Series
Enclosures
CE-3X2/CE-9X2 Enclosures
Installation Manual
Effective: May, 2000
Preface
Series Enclosures
CE-3X2/CE-9X2
T o p ic
Page
Overview
i
About this Manual
i
T able of Contents
ii
List of Figures
iv
Safety Information
vi
Installation Notes
ix
Auxiliary Power Unit Notes
x
Battery Safety Notes
x
i
Overview:
The purpose of the AlphaGen CE-3X2/9X2 Enclosure Site
Prep and Installation Manual is to provide a high-level
overview of the system and to detail the installation
procedure for the enclosures.
Audience:
This manual intended for the installers of the system.
About this manual:
Contents:This Installation Manual is comprised of four sections.
Section 1 System Overview. This section describes the
CE-3X2 /9X2 Enclosure.
Section 2 Pre-Installation. This section describes site selection,
pad layout, and enclosure grounding.
Section 3 Installation. This section describes the installation
of the enclosure to the pad.
Section 4 Addendum. Pad layout drawings, cabinet interconnection
diagrams.
031-099-C0-001
Rev. A.
Preface
Series Enclosures
CE-3X2/CE-9X2
Table of Contents
Section 1, Introduction
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
ii
System Overview ................................................................ 1-1
Specifications ..................................................................... 1-2
Block Diagram ..................................................................... 1-3
Acoustics .......................................................................... 1-3
Collocated Configuration ...................................................... 1-5
Collocated Sweep Configuration ............................................ 1-5
Remote, Ground-mount configuration ..................................... 1-6
Pole-Mount Configuration ..................................................... 1-6
Enclosure Protection ........................................................... 1-7
1.9.1 Installation Topology ...................................................... 1-7
1.9.2 Natural Gas Protection, Vehicular areas ............................. 1-7
1.9.2.1 Collocated Meter .................................................... 1-7
1.9.2.2 Remote Meter ......................................................... 1-8
1.9.3 Natural Gas Protection, Non-Vehicular areas ....................... 1-8
1.9.3.1 Collocated Meter .................................................... 1-8
1.9.3.2 Remote Meter ......................................................... 1-9
1.9.4 Propane Cabinet Protection, Vehicular areas ....................... 1-9
1.9.4.1 Collocated Propane Cabinet ...................................... 1-9
1.9.4.2 Remote Propane Cabinet ........................................ 1-10
1.9.5 Propane Cabinet Protection, Non-Vehicular areas .............. 1-10
1.9.5.1 Collocated Propane Cabinet .................................... 1-10
1.9.5.2 Remote Propane Cabinet ........................................ 1-11
1.10 Natural Gas Systems ......................................................... 1-12
1.10.1 Metered, 1-2 PSI Nominal Pressure ................................. 1-12
1.10.2 Metered, 0.5-0.8 PSI Nominal Pressure ............................ 1-12
1.10.3 Nonmetered, 0.5 PSI Nominal Pressure ............................. 1-13
1.11 Meter Configurations ......................................................... 1-14
1.11.1 Natural Gas, Collocated Meter ........................................ 1-14
1.11.2 Natural Gas, Remote Meter ............................................ 1-15
1.12 Dual Propane Tank System ................................................. 1-16
Section 2, Site Preparation
2.1
2.2
2.3
031-099-C0-001
Rev. A.
Site Considerations ............................................................. 2-1
Introduction to procedures ................................................... 2-2
Concrete Pad Layout ........................................................... 2-3
Preface
Series Enclosures
CE-3X2/CE-9X2
Table of Contents
Section 3, Installation
3.1
3.2
3.3
3.4
3.5
Transportation and Lifting .................................................... 3-1
Enclosure Installation Procedure ............................................ 3-4
Connecting the Batteries ...................................................... 3-5
Utility Fuel Hookup .............................................................. 3-6
Final Inspection Checklist ..................................................... 3-7
Section 4, Addendum
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
Typical cross-section of concrete pad .................................... 4-1
Typical Grounding arrangement .............................................. 4-2
Remote Generator - Ground Rod Installation Example ................ 4-3
CE-3X2 Concrete Pad (stand-alone) Dimensions ...................... 4-4
CE-3X2 Concrete Pad (collocated cabinet) Dimensions .............. 4-5
Pad Dimensions, CE-3X2/9X2 Enclosure, CESC Side Chamber ..... 4-6
Pad Dimensions, CE-8/CE-9 and CE-3X2/9X2 Enclosures ........... 4-7
Pad Dimensions, CE-8/CE-9, CE-3X2/9X2, CE-G Enclosures ....... 4-8
Wiring arrangement collocated cabinet configuration ................ 4-9
Wiring arrangement, collocated cabinet, 1’-3’ separation ......... 4-10
Wiring arrangement, collocated cabinet, 5’-75’ separation ....... 4-11
Interconnection wiring, 3kW APU, ECM ................................. 4-12
5kW APU intra-cabinet wiring .............................................. 4-13
031-099-C0-001
iii
Rev. A.
Preface
Series Enclosures
CE-3X2/CE-9X2
List of Figures
Section 1, Introduction
iv
Fig. 1.1
Fig. 1.2
Fig. 1.3
Fig. 1.4
Fig. 1.5
Fig. 1.6
Fig. 1.7
Fig. 1.8
Fig. 1.9
Fig. 1.10
Fig. 1.11
Fig. 1.12
Fig. 1.13
Fig. 1.14
Fig. 1.15
Fig. 1.16
Fig. 1.17
Fig. 1.18
Fig. 1.19
Fig. 1.20
Fig. 1.21
Fig. 1.22
Fig. 1.23
CE-3X2 Enclosure with 2.7kW/3.0kW APU ............................... 1-2
Block diagram ..................................................................... 1-3
CE-3X2 Series sound ratings ................................................. 1-3
E-G Acoustical Measurements ............................................... 1-4
Collocated application .......................................................... 1-5
Collocated sweep application ................................................ 1-5
Remote application .............................................................. 1-6
Remote Pole-Mount system .................................................. 1-6
Impact protection, collocated Nat. Gas meter, vehicular area ..... 1-7
Impact protection, remote Nat. Gas meter, vehicular area ......... 1-8
Impact protection, colloc. Nat. Gas meter, non-vehicular area ... 1-8
Impact protection, remote NG meter, non-vehicular area ........... 1-9
Propane Gas protection, collocated cabinets, vehicular area ...... 1-9
Impact protection, remote Propane cabinet, vehicular area ..... 1-10
Impact protection, colloc. Propane cabinet, non-vehicular area 1-10
Impact protection, rem. Propane cabinet, non-vehicular area .. 1-11
Metered, Nominal Pressure (1-2psi) Natural Gas System .......... 1-12
Metered, Low Pressure (0.5-0.8psi) Natural Gas System ......... 1-12
Non-Metered, low-pressure (0.5 - 0.8psi) Natural Gas System . 1-13
CE-3X2 w/Natural Gas Meter .............................................. 1-14
Overhead View of collocated system w/meter ....................... 1-14
CE-3X2 w/remote Natural Gas meter .................................... 1-15
Overhead view of collocated system w/ remote meter ............ 1-15
Section 2, Site Preparation
Fig. 2.1
031-099-C0-001
Rev. A.
Pad dimensions, stand-alone cabinet ..................................... 2-3
Preface
Series Enclosures
CE-3X2/CE-9X2
List of Figures
Section 3, Installation
Fig. 3.1
Fig. 3.2
Fig. 3.3
Fig. 3.4
Fig. 3.5
Fig. 3.6
Fig. 3.7
Shipping bolt locations ......................................................... 3-1
Exploded view, lifting ear ...................................................... 3-2
Lifting ear attached to cabinet .............................................. 3-2
Cabinet with lifting ears in place ............................................ 3-3
Water Intrusion Alarm, and pad shear sensor/magnet assembly .. 3-4
Battery Terminal Connection ................................................. 3-5
Utility Gas Service Input ...................................................... 3-6
Section 4, Addendum
Fig. 4.1
Typical cross-section of concrete pad .................................... 4-1
Fig. 4.2
Typical Grounding arrangement .............................................. 4-2
Fig. 4.3
Remote Generator - Ground Rod Installation Example ................ 4-3
Fig. 4.4
CE-3X2 Concrete Pad (stand-alone) Dimensions ...................... 4-4
Fig. 4.5
CE-3X2 Concrete Pad (collocated cabinet) Dimensions .............. 4-5
Fig. 4.6
Pad Dimensions, CE-3X2/9X2 Enclosure, CESC Side Chamber ..... 4-6
Fig. 4.7
Pad Dimensions, CE-8/CE-9 and CE-3X2/9X2 Enclosures ........... 4-7
Fig. 4.8
Pad Dimensions, CE-8/CE-9, CE-3X2/9X2, CE-G Enclosures ....... 4-8
Fig. 4.9
Wiring arrangement collocated cabinet configuration ................ 4-9
Fig. 4.10 Wiring arrangement, collocated cabinet, 1’-3’ separation ......... 4-10
Fig. 4.11 Wiring arrangement, collocated cabinet, 5’-75’ separation ....... 4-11
Fig. 4.12 Interconnection wiring, 3kW APU, ECM ................................. 4-12
Fig. 4.13 5kW APU intra-cabinet wiring .............................................. 4-13
031-099-C0-001
v
Rev. A.
