpha p/n 746-080-20 Fro nt of Pa d Concrete-to-Aluminum Corrosion Barrier Alpha p/n 648-173-10 Fro nt Precast Polymer Concrete Pad Alpha p/n 641-131-10 of Pa d Fig.3-1, Placement of Plinth and Corrosion Barrier on Enclosure on Pad 021-517-B0-001, Rev. A 23 3.0 Installation 3.2 Installing the Cabinet The enclosure is shipped from Alpha Technologies bolted to a wooden pallet. Follow the procedure below for lifting and positioning the unit. Installation Procedure: 1. Unbolt the enclosure from the pallet (4 pl). The bolts fastening the enclosure to the pallet are located at the front and rear corners of the enclosure. Follow the steps below to free the enclosure from the pallet. a.) Open enclosure front door and remove the two bolts located in the front corners. b.) Close and latch front door. If front door is open when the rear bolts are removed, the cabinet can tip over. c.) Open enclosure rear door and remove the two bolts located in the rear corners. 2. Position the corrosion inhibiting barrier material (Concrete-to-Aluminum Corrosion Barrier MSTCD, 3/6" RBR, WTE, Alpha P/N 648-173-10) between the enclosure or plinth and the pad and make all necessary cutouts. WARNING! Do not allow personnel to walk beneath the suspended unit during the lifting operation. Use steel-toe work shoe protection. Use “hard hats” at all times during this procedure. CAUTION! Do not lift the enclosure with the batteries in place. 3. Refer to Fig. 3-2 for the following. Attach the lifting chain to the lifting ears located in the top of the enclosure. Verify the adjustable chain links are tightened securely. Also verify the length of the cable between the lifting ears and the lifting hook (2d) is at least twice the distance (d) between the lifting ears, and that the lifting angle of the chain is greater than or equal to 60 degrees. 4. Lift the enclosure off of the truck using a winch capable of supporting approximately 330 lb. (150kg). 5. Verify all cabling passing through the enclosure is bundled and maintained within the cutout area. 6. Position the enclosure above the concrete pad and slowly lower it into position over the pad’s 1/2" anchor, J-bolts or threaded inserts. Verify the corrosion inhibiting barrier is in place between the enclosure and the pad (Concrete-to-Aluminum Corrosion Barrier MSTCD, 3/6" RBR, WTE, Alpha P/N 648-173-10). NOTE: To prevent damage, enclosures must be mounted flush with a smooth surface and not over-torqued. The enclosure must be bolted down to a completely flat surface. If the concrete pad is uneven or has bumps, cracks, or other imperfections, the installer is responsible for correcting these defects prior to installing the enclosure. 7. Perform steps 1a, 1b, and 1c in reverse order to secure the enclosure using stainless flat washers, lock washers and 1/2" nuts (or bolts for precst pad) at each mounting location and torque to 50 ft-lbs. 8. Seal cable pass through with the 3MTM Moldable Fire Barrier Putty+ , ref. Section 2.4, "Cable Sweep Sealing". 9. Upon completion of installation, remove or invert and secure the lifting ears. 24 021-517-B0-001, Rev. A 3.0 Installation Installing the Cabinet, continued DX2 3.2 D Fro nt of Pa d Fig.3-2, Placing Enclosure onto Preinstalled Plinth and pad 021-517-B0-001, Rev. A 25 3.0 Installation 3.3 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. WARNING! Verify power is locked out and tagged prior to starting this procedure. Connection Procedure: 1. Verify all upstream and downstream circuit breakers are open and no power is present on the input cabling. 2. Locate the power distribution panel on the enclosure. Remove the cover to access the circuit breaker assembly. NOTE: Input power wiring (#10 AWG minimum) to be 120/240 3W+ P/E and labeled appropriately (L1, L2, N, G). 3. Locate 3/4" flex conduit in plinth or base access area. 4. Use pull tape to feed utility cabling into enclosure and up to power distribution panel. 