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. Use caution whenever working in the area to prevent
electrical shock.
INHALATION HAZARD - DON’T BREATHE VAPORS
This symbol indicates an “inhalation hazard” exists in this area of the
product. Use caution whenever working in the area to prevent possible
inhalation of harmful (fuel or exhaust) vapors.
vi
NO MATCHES OR OPEN FLAMES
This symbol indicates a fire or explosive hazard exists in this area of
the product. Use caution whenever working in the area to prevent
possible combustion fuel vapors.
MECHANICAL OR MOVING PARTS HAZARD
These symbols indicate the presence of a “mechanical or moving parts
hazard” in this area of the product. Use caution whenever working in
the area to prevent possible injury to the operator or servicepersonnel.
LEAK HAZARD
This symbol indicates a “leak hazard” exists in this area of the product.
Use caution whenever working in the area to prevent and correct any
leaks detected.
HOT SURFACES
This symbol indicates the presence of high temperatures which result
from the operation of the system. To prevent burns, do not touch
these areas while the system is in operation or immediately after it has
been turned off.
ATTENTION
This symbol indicates important installation, operation or maintenance
instructions. Always follow these instructions closely.
031-099-C0-001
Rev. A.
Preface
SAFETY PRECAUTIONS
NOTE:
Failure to follow these precautions could result in
injury or death caused by the explosion of fuel,
moving parts hazards or electrocution.
CAUTION:
This set of procedures will require the
operation of the generator and should
only be performed by qualified,
experienced personnel in a well-ventilated area.
1.
Technicians must have easy access to a fire extinguisher at all
times.
2.
Propane/Natural Gases are highly explosive. Use extreme caution
while handling and operating the Generator gas package and
equipment. Keep flame or spark away from Propane bottles. Do
not smoke during assembly of gas package.
3.
Any test equipment used in the testing of the CE Series system
must have isolated inputs to prevent shock hazards and short
circuits with the enclosure or other grounded objects.
4.
Run Generator only in properly ventilated areas. Exhaust gasses
can be lethal. Prolonged exposure can cause nausea, headaches,
dizziness, or Carbon Monoxide poisoning.
5.
All pipe connections must be leak tested immediately.
6.
Output of upper air dam must be unobstructed.
7.
“Test” Propane bottles MUST not come into contact with the
cabinet(s). Use a Digital Voltmeter (DVM) to ensure proper
cabinet grounding.
8.
“Test” Propane bottles must remain upright at all times.
9.
All generator grid screens, covers, and access panels on the
generator must be closed before operation. Moving parts are a
hazard.
10.
Both generator compartment fans must be operational any time gas
pressure is applied.
031-099-C0-001
vii
Rev. A.
Preface
SAFETY PRECAUTIONS
• The system must be serviced only by qualified personnel.
• Remove all rings, watches and other jewelry before servicing
batteries or servicing the system.
• Verify the voltage requirements of the equipment to be protected
(load), the AC input voltage to the power supply (line), and the output
voltage of the system prior to installation.
• The utility service panel must be equipped with a properly rated circuit
breaker for use with this power supply.
• When connecting the load, DO NOT exceed the output rating of the
system.
• Always use proper lifting techniques whenever handling units, modules
or batteries.
• If batteries are being stored prior to installation, they should be
charged at least once every three months to ensure optimum
performance and maximum battery service life.
• The battery pack, used to provide backup power, contains dangerous
voltages. Battery inspection and replacement must be performed by
qualified personnel.
viii
• Always wear protective clothing, insulated gloves and eye protection
(i.e. safety glasses or a face shield) whenever working with batteries.
• Always carry a supply of water, such as a water jug, to wash the eyes
or skin in the event of exposure to battery electrolyte.
• Do not allow live battery wires to contact the enclosure chassis.
Shorting battery wires can result in a fire or possible explosion.
• Batteries must be inspected every three to six months for signs of
cracking, leaking or swelling.
• Always replace batteries with those of an identical type and rating.
Never install old or untested batteries.
• Avoid using uninsulated tools or other conductive materials when
handling batteries or working inside the enclosure.
• Spent or damaged batteries are considered environmentally unsafe.
Always recycle used batteries or dispose of in accordance with all
Federal, State, and local regulations.
031-099-C0-001
Rev. A.
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.
For general product information and Customer Service
7:00AM to 5:00PM Pacific Time
✆ 1-800-863-3930
To obtain complete Technical Support,
7:00AM to 5:00PM Pacific Time
or
For after-hours Emergency support
7 days per week, 24 hours a day
✆ 1-800-863-3364
NOTE:
ix
Alpha Technologies’ products are subject to change
through continual improvement processes. Therefore,
specifications and/or design layouts may vary slightly
from descriptions included in this manual. Updates to the
manual will be issued when changes affect form, fit or
function.
Save these instructions for future reference
031-099-C0-001
Rev. A.
Preface
Auxiliary Power Unit (APU) Notes
x
NOTE:
When the engine is stopping, a small amount of unburned fuel
may be detected by the odor of gas fumes. Fans are used to
expel these fumes from the enclosure and may be detected
outside the enclosure for a short period of time after engine
shutdown. This is a normal condition and does not present a
hazard.
NOTE:
Most utilities add a chemical agent to the gas which produces a
strong odor so leaks can be detected before they reach a
dangerous or explosive level. It may be possible to detect this
gas additive odor even though the gas hazard sensor does not
issue an alarm. The gas sensor will issue an alarm when the
detected levels of gas reaches 10% - 20% of the Lower
Explosive Limit (LEL). The gas hazard sensor has a 10 minute
delay for periods of purging and power up. During the purge
phase, the Green alarm light will flash. When the purge phase is
completed, the light will glow steadily. In the event the
detector has been disconnected from power for more than 24
hours, it may require a period of more than 10 minutes to
complete its purge phase. In that event, push the reset button
to disable the alarm for repeated purge cycles. Also, the reset
button may be used to disable the alarm for 10 minutes at any
time.
NOTE: If gas fumes are detected before the engine is run, or in
excess of approximately 10 minutes after running the
engine, you must check the system for leaks as
described in the INSTALLATION manual and correct as
necessary.
Battery Safety Notes
Chemical Hazards
Any gelled or liquid emissions from a Valve-Regulated Lead-Acid (VRLA) battery
is electrolyte which contains dilute sulfuric acid which is harmful to the skin
and eyes; is electrically conductive; and is corrosive.
If electrolyte contacts the skin, wash immediately and thoroughly with water.
If electrolyte enters the eyes, wash thoroughly for 10 minutes with clean
water or a special neutralizing eye wash solution and seek immediate medical
attention.
Neutralize any spilled electrolyte with the special solutions contained in a “spill
kit” or with a solution of 1 lb. Bicarbonate of soda to 1 gal. of water.
Fire, Explosion, and Heat hazards
Lead acid batteries can contain an explosive mixture of hydrogen gas which
can vent under overcharging conditions.
Do not smoke or introduce sparks in the vicinity of the battery.
Prior to handling the batteries, touch a grounded metal object, such as the
rack, to dissipate any static charge that may have developed in your body.
Do not charge batteries in a sealed container. The individual batteries should
have 0.5 inches of space between them to allow for convection cooling. If
contained, assure the container or cabinet and room have adequate ventilation
to prevent an accumulation of potentially dangerous gas.
031-099-C0-001
Rev. A.
1. Introduction
1.1 System Overview
The CE-X2 series of enclosures from Alpha Technologies has been designed to
meet the needs of today’s outside plant powering requirements. When an
alternate fuel source is not available, the CE-G propane natural gas option
(shown below) can provide up to 16 hours of continuous operation. Refer to the
CE-G Enclosure Installation manual p/n 031-089-C0-001)
The procedures described in this document describe the installation of a CE-X2
Series Enclosure. The installation procedures are identical for the CE-3X2 and
the CE-9X2. The cabinet footprint (and mounting hole location) is identical for
each enclosure. The only physical difference between the enclosures is that the
CE-3X2 is 44” tall and the CE-9X2 is 52” tall.
1-1
Fig.1.1
CE-3X2 Enclosure with 2.7kW/3.0kW APU
shown collocated with CE-3G enclosure.
(Propane tanks and fuel delivery system shown installed)
Note: The above photograph is for illustrative purposes only. Actual cabinet configuration
may vary slightly from figure.
031-099-C0-001 Rev. A.
1. Introduction
1.2
Specifications
Nominal system specifications for 3kw and 5kW APU:
3kW
36V/48V/96V
39/52/107
36V, 69A max.
48V, 57A max.
96V, 28A max.
220cc
7Hp Single OHV
4000RPM max.
(variable speed)
DC Output voltage
(VDC @ full load)
AC Output Voltage
Output frequency
Output current
Engine (air cooled)
RPM
System size: (CE9X2)
Height
Width
Depth
Weight (CE9X2)
Continuous Output Power vs. Fuel
Natural Gas
Propane Gas
APU Fuel Consumption
Propane - 2520 BTU/ft3
1-2
Natural Gas 1000 BTU/ft3
Gas Inlet Pressure
Ign. charger voltage
Ign. charger current
Remote Interface Length
Agency compliance
Exterior surface temperature:
44” (52”)
26”
24”
250lbs. (355lbs.)
Input*
36V/48V/96V
2700/3000/3100
2750/3050/3150
5kW
36V/48V
39/52
36V, 120A max.
48V, 96A max.
400cc
14Hp Single OHV
3900 RPM max.
(variable speed)
44” (52”)
26”
24”
275lbs. (380lbs.)
36V/48V
5000/5000
5150/5150
0.88gal/hr.
1.00gal/hr.
40.0ft3/hr
31.78ft3/hr
3.72 lb/hr
4.68 lb/hr
80 ft3/hr
90 ft3/hr
0.5-2 psi
0.5-2 psi
13.1-14.1 VDC
13.8-14.4 VDC
3A max.
3A max.
250’ max.
250’ max.
UL2200
UL2200
NFPA 37/54/58
NFPA 37/54/58
CSA 22.2
CSA 22.2
<65°C max. (meets requirements of UL/CSA)
Fuel System Controls & Monitoring:
The controls and fuel system meet
appropriate sections of NFPA 37,54,
and 58 for automatic, unattended
operation of remotely enclosed
generators.
Full System Control and Status Monitoring included on all models.
Sensors:
Safety Shutdowns:
031-099-C0-001 Rev. A.
Gas Hazard, Pad Shear, Water Intrusion, Tamper
Low oil shutdown
Oil over-temp
Engine overspeed
Over-crank (Crank limit)
Gas hazard (LPV or Natural Gas)
Low fuel pressure shutdown (LPV)
Water intrusion
Pad shear
1. Introduction
1.3
Block Diagram
CEX Series APU Enclosure
Alpha System Enclosure
Communications
Alpha
ECM
Comm
Alpha
Interface
AC Line Sense (Line-powered 3kW)
AC Line
36, 48, 96 VDC
Battery Pack
DC Sense (Bus-powered 5kW)
AlphaGen
Engine
Generator
Control
Engine
Charger
DC
Bus
Inductor
Rectifier
Filter
Interface
Cable
12V
Ignition
Battery
Charger
UPS
AC out
UPS
AC out
N+1
AC out
AC Line
Utility
Service
Entrance
Fig.1.2
Block diagram, system with DC Engine Generator
1.4 Acoustics
The presence of a curbside E-G (Engine-Generator) and its placement
causes many concerns in the local communities, but nuisance noise is perhaps of
most concern to nearby residents. Nuisance noise is a directional noise which
can cause discomfort during E-G operation to nearby residential occupants.
These concerns with audible impact on neighborhoods are mitigated by
recent advances in mufflers, flame resistant sound materials, intake air sound
attenuators, along with improved cabinet airflow dynamics. The figures below
show the measured audible levels from an example E-G. Note the symmetry of
these emissions. The elimination of nuisance noises and the reduction of
directional impact within a residential community is critical for deployment.
North
70.15dBA
North West
67.3dBA
1-3
50
North East
67.15dBA
55
50’
25’
60
15’
62
10’
Exhaust
West
66.0dBA
10’
Intake
66
East
67.7dBA
50
56
60
64
67
5’
66
61
58
54
48
Front
5’
74
68
66
South East
68.85dBA
South West
67.75BA
59
South
69.2dBA
Wind: Calm
CE-X Series Sound Ratings
5kW Generator powering one 1350
XM power Supply at full load
52
Ambient Noise @ 43dBa
CE-X Series Sound Ratings
3kW Generator powering one 1350
XM power Supply at full load
Fig. 1.3
CE-3X2 Series sound ratings
031-099-C0-001 Rev. A.
1. Introduction
1.4 Acoustics, continued
The design of the engine-generator system directs a majority of the
operational system noise toward the street and away from residences that may
be located behind the curbside system. This strategic cabinet design and
placement within the community can minimize noise and city ordinance issues.
House
25 Feet (55dBa)
Engine-Generator
Street
50 Feet (52dBa)
1-4
House
Fig. 1.4
E-G Acoustical Measurements in relation to placement near residences
031-099-C0-001 Rev. A.
1. Introduction
1.5 Collocated Configuration
Gas
Power
Meter
CPS Power
Supply Enclosure
CE-X
Engine Generator
Enclosure
3" Conduit
Fig. 1.5
Collocated application where the distance (D) is less than 1’
1-5
1.6 Collocated Sweep Configuration
Cabinet
separation is
less than 3'
Utility
power
input
CPS Power
Supply
Enclosure
Gas Regulator Box
CE-X
Engine
Generator
Enclosure
Natural
Gas
Meter
3" Sweep
3" Sweep
3" Conduit
Fig. 1.6
Collocated Sweep application where the distance
between the cabinets is less than 3’
031-099-C0-001 Rev. A.
1. Introduction
1.7 Remote Ground Mount Configuration
Cabinet separation
ranges from 3' to 250'
Gas Regulator
Box
Utility power
input
Natural
Gas
Meter
CPS
Power
Supply
Enclosure
Engine
Generator
Enclosure
3" Sweep
3" Sweep
3" Conduit
Fig. 1.7
Remote application where the separation
between cabinet ranges from 3’ to 250’
1-6
1.8 Remote Pole-Mount Configuration
The figure below illustrates a supplemental remote variation for polemount applications.
Utility
power
input
CPS
Power Supply Enclosure
Gas Regulator Box
Engine
Generator
Enclosure
3" Sweep
3" Conduit
3" Sweep
Fig.1.8
Remote Pole-Mount system
031-099-C0-001 Rev. A.
Natural
Gas
Meter
1. Introduction
1.9
Enclosure Impact Protection
1.9.1
Installation Topology
The National Fire Protection Agency requires that equipment utilizing natural
gas or LP-gas be protected, based on good engineering practices, in areas were
vehicle traffic is normally expected at that location. The requirement that good
engineering practices be used allows for flexibility in the design and materials.
The required protection is based upon the anticipated speed of the vehicles
operated in that area. The NFPA does not provide specific guidelines for when
protection is needed or the nature of the protection. However, the intent is to
provide sufficient protection for the equipment should contact occur by a vehicle
operating in the area at a reasonable expected speed.
Alpha Technologies, Inc. cannot anticipate all of the ways a vehicle may
potentially threaten an installed generator system or the specific type of protection that is appropriate for a particular location. The determination of the threat
to the equipment and the means of protection are the responsibility of the end
user of the equipment and the authority having jurisdiction. The following installation drawings for Alpha’s Standby Generator systems are general recommendations and not intended to be specific guidelines for protecting the equipment.
The numbers of Bollard posts (or other protection devices) depend upon equipment locations, site surveys, and traffic patterns as shown below in a typical
installation.
1.9.2
1-7
Natural Gas Protection, Vehicular Areas
Several variations of installation are possible, the intent of the
diagrams are to provide information of the different configurations
and site installations.
1.9.2.1
Collocated Meter
The Collocated located Natural Gas meter shown below may require
two to four bollard posts depending on locations, site surveys, and traffic
patterns. Typical bollard post construction may change based on local
codes regarding pipe material, concrete, or stanchion design.
COLLOCATED
PAD
SYSTEM
CPS
APU
CE - X
NATURAL
GAS METER
POWER
FRONT
POSTS
SIDEWALK
SIDEWALK
TRAFFIC
TRAFFIC
CURB
STREET
Fig.1.9
Impact protection, collocated Natural Gas meter, vehicular area
031-099-C0-001 Rev. A.