5. Locate terminals for L1, L2, N, and G. make appropriate connections of the #10AWG (minimum gauge) wires to per Figures 3-3, and 3-4. 26 021-517-B0-001, Rev. A 3.0 Installation 3.3 Connecting to Utility Power, continued Spare 120/240Vac Surge protector 240Vac customer-installed Rectifier 1, Modules 1 & 2 Ground bar 240Vac customer-installed Rectifier 2, Modules 3 & 4 120Vac GFCI 240Vac generator input 240Vac Main input Enclosure Ground Input Power Ground Generator Inlet Ground Low-impedance Earth Ground Fig.3-3, Load Center Wiring 021-517-B0-001, Rev. A 27 3.0 Installation Connecting to Utility Power, continued EQUIPMENT ENCLOSURE 874-530-20 Hinged Door FLORESCENT LAMP SURGE PROTECTOR 875-077-21 Optional Ground Bar Location GND Neutral 8b 8 8a 15A 7b 7 7a 15A 6b 6 6a 15A 5b 5 5a 15A 120/240Vac Surge Protector 15A 240Vac Customer Installed Rect 1, Mod 1&2 15A 240Vac Customer Installed Rect 2, Mod 3&4 120Vac GFCI Outlet 15A 4 3 240Vac Generator Inlet 30A 2 L2 1 L1 N 120Vac Spare 15A 5 L IN Rear Door Intrusion 240Vac Main Input 30A GND GND 875-780-20 G HEAT EXCHANGER TX33 -48VDC PWR BLK (+) COM RED (-) 48VDC GRN GND Isolated Return Bar ALRM WHT COM BRN NO Out N L Enclosure Ground Customer Provided 120/240VAC 60Hz Input Power 2 RED BLK RED BLK GRN YEL PURP ORG RED BLK GRN WHT BRN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Door Alarm on Open Door Alarm Common 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 CUSTOMER SPECIFIED: -48Vdc POSITIVE GND SYSTEM RED (-48Vdc) HOT BLK (0Vdc) RETURN TEC Pwr (-48Vdc) Hot TEC Pwr (0Vdc) Return TEC Ground TEC Alarm Common TEC ALRM (not used) TEC Alarm On Open HE PWR (-48Vdc) HOT HE PWR (0Vdc) Return HE Ground HE Alarm Common HE Alarm ON Open Gnd N L1 L2 Term Block Earth Ground* Front Door Intrusion 875-801-20 875-802-20 THERMAL ELECTRIC COOL/HEATER TE16 -48VDC PWR BLK (+) COM RED (-) 48VDC GRN GND BATTERY STORAGE AREA 120/240VAC Gen Inlet L14-30P ALRM YEL COM PURP NC ORG NO 2 3 874-530-20 Door Switch Line 2 GND Line 1 DBX 8-Space Load Center Removable Door 3.3 Earth Ground* *(Customer-installed low-impedance ground point) NOTES: 28 Fig.3-4, System Schematic 1 Length of wires can be cut to fit if required. Remake terminations using same Alpha workmanship and parts. 2 When device is powered, alarm coil is energized. Alarm coil de-energizes on alarm condition 3 Warning! The RS-232 serial port is non-isolated. Connection should be made via an RS-232 Isolator, or unit may be damaged. 4 Input power to Thermal Electric Cooler / Heater must be protected by a 15A (maximum) circuit breaker or fuse. 5 Input power to Heat Exchanger must be protected by a 5A (maximum) circuit breaker or fuse. 021-517-B0-001, Rev. A 3.0 Installation 3.4 Thermal Electric Cooler (TEC) Condensate Hose Mounting The system comes with a condensate hose and hardware and should be installed only after the unit has been installed either on the plinth or pad Fig.3-5, Condensate hose mounting NOTE: The condensate hose should have a minimum two-inch bend radius and should not kink when the door is opened. Check the hose annually for blockage or disconnection. 3.5 Initial Turn Up — Placing the unit in Service WARNING! This procedure MUST be followed to reduce stress on the Heating/Cooling unit. 1. Turn off circuit breaker or remove fuse before disconnecting or reconnecting input power connectors. 2. Wait at least 20 seconds before reapplying power. 3. Service unit as necessary, remake input power connections. 4. Close curcuit breaker to apply power to unit. 5. After customer equipment has been installed, close AC input circuit breaker and apply power to each unit and clear any existing alarm conditions. 6. Upon successful installation and turn-up (alarms cleared, self-tests passed) of customer equipment, close output breakers (if applicable) to place unit into service. 