1. Introduction
1.9
Enclosure Impact Protection, continued
1.9.2.2
Remote Meter
The Remote located Natural Gas meter shown below may require
two to four bollard posts also depends upon locations, site surveys,
and traffic patterns. This design, shown below is another typical
installation, with gas meters located near the cabinet (under 25 feet)
main and supported by dual risers.
C H E C K C O D E S F O R PIPE TYPE
3/4"
REMOTE
U N D E R G R O U N DP I P E
NATURAL GAS
PAD
SYSTEM
APU
CPS
C E -X
25’
METER
MAX LENGTH
POSTS
POWER
POSTS
FRONT
SIDEWALK
SIDEWALK
TRAFFIC
CURB
STREET
TRAFFIC
Fig.1.10
Impact protection, remote Natural Gas meter, vehicular area
1-8
1.9.3
Natural Gas Protection, Non-Vehicular Areas
For residential, private property, or other non-vehicular traffic areas,
bollards may not be necessary. Shown below are a few examples for both
Collocated and Remote located meters.
1.9.3.1
Collocated Meter
The Collocated located Natural Gas meter shown below located in a
residential, private easement, or other areas not located in traffic zones
bollards may not be necessary.
COLLOCATED
NATURAL GAS METER
PAD
SYSTEM
APU
CPS
CE - X
POWER
FRONT
Fig.1.11
Impact protection, collocated Natural Gas meter, non-vehicular area
031-099-C0-001 Rev. A.
1. Introduction
1.9
Enclosure Impact Protection, continued
1.9.3.2
Remote Meter
The Remote located Natural Gas meter shown below located in a
residential, private easement, or other areas not located in traffic zones
bollards may not be necessary. Note, it is assumed the meter is mounted
on typical support risers that are supplied by the gas utility company.
C H E C K C O D E S F O R PIPE T Y P E
3/4"
PAD
U N D E R G R O U N D PIPE
REMOTE
NATURAL GAS
METER
SYSTEM
APU
CPS
C E -X
25’
MAX . LENGTH
POWER
FRONT
Fig.1.12
Impact protection, remote Natural Gas meter, non-vehicular area
1.9.4
Propane Cabinet Protection, Vehicular Areas
1.9.4.1
Collocated Propane Cabinet
1-9
The Collocated located CE-G Propane Gas cabinet shown below
may require two to four Bollard posts depending on locations, site
surveys, and traffic patterns. Typical Bollard post construction may change
based on local codes regarding pipe material, concrete, or stanchion
design.
SYSTEM
APU
PROPANE
CPS
C E -X
C E -G
PAD
POWER
POSTS
FRONT
SIDEWALK
SIDEWALK
TRAFFIC
TRAFFIC
CURB
STREET
Fig.1.13
Propane Gas protection, collocated cabinets, vehicular area
031-099-C0-001 Rev. A.
1. Introduction
1.9
Enclosure Impact Protection, continued
1.9.4.2
Remote Propane Cabinet
The Remote located CE-G Propane Gas cabinet shown below may
require two to four Bollard posts also depends upon locations, site
surveys, and traffic patterns. This design, shown below is another typical
installation with the CE-G propane cabinet is remote located (under 25
feet) where Natural Gas may become available in the future.
CHECK CODES FOR PIPE TYPE
3/4" UNDERGROUND PIPE
(25’ MAX . LENGTH )
PAD
SYSTEM
CPS
PAD
REMOTE
PROPANE
CE - G
APU
CE - X
FRONT
POWER
POSTS
FRONT
POSTS
SIDEWALK
SIDEWALK
TRAFFIC
CURB
STREET
TRAFFIC
Fig.1.14
Impact protection, remote Propane cabinet, vehicular area
1-10
1.9.5
Propane Cabinet Protection, Non-Vehicular Areas
For residential, private property, or other non-vehicular traffic areas,
bollards may not be necessary. Shown below are a few examples for both
Collocated and Remote located CE-G Propane Gas Enclosures.
1.9.5.1
Collocated Propane Cabinet
The Collocated located Propane cabinet shown below located in a
residential, private easement, or other areas not located in traffic zones
bollards may not be necessary.
SYSTEM
APU
PROPANE
CPS
C E -X
C E -G
PAD
POWER
FRONT
Fig.1.15
Impact protection, collocated Propane cabinet, non-vehicular area
031-099-C0-001 Rev. A.
1. Introduction
1.9
Enclosure Impact Protection, continued
1.9.5.2
Remote Propane Cabinet
The Remote located Propane Cabinet shown below located in a
residential, private easement, or other areas not located in traffic
zones bollards may not be necessary.
C H E C K C O D E S F O R PIPE T Y P E
3/4" U N D E R G R O U N D PIPE
25’
PROPANE
C E -G
PAD
MAX . LENGTH
PAD
SYSTEM
APU
CPS
C E -X
FRONT
POWER
FRONT
Fig.1.16
Impact protection, remote Propane cabinet, non-vehicular area
1-11
031-099-C0-001 Rev. A.
1. Introduction
1.10
Natural Gas Systems
1.10.1
Metered, 1-2 PSI Nominal Pressure
ENGINE
Demand
Low-pressure
Regulator
CONTROLS
8 oz.
(max.)
CONTROL
Solenoid
APU
Enclosure
S
11" WC
inlet
Engine must have
11" WC to operate
(7"-11" WC for 5kW APU)
Maxitrol
Pre-Regulator
5 psi inlet (max.)
Flare Coupling
(Quick-Disconnect)
Low pressure
excess flow valve
(optional)
Meter
NOTE: 1 psi = 28" WC
2psi (min.)
1psi (nominal)
Gas Utility
Box
Manual
1 psi
High pressure
excess flow valve
(optional)
2 psi
Shutoff
Gas Main
WC = Water Column H2O
1.0 psi to 50 psi
Fig.1.17
Arrangement of Metered, Nominal Pressure (1-2psi) Natural Gas System
1-12
1.10.2 Metered, 0.5-0.8 PSI Nominal Pressure
ENGINE
Demand
Low-pressure
Regulator
CONTROLS
CONTROL
8 oz.
(max.)
APU
Enclosure
11" WC
inlet
Flare Coupling
(Quick-Disconnect)
Low pressure
excess flow valve
(optional)
NOTE: 0.5psi = 14" WC
0.5psi (min.)
or
11"-14" WC
Solenoid
S
Engine must have
11" WC to operate
(7"-11" WC for 5kW APU)
Maxitrol
Pre-Regulator
removed
Meter
Gas Utility
Box
Street
Manual
Regulator
Shutoff
0.5psi
WC = Water Column H2O
Low pressure
excess flow valve
(optional)
Gas Main
0.5psi to 0.8psi
Fig.1.18
Arrangement of Metered, Low Pressure (0.5-0.8psi) Natural Gas System
031-099-C0-001 Rev. A.
1. Introduction
1.10
Natural Gas System Diagrams, continued
1.10.3 Non-Metered, 0.5 PSI Nominal Pressure
ENGINE
Demand
Low-pressure
Regulator
CONTROLS
8 oz.
(max.)
CONTROL
Solenoid
APU
Enclosure
S
11" WC
inlet
Flare Coupling (QuickDisconnect)
Engine must have
11" WC to operate
(7"-11" WC for 5kW APU)
Maxitrol
Pre-Regulator
5psi inlet max.
Gas Utility Box
Manual
NOTE: 0.5psi = 14" WC
14" WC Nominal
12" WC Minimum
No meter or street regulator
CAUTION: Max. surge 5psi
Shutoff
Low pressure excess
flow valve (optional)
1-13
W C = W A T E R C O L U M N H2 0
Gas Main
Fig.1.19
Arrangement of Non-Metered, low-pressure (0.5 - 0.8psi) Natural Gas System with preregulator protection (no street regulator)
NOTE: For added safety, excess flow valves may be installed in either or both
locations.
NOTE: Effective February 3, 1999, a new
law, Federal DOT Regulation 49
CFR Part 192.383; Excess
Flow Valve Customer Notification requires gas utilities either
voluntarily install Excess Flow
Valves (EFVs) on all new home
service lines for builders or notify
builders about EFVs’ benefits
and availability. EFVs are valves
installed on gas service lines
during pre-construction site
work that automatically activate
when a gas line is ruptured.
Low pressure Excess Flow Valve
(above ground ¾” x 4” NPT nipple)
Alpha p/n 042-146-10
NOTE: High-pressure valves provided by Gas company
031-099-C0-001 Rev. A.
1. Introduction
1.11
Meter Configurations
1.11.1 Natural Gas, Collocated Meter
Gas Utility Box
Centralized
Powering
System
Natural Gas Meter
CEX Series
Engine
Generator
Enclosure
Street Regulator
Manual Shutoff
Excess flow valve
(optional)
1-14
Street Pressure
Fig.1.20
Collocated cabinets with Natural Gas meter
Precast or
"poured-inplace"
concrete pad
Centralized
Powering
System
CEX Series
Engine
Generator
Enclosure
Service
Entrance
Protective
posts
Front of system
Fig.1.21
Overhead view of collocated system with meter
031-099-C0-001 Rev. A.
Natural Gas
Meter
1. Introduction
1.11
Meter Configurations, continued
1.11.2 Natural Gas, Remote Meter
Gas Utility Box
MAXITROL
PRE-REGULATOR
CEX Series
Engine
Generator
Enclosure
Centralized
Powering
System
NATURAL
GAS
METER
MANUAL SHUTOFF
REQUIRED IF METER
CANNOT BE SEEN
STREET REGULATOR
MANUAL SHUTOFF
METERED SUPPLY
3" SWEEP
Excess flow valve
(optional)
STREET PRESSURE
1-15
Fig.1.22
Collocated cabinets with remote Natural Gas meter
Check codes for pipe type
3/4" Underground pipe
25' max length
SYSTEM
CPS
APU
CE-X
REMOTE
NATURAL GAS
METER
PAD
POSTS
POWER
FRONT
POSTS
Fig.1.23
Overhead view of collocated system with remote meter
031-099-C0-001 Rev. A.
1. Introduction
1.12
Dual Propane Tank System
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
11"WC
OUTLET
1-16
GAS
UTILITY
BOX
PROPANE
POST-REG
10 PSI TO 11"WC
PROPANE 150 PSI
HIGH PRESSURE
PRE-REGULATOR
PROPANE
CONTROL
AUTO/MANUAL
DUAL TANK
VALVE
PROPANE
ENCLOSURE
PROPANE
Fig.1.24
Block diagram, Dual Propane tank system
031-099-C0-001 Rev. A.
2. Site Preparation
2.1
•
•
•
•
•
•
•
•
•
Site Considerations
Where possible, select a site that is above the 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 wind-borne dust.
Evaluate the soil conditions for suitability for the installation
of the required grounding system applicable to your particular
installation.
Verify utility power cabling run and terminated at the site.
Verify preparation of site per Figure 4.1.
2-1
031-099-C0-001
Rev. A.
2.
Site Preparation
2.2 Introduction to Procedures
Description
The section describes the procedure for installing the CE3X2 or CE9X2
enclosure.
Subsection
2.3
Installation Instructions
Concrete Pad Fabrication
See page
2-3
When to use this document:
Upon receipt of the CE3X2 Enclosure.
Before installation:
Verify the following:
• All necessary grounding rods and materials in place.
• Utility power run to site in accordance with NESC
(National Electric Safety Code).
• Obtained local safety practices for working with highvoltage systems.
• Gas piping, hardware, supports, and other gas carrying components to
the pad location conform to NFPA and local requirements.
2-2
To perform the installation procedures, the installer(s) will need to have
the following materials on hand.
Crane to lift enclosure from shipping pallet and place on pad.
Key(s) to enclosure doors
Digital voltmeter
Torque wrench with insulated handle and 7/16" socket
7/16" box-end wrench
NO-OX or other suitable corrosion inhibiting agent (NCP-2)
Battery Cabling Kit (Alpha p/n 874-590-20)
Contains:
Battery string interconnect cables
Silicone sealant
GE RTV123 (or equivalent)
NOTE:
031-099-C0-001
Rev. A.
The batteries used in this application may vary slightly
depending upon optional configurations, battery types, or
customer requirements. The batteries are typically
gelled-electrolyte valve-regulated, such as the Alpha
Cell or absorbant glass-mat (AGM). Should a battery be
found damaged, refer to the battery manufacturer's
documentation regarding the safe handling of the
battery.
2. Site Preparation
2.3 Concrete Pad Layout
The illustration below (Fig.2.1) 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. (Refer to section 4,
Addendum, for additional information regarding pad layouts).
38"
32"
6"
3
A1
6"
3
C1
36"
CE-3X2/CE9X2
ENCLOSURE
25.5"
Front of Pad
2-3
13.25"
10.75"
9.25"
28.75"
3
B1
29.5"
Fig.2.1
Pad dimensions, standalone cabinet
Stand-alone pad notes:
1
A1
1
B1
1
C1
3/8" to 1/2" Bolts (4 places) The bolts should extend 1" to 1-1/2"
above the surface of the cement.
3" Opening for DC Output Cable and Status Monitoring harness.
A 25+ year continuous vapor barrier must be used between the
enclosure and pad to prevent moisture ingress and possible corrosion
caused by metal to concrete contact. The vapor barrier material
(such as 30 lb. felt, neoprene pond liner, or heavy grade tar paper)
should initially extended at least 6" in all directions around the
perimeter of the enclosure and be trimmed closer to the enclosure,
using the appropriate knife or cutting tool.
031-099-C0-001
Rev. A.
3. Installation
3.1 Transportation and Lifting
The enclosure as shipped contains the Auxiliary Power Unit (APU) and,
therefore, is heavy (approximately 355 pounds). 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.
CAUTION:
The ignition battery MUST NOT be installed until
the enclosure is set in place on its permanent
location.
The system is shipped bolted to a pallet. Once the system arrives,
remove the protective outer wrapping material and inspect the outside of the
enclosure for shipping damage. Use a forklift to place the unit (still bolted to
its pallet) in the back of the transport vehicle for delivery to the installation
site. Once on site, follow the procedure outlined on the following pages to lift
the enclosure from the shipping pallet and place it on the concrete pad.
3.1.1
Lifting Procedure
3-1
Fig.3.1
Location of bolts which secure the enclosure to the pallet.
031-099-C0-001
Rev. A.
3. Installation
3.1 Transportation and Lifting, continued
3.1.1
Lifting Procedure, continued
The enclosure is lifted via the attached lifting ears. The lifting ears
are attached to the cabinet with 1/4-20 x 3/8" stainless steel SAE J429 Grade
8 hex head bolts torqued to 80-90 in-lbs.
CAUTION:
1
A1
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.
1/4-20 x 3/8" stainless steel
SAE J429 Grade 8 hex head
bolts. 4 places per ear.
1
A1
3-2
Fig.3.2
Exploded view, lifting ear
1
B1
Bolts
torqued to 80-90 in.-lbs.
1
B1
Fig.3.3
Lifting ear attached to cabinet
031-099-C0-001
Rev. A.
3. Installation
3.1 Transportation and Lifting, continued
3.1.1
Lifting Procedure, continued
Lift the enclosure with a lifting appararatus rated to lift in excess of
500 lbs. The lifting arrangement must be configured such that the distance
from the top of the cabinet to the lift ring or hook is at least twice the
distance between the lifting ears.
CAUTION:
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.
3-3
2 D
D
Fig.3.4
Cabinet with lifting ears in place
031-099-C0-001
Rev. A.
3. Installation
3.2 Enclosure Installation Procedure
1.
Position the enclosure above the concrete pad and slowly lower it into
position over the pad's 3/8" (or 1/2") anchor or J-bolts. A 25+ year
vapor barrier MUST be used between the concrete and enclosure base
to inhibit moisture ingress, and to prevent possible corrosion caused
by metal to concrete contact. The vapor barrier material (such as 30 lb.
felt, neoprene pond liner, or heavy grade tar paper) should initially
extend at least 6" in all directions around the perimeter of the enclosure.
After the enclosure is in place, the material should be cut closer to the
enclosure, using the appropriate knife or cutting tool.
2.
Secure the enclosure using stainless, galvanized (or better), flat
washers, lock washers and 3/8" (or 1/2") nuts at each mounting bolt.
TORQUE MOUNTING HARDWARE IN ACCORDANCE WITH HARDWARE'S
MANUFACTURERS' RATINGS.
NOTE:
3.
To prevent damage to the enclosure, it must be mounted
flush 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.
Make a small cutout in the vapor barrier material directly under the Pad
Shear Sensor, Apply silicone glue to the concrete pad (in the cutout
section) and set the Pad Shear magnet into the glue (potted side
down). Allow glue to set 12-24 hours.
3-4
W ATER
I NTRUSION
F LOAT
S ENSOR
M AGNET
Fig. 3.5
Water Intrusion Alarm, and pad shear sensor/magnet assembly
CAUTION:
031-099-C0-001
Rev. A.