021-517-B0-001, Rev. A 29 Appendix A, Agency Compliance 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 standards1. Argus Rectifier and Power System products bearing the CSA NRTL/C Mark are certified to CSA C22.2 No. 950 and UL 1950. ® C US As part of the reciprocal U.S./Canada agreement regarding testing laboratories, Standards Council granted Underwriters Laboratories (UL) authority to certify products manufactured in the U.S. for sale in Canada. Only Underwriters Laboratories may grant a license for the use of this mark which indicates compliance with both Canadian and U.S. requirements2. Go to: http://www.osha.gov for more information. C ® US What are NRTLs and what do they do? NRTL’s are third party organizations recognized by OSHA, U.S. Department of Labor under the NRTL Program. The testing and certifications are based on product safety standards developed by the U.S.-based standards developing organizations and often issued by ANSI3. The NRTL determines that a product meets the requirements of an appropriate consensus based product safety standard either by successfully testing the product itself, or by verifying that a contract laboratory has done so. The NRTL certifies that the product meets the requirements of the product safety standard4. When was the NRTL started, and who governs it? OSHA In 1983, in a suit brought on by an independent testing laboratory, OSHA was court ordered to remove specific references to UL (Underwriters Laboratories) and FRMC (Factory Mutual Research Corporation). NRTL Program In 1988, OSHA revised its regulations to remove those references and the NRTL program was established. The NRTL program is both national and international in scope with foreign labs permitted. As of Dec. 17, 1998, 17 recognized labs were permitted, with pending applications from 21 other labs5. ® ® References: 15 Others Dec. 17, 1998 NRTL/C Information presented has been developed from the official web sites of the respective organizations. Specific references are as follows: (1) www.csa-international.org/english/product_services/index_cert.htm (2) www.ul.com/mark/ulmark.htm (3) www.osha-slc.gov/dts/otpca/nrtl/slide02.html (4) www.osha-slc.gov/dts/optca/nrtl/slide04.html (5) www.osha-slc.gov/dts/optca/nrtl/slide18.html 30 021-517-B0-001, Rev. A Appendix B, Connecting Auxiliary Generator Procedure (upon loss of utility power) 1. Open AC input breaker. 2. Open output breaker. 3. Remove fasteners behind Generator Cable access panel, aside. 1 remove panel and set 4. Connect output cable from auxiliary generator to generator input cable 2 . 5. Start Generator. 6. Close AC input breaker. NOTE: The Generator Input Breaker is equipped with an interlock that prevents it from being switched ON unless the Main Input Breaker is OFF. 7. Apply power to equipment, clear alarms as needed 8. Close output breaker 9. Upon restoration of utility power, reverse procedure to disconnect auxiliary generator. 2 1 Fig. App-1, Auxiliary generator connection 021-517-B0-001, Rev. A 31 This page intentionally blank 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. 7700 Riverfront Gate Burnaby, BC, V5J 5M4 Canada Tel: +1 604 430 1476 Fax: +1 604 430 8908 Alpha Technologies Europe Ltd. Twyford House Thorley Bishop's Stortford Hertfordshire CM22 7PA UNITED KINGDOM Tel: +44 01279 501110 Fax: +44 01279 659870 Alpha Technologies GmbH Hansastrasse 8 D 91126 Schwabach GERMANY Tel: +49 9122 79889 0 Fax: +49 9122 79889 21 Alphatec, Ltd P.O. Box 56468 Limassol, Cyprus CYPRUS Tel: +357 25 375675 Fax: +357 25 359595 AlphaTEK ooo Khokhlovskiy Pereulok 16 Stroenie 1 109028 Moscow RUSSIA Tel: +7 495 916 1854 Fax: +7 495 916 1349 Alphatec Baltics S. Konarskio G. 49 Vilnius 2009 LITHUANIA Tel: +350 5 210 5291 Fax: +350 5 210 5292 Alpha Technologies 34, Grande Rue Bétheny, F-51450 France Phone: +33 32 64990 54 Fax: +33 67 54289 44 Due to continuing product improvements, Alpha reserves the right to change specifications without notice. Copyright © 2009 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies. 021-517-B0-001, Rev. A (12/2009)