The pad shear sensor is a safety feature and MUST
be correctly installed before connecting the gas
utility. This is a CRITICAL safety feature required
to disable the generator in the event of automobile
impact, seismic, or other unforeseen catastrophic
event.
3. Installation
3.3 Connecting the Ignition Battery
1.
NOTE:
For further information regarding the safe handling of
batteries, refer to the Preface.
NOTE:
Always disconnect the battery connector, located on the left
side of the generator compartment, before working with the
battery!
Install the battery on to the shelf, negative (-) terminal to the
right,positive (+) to the left.
WARNING: Observe battery polarity. DO NOT short battery
terminals together or allow metal tools to come into
contact with the battery terminals or cables. Shorted
batteries can explode causing severe acid and or electrical
burns.
WARNING: Batteries contain ACID. Do not allow this acid to come
into contact with skin or clothing. Wash affected area
immediately with soap and water. Seek immediate
medical attention if acid comes into contact with eyes.
2.
3.
4.
Before connecting the battery cables, coat the battery terminals with an
anti-oxidizing gel such as NCP-2. Install the battery cables.
Verify battery voltage and polarity on the battery connector.
Battery voltage should be at least 12.5VDC; if low,
recharge before placing into operation.
Mate the ignition battery connector in the APU compartment after gas
service is connected.
NOTE:
3-5
The battery supplies power to the cabinet fan. Disconnect
the ignition battery connector in the APU compartment when
leaving cabinet out-of-service, or when gas is not available to
run the generator.
External Charger or Sense Lead
Battery Cable
Flat
Washer
Split Washer
Flat Washer
Bolt
Nut
Battery Terminal
Fig. 3.6
Battery Terminal Connection
031-099-C0-001
Rev. A.
3. Installation
3.4 Utility Fuel Hookup
CAUTION: Fuel vapors
can be explosive!
NOTE: These general instructions are applicable for either remote or
collocated systems. For specific information regarding the
propane fuel connection, refer to the CE-G Series Enclosure
Installation Manual.
Check fuel system for leakage using an approved leak detector liquid or a
soap-water solution with the fuel system pressurized to the cabinet with one
pound or 1/2 pound of fuel pressure. For an accurate leakage check, DO NOT
use test solutions that contain ammonia or chlorine, since they will prevent
the soap from bubbling.
CAUTION:
Observe all safety precautions when working with fuel
lines. The illustrations on this page should be considered
for general reference only.
Utility Fuel Connection (Please refer to Section 1 for block diagrams of
various configurations)
3-6
The connection to the utility fuel line is made to the gas utility box using a
3/4" shear point union, 1/2" black iron pipe (supplied), and the appropriate
pipe thread sealant suitable for use with natural gas or propane vapor.
Suitable pipe thread sealant must be used on ALL (except flare fittings) fuel
line connections. Thoroughly check the fuel system for vapor leaks.
Installation should ONLY be done by qualified personnel. Check all local codes
before connecting gas to the fuel system.
CE-X Engine Generator
Gas Utility box
MAXITROL
Pre-Regulator
Natural Gas
Meter
Union
Manual Shutdown
required if meter cannot
be seen
Street Regulator
Manual Shutoff Valve
3" sweep
Metered Supply
Street Pressure
Fig. 3.7
Utility Gas Service Input
031-099-C0-001
Rev. A.
3. Installation
3.5 Final Inspection Checklist
Once the installation has been completed verify the following:
Engine oil at proper level
All electrical connections securely made
ECM set to "STOP"
CAUTION:
It is recommended that the "CTRL SELECT" switch be set
to the "STOP" position before initially powering up the
ECM. This allows the operator to control the "START" and
"STOP" functions of the APU until the system is set up.
This also prevents the APU from starting unexpectedly.
Battery connections made
Battery voltage normal
Gas connections checked for leak integrity
Gas pressure normal
When the above test/checks have been made, the unit is ready for initial turnup. Refer to the Engine Control Module Manual (Alpha p/n 744-862-C0-XXX).
3-7
031-099-C0-001
Rev. A.
4.
Addendum
Site/Pad Preparation Notes:
1
A1
1
A1
12"
1
B1
11.25"
2"
1
C1
12"
8.5"
2"
3/8” Ø bolts (4 places) as specified. All
mounting hardware must be stainless,
galvanized, or better to prevent corrosion.
Bolts should extend 1”-1½” above surface of
cement.
1
B1
5/8” Ground Rod.
1
C1
Compacted Stone (12" recommended depth)
1
D1
4” CATV conduit as needed.
7
E1
3” Utility Power/Status Monitoring conduit
4"
Level
Elevation
18" 12"
12"
24"
96"
NOTE: Local codes may require the
examination of ground rod
connections by inspectors prior
to back filling. Verify
with local codes prior to
installation.
1
D1
1
E1
3"
6"
Fig. 4.1
Typical cross-section of concrete pad
(This figure is provided for illustrative purposes only)
031-099-C0-001 Rev. A.
4-1
4.
Addendum
Cabinet Grounding Notes:
2
A1
2
E1
2
C1
2
B1
8 foot long x 1/2" dia Copper Electrode (1
piece).
2
C1
#6 AWG bare copper wire exposed 5' above
grade (minimum) for output ground bus bar.
2
D1
2
E1
2
A1
2
F1
2
D1
Front of pad
2
B1
Fig. 4.2
Typical Grounding arrangement
To aid in serviceability, place the ground
electrode outside the concrete pad's
perimeter. Consult local utility codes for
additional cabinet grounding and utility
requirements.
2
F1
Clamp #6 AWG bare copper wire to ground
electrode with clamps suitable for direct
burial. 25 year corrosion proof connections
and hardware material MUST be used.
Posts should be placed by the gas utility
riser to protect the gas regulator from
impact and/or lawn equipment
6" dia. concrete-filled steel posts should be
placed at the corners of enclosures that may
be exposed to accidental traffic damage.
NOTE: Local codes may require the
examination of ground rod
connections by inspectors prior
to back filling. Verify
with local codes prior to
installation.
(This figure is provided for illustrative purposes only)
The ground rod system is typically used for “remote” applications where the generator is located away from the
power supply enclosure and prone to lightning strikes, or coincidental surges in the event of a “near miss” lightning
strike. The wiring interface between the DC Genset and system carries a “system” ground to ensure common ground
between both cabinets and communications devices. The remote APU cabinet ground rod serves only as an alternate
discharge path.
031-099-C0-001 Rev. A.
4-2
4.
Addendum
System Grounding:
The power supply systems can utilize a DC engine
generator backup for extended outages, either collocated
next to he power supply cabinet, or shown below in the
remote application.
DC
Engine Generator
Ground Rod
System
Dissipation
Field
COAX
Ground Rod Area of
Dissipation
Fig. 4.3
Remote Generator - Ground Rod Installation Example
031-099-C0-001 Rev. A.
Ground Rod Area of
Dissipation
For small power supplies with less than two coax output
feeders (only one shown for clarity), a two-ground rod
installation was sufficient to provide the grounding field
shown below. The large circular path around the entire
enclosure is envisioned as the clamping field, the area of
which lightning or other high-energy discharges are
dissipated. The 8 foot long ground rods are placed a
minimum of 6 feet apart (per NEC Article 250-56
requirement) that is shown below as the “Ground Rod
Dissipation Area”, which is described as the area
immediately around the ground rod that provides the
conductive path to earth.
In some case, the enclosures cannot be located together
based on fuel location, easements, traffic patterns, etc. so
the external DC generator cabinet should include a locally
driven 8 foot ground rod at the engine generator cabinet
(NEC Article 250-32 Sub (d)) to provide a discharge path
should a high energy discharge, or a direct strike to the
cabinet enclosure skin. The engine generator and system
have a common “interface ground wire” between the two
enclosures to ensure all the electronic interface is protected
according to NEC Article 250-32 Sub (b) Sub (1), with one
exception, the secondary interface feeds only 100VA from
the systems enclosure to the generator enclosure for alarm
and monitoring.
NOTE:
Note: The size of single conductive
Ground Rod Dissipation Area (or
ground rod POD – point of dissipation)
depends on soil composition, ground
rod impedance and ground wire
sizing. The lower the impedance for a
single POD (less than 25 ohms for a
single electrode required by NEC
Article 250-56 ), the more effective
the clamping field and dissipation of
high-energy discharges. When two
rods are used, according to the NEC, a
ground impedance verification test is
not required.
4-3
4.
3’-2"
Addendum
6"
4
A1
Stand-alone pad notes:
6"
4
A1
4
C1
4
B1
4
D1
4
B1
3’-0"
CE-3X2/CE-9X2
ENCLOSURE
1’-3"
4
C1
2-5/8"
10-5/8"
4
D1
8-1/2"
Front of pad
9-1/4"
3/8” Ø bolts (4 places) as specified. All
mounting hardware must be stainless,
galvanized, or better to prevent corrosion.
Bolts should extend 1”-1½” above surface
of cement.
3" Opening for DC Output Cable and
Status Monitoring harness.
A 25+ year continuous vapor barrier must
be used between the enclosure and pad to
prevent moisture ingress and possible
corrosion caused by metal to concrete
contact. The vapor barrier material (such
as 30 lb. felt, neoprene pond liner, or heavy
grade tar paper) should initially extended at
least 6" in all directions around the
perimeter of the enclosure and be trimmed
closer to the enclosure, using the
appropriate knife or cutting tool.
Alpha Technologies recommends the pad
extend 6" in all directions around the
enclosure(s).
1’-7-1/2"
Fig. 4.4
CE3-X2 Concrete Pad (stand-alone) Dimensions
031-099-C0-001 Rev. A.
4-4
4.
Colocated pad notes:
5’-4"
5
A1
5
A1
5
A1
9-1/4"
6"
6"
5
B1
5
C1
5
C1
3"-0"
5
B1
CE-3X2/CE-9X2
ENCLOSURE
Addendum
CE-G
ENCLOSURE
1’-3" 1’-6-1/2"
2-5/8"
10-5/8"
3/8” Ø bolts (8 places) as specified. All
mounting hardware must be stainless,
galvanized, or better to prevent corrosion.
Bolts should extend 1”-1½” above surface
of cement.
3" Opening for DC Output Cable and
Status Monitoring harness.
A 25+ year continuous vapor barrier must
be used between the enclosure and pad to
prevent moisture ingress and possible
corrosion caused by metal to concrete
contact. The vapor barrier material (such
as 30 lb. felt, neoprene pond liner, or heavy
grade tar paper) should initially extended at
least 6" in all directions around the
perimeter of the enclosure and be trimmed
closer to the enclosure, using the
appropriate knife or cutting tool.
8-3/4"
8-1/2"
1’-7-1/2"
4-7/8"
1’-10-3/4"
Front of pad
031-099-C0-001 Rev. A.
Fig. 4.5
CE3-X2 Concrete Pad (collocated cabinet) Dimensions
4-5
4.
Addendum
4’-5"
1"-7-1/2"
9-1/4"
6
A1
Pad notes:
6
A1
6
A1
3’-0"
6
C1
6
D1
6
C1
CE-3X2/CE-9X2
ENCLOSURE
Side
Chamber
1’-10"
6
B1
1’-3"
Front of pad
3-5/8"
7"
6
D1
2-11/16"
3/8” Ø bolts (8 places) as specified. All
mounting hardware must be stainless,
galvanized, or better to prevent corrosion.
Bolts should extend 1”-1½” above surface
of cement.
3" Opening for Utility Power Cable and
Status Monitoring harness.
A 25+ year continuous vapor barrier must
be used between the enclosure and pad to
prevent moisture ingress and possible
corrosion caused by metal-to-concrete
contact. The vapor barrier material (such
as 30 lb. felt, neoprene pond liner, or heavy
grade tar paper) should initially extended at
least 6" in all directions around the
perimeter of the enclosure and be trimmed
closer to the enclosure, using the
appropriate knife or cutting tool.
4" openings for CATV cabling.
10-5/8"
1/4"
6
B1
9-1/2"
1-9/16"
4-1/2"
5-1/2"
9-3/16"
1’-2-3/4"
031-099-C0-001 Rev. A.
Fig. 4.6
Concrete Pad Dimensions
CE3X2/9X2 Enclosure and CESC Side Chamber
4-6
4.
Addendum
5’-4"
Pad notes:
7
A1
6"
(2 PLCS)
7
C1
2"
6"
7
A1
7
A1
7
B1
7
C1
7
B1
8-1/16"
CE-9 or CE-8
ENCLOSURE
CE-3X2/CE-9X2
ENCLOSURE
1’-3"
2’-2-3/16"
Front of pad
1’-1-15/16"
11"
10-5/8"
9-13/16"
6"
3-1/2"
1’-7-1/4"
6-5/8"
1’-7-1/2"
9-1/4"
7
D1
3/8” Ø bolts (8 places) as specified. All
mounting hardware must be stainless,
galvanized, or better to prevent corrosion.
Bolts should extend 1”-1½” above surface
of cement.
3" Opening for DC Output Cable and Status
Monitoring harness.
A 25+ year continuous vapor barrier must
be used between the enclosure and pad to
prevent moisture ingress and possible
corrosion caused by metal-to-concrete
contact. The vapor barrier material (such
as 30 lb. felt, neoprene pond liner, or heavy
grade tar paper) should initially extended at
least 6" in all directions around the
perimeter of the enclosure and be trimmed
closer to the enclosure, using the
appropriate knife or cutting tool.
4" opening for CATV cabling.
7
D1
Fig. 4.7
Concrete Pad Dimensions
CE 8/CE 9 and CE3X2/9X2 Enclosure
031-099-C0-001 Rev. A.
4-7
4.
Pad notes:
7’-6-1/2"
6"
6"
8
A1
8
A1
(2 PLCS.)
2" (2 PLCS.)
8
A1
8
A1
6"
6"
8
B1
8
C1
8-1/16"
3’-00"
2’-2-3/16"
8
B1
CE-9 or CE-8
ENCLOSURE
8
C1
CE-3X2/CE-9X2
ENCLOSURE
CE-G
ENCLOSURE
1’-1-15/16"
1’-3"
1’-6-1/2"
1-7/8"
11"
3-1/2"
9-13/16"
8
D1
1’-7-1/4"
8-3/4"
6-7/8"
Addendum
8
D1
1’-7-1/2"
3/8” Ø bolts (4 places) as specified. All
mounting hardware must be stainless,
galvanized, or better to prevent corrosion.
Bolts should extend 1”-1½” above surface
of cement.
3" Opening for DC Output Cable and Status
Monitoring harness.
A 25+ year continuous vapor barrier must
be used between the enclosure and pad to
prevent moisture ingress and possible
corrosion caused by metal-to-concrete
contact. The vapor barrier material (such
as 30 lb. felt, neoprene pond liner, or heavy
grade tar paper) should initially extended at
least 6" in all directions around the
perimeter of the enclosure and be trimmed
closer to the enclosure, using the
appropriate knife or cutting tool.
4" opening for CATV cabling.
5-1/8"
2’-2-1/8"
1’-10-3/4"
Front of pad
Fig. 4.8
Concrete Pad Dimensions
CE 8/CE 9, CE3X2/9X2, and CE-G Propane Enclosure
031-099-C0-001 Rev. A.
4-8
SYSTEM ENCLOSURE
4.
CE-X2 ENGINE GENERATOR ENCLOSURE
ECM
Addendum
PWR-GRI
(OPTION)
COMM
ALARM
INTERFACE
RED
STATUS
MONITORING
TRANSPONDER
POS
NEG
PAD
SHEAR
INVERTER
BATT
WATER
INTRUSION
LOW
FUEL
PRESSURE
Wiring arrangement colocated
cabinet configuration
CONTROL
INTERFACE
BLK
ALARM
RESET
READY
LINE
120V
3X4
MM
Fig. 4.9
DOOR
OPEN
INV BATT
SENSE
ALARM
INDUCTOR
FILTER
G A S MDO DEE LTH E
CTOR
IC
Chestec Corporation
Port Washington, NY
842
CHASSIS
SAFETY
GROUND
GAS
SENSOR
POS
CHARGER
2
GAS
SOLENOID
1
S/O CABLE
NEG
POS
(OPTION)
COMM
-
LINE
SENSE
+
DC
OUTPUT
FUSE
100VA
SMH
SY120
DC OUT
I/O
GAS
SOLENOID
ENGINE ALTERNATOR
COMPARTMENT
BLK
RED
L1
NEUT
120V
+
THN OR THHN
-
LINE
120V
TO
APU
+
-
PIN 1
LINE
NEUT
GND
NOTE: 3kW generator configuration
shown. 5kW Series will differ for
internal cabinet wiring.
CHASSIS
SAFETY
GROUND
GREEN GROUND
BLK
DC CABLES 6AWG
ALARM / CONTROL INTERFACE
RED
DC OUT
CONDUIT CONNECTED < 1 FOOT
031-099-C0-001 Rev. A.
4-9
4.
Addendum
CE-X2 ENGINE GENERATOR SERIES
COLLOCATED BELOW GRADE 3' SWEEP
OPTION AT 1-3' SEPARATION
ECM
PWR-GRI
(OPTION)
COMM
ALARM
INTERFACE
SYSTEM ENCLOSURE
RED
STATUS
MONITORING
TRANSPONDER
POS
NEG
Fig. 4.10
INVERTER BATT
BLK
Chassis Safety Ground
LINE
120V
INV BATT
SENSE
ALARM
INDUCTOR
FILTER
POS
CHARGER
GAS
SOLENOID
2
3X4
MM
Wiring arrangement, colocated cabinets
with 3’ sweep option and 1’-3’cabinet
separation.
CONTROL
INTERFACE
1
S/O CABLE
NEG
POS
-
LINE
SENSE
+
DC
OUTPUT
FUSE
SMH
SY120
TO
APU
+
DC OUT
I/O
GAS
SOLENOID
ENGINE ALTERNATOR
COMPARTMENT
L1
+
ENGINE/GEN-SET
APU-xxDCG
RED
NEUT
-
120V
100VA
BLK
PIN 1
-
(OPTION)
COMM
Note: 3kW generator
configuration shown.
5kW Series will differ
for internal cabinet
wiring.
SWEEP
SWEEP
LINE
NEUT
GND
THW OR THWN
LINE
120V
Chassis
Safety
Ground
GREEN GROUND
BLK
2 FEET
CABLES 6AWG
COLLOCATED SWEEP CABLE INTERFACE
031-099-C0-001 Rev. A.
RED
DC OUT
4-10
4.
Addendum
CE-X2 ENGINE GENERATOR SERIES
ECM
PWR-GRI
(OPTION)
COMM
REMOTE LOCATED OPTION
AT > 5' TO 75' SEPARATION
ALARM
INTERFACE
SYSTEM ENCLOSURE
NEG
INVERTER BATT
INV BATT
SENSE
ALARM
120V
GAS
SOLENOID
1
NEG
S/O CABLE
POS
FUSE
100VA
DC
OUTPUT
CHASSIS
GROUND
RED
GREEN
GRAY
BROWN
BLUE
WHITE RED
YELLOW
WHITE
BLACK
ORANGE
WHT/BLK
NOT USED
120V
SMH
SY120
DC OUT
GAS
SOLENOID
ENGINE/GEN-SET
APU-xxDCG
CHASSIS
SAFETY
GROUND
APU
OUT
NEG
L
L
GND
POS
NEG
L
L
GND
POS
RED
BLACK
BLK W/WHT
GRN W/WHT
GRN W/BLK
BLUE
GREEN
ORANGE
WHITE
WHT W/BLK
BLU W/WHT
RED W/BLK
APU
OUT
AC
SENSE
60-60V
I/O
ENGINE ALTERNATOR
COMPARTMENT
GND
TERMINAL BLOCK LINE
SENSE FUSE HOLDERS
TWO 1A SLOW BLOW FUSES
TO
APU
+
L1
NEUT
+
CLASS 3
ISOLATION
TRANSFORMER
DUAL 60V
OUTPUT
-
LINE
120V
NEUT
60-60V
Belden
Cable
LINE
SENSE
+
PIN 1
-
-
FUSE
Interface
Cable
POS
CHARGER
BLK
3X4
MM
INDUCTOR
FILTER
2
STATUS
MONITORING
TRANSPONDER
3kW APU Wiring arrangement, colocated
cabinets with 3’ sweep option and 5’ - 75’
cabinet separation.
CONTROL
INTERFACE
POS
RED
Fig. 4.11
AC
SENSE
60-60V
OUTPUT
TERMINAL
BLOCK
FILE: X2-INT-3.DWG
BY: T.THORNE
DATE: 20 MAR 00
ALPHA TECHNOLOGIES
REMOTE CABLE INTERFACE
ALARMS - BELDEN TYPICAL MULTI PAK
CUT TO LENGTH
DC OUTPUT 4 OR 2 AWG BLK
8 OR 6AWG GROUND WIRE GRN/YEL
AC LINE SENSE - 18AWG BLK WIRE
031-099-C0-001 Rev. A.
4-11
4.
Addendum
Fig. 4.12
Interconnection wiring between
AlphaGen 3kW APU and Engine Control
Module.
031-099-C0-001 Rev. A.
4-12
4.
ECM
Addendum
PWR-GRI
(OPTION)
J10
COMM
GHD
Alarm Interface
PLUG
LFP
PLUG
Water
Intrusion
J4
Fig. 4.13
Door
Open
Pad
Shear
Wiring arrangement within the 5kW
engine-generator cabinet.
APU Control Interface
NOTE: For additional information
regarding the generator set, refer
to the Alpha-5 Operation Manual.
(Kohler Power Systems document
number TP-6076 12/99)
ALARM
RESET
READY
Inverter Battery Sense
J8
ALARM
GAS DETECTOR
Charger Control
MODEL HIC
Chestec Corporation
Output
RED
Port Washington, NY
842
Gas
Sensor
Low
Fuel
Pressure
BLK
RED
DC Power
Fan
2
1
J2
J6
1
3
2
4
DCN-DCP
Line
Sense
Pin 1
Gas
Solenoid
APU
I/O
-
+
GSC
Plug
120V
POS
Ign.
Batt.
120V
NEUT
Battery
Heater
option
120V
-
+
Line
Sense
DC
Output
031-099-C0-001 Rev. A.
NEG
-
+
APU Control PCB
NEG
Alarm
Interface
POS
POS
NEG
Ignition Battery
DC Out
See Alpha 5 Manual,
Kohler Power Systems document
# TP-6076, 12/99
Engine Alternator Compartment
4-13
4.14
4.
Cabinet Lifting Procedures
4.14.1
Lifting Bar
3.
Use the "quick pins" to attach the cross
support brace (flat side up).
The enclosure as shipped contains the Auxiliary Power Unit
(APU) and, therefore, is heavy (approximately 355 pounds). 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.
CAUTION: 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.
7.
CAUTION: The ignition battery MUST NOT be installed
until the enclosure is set in place on its
permanent location.
The system is shipped bolted to a pallet. Once the system
arrives, remove the protective outer wrapping material and inspect
the outside of the enclosure for shipping damage. Use a forklift to
place the unit (still bolted to its pallet) in the back of the transport
vehicle for delivery to the installation site. Once on site, follow the
procedure outlined on the following pages to lift the enclosure from
the shipping pallet and place it on the concrete pad.
Lifting Procedure (2.7kW - 3kW APU):
1.
Remove the front and rear doors of
the enclosure, and remove the bolts
which secure the enclosure to the
pallet.
4.
Insert lifting bar into guide channels
with the "center notch" facing up.
The center notch serves to locate
the bracket within the rack for
stability. Use caution not to hit the
gas hazard sensor which is located
in the right rear of the cabinet (see
detail below).
Lifting bar assembly
The center buckle "quick-bolt" will
become the lifting point as shown.
Hold the straps and center buckle away
from the cabinet surface to prevent paint
damage. Have the lift operator begin to
take up the slack in the straps.
CAUTION : Do not allow fingers
or hands to get between the
strap(s) and the buckle. This is a
pinch hazard!
8.
The unit is now suspended from the
center buckle "quick-bolt" and
ready to be positioned over the
concrete pad.
Failure to comply with the warnings
could result in severe personal injury
or death!
5.
2.
Attach the nylon lifting straps (1,800 lb.
capacity each) to the u-bolts, and secure ubolt to the end of each lifting bar (4 places)
by means of a hand-tightened pin.
WARNING! Read the accompanying safety
labeling tags on the lifting straps. The labels
detail important information regarding the safe
and proper use of the lifting straps.
Addendum
6.
Attach the nylon lifting straps (1,800 lb.
capacity each) to the center buckle.
Arrange the straps such that the two straps
from the rear of the enclosure are at the
center of the buckle and inside the two
straps from the front of the cabinet.
9.
During the lifting procedure, use a safety
spotter to prevent personnel from
walking under the suspended cabinet
and to ensure the lifting bars and straps
are properly positioned at the beginning
of and throughout the lifting procedure.
Insert the center buckle "quick-bolt" as
shown. Notice the rear straps located in the
center of the buckle, and the front straps
located at the sides of the buckle. The
center buckle "quick bolt" will become the
lifting point.
Gas sensor
Detail of lifting bar placement
031-099-C0-001 Rev. A.
4-14
Investigate the
of Alpha @ www.alpha.com
©
UNITED STATES
ASIA PACIFIC
LATIN AMERICA
Alpha Technologies
3767 Alpha Way
Bellingham, WA 98226
Tel: (360) 647-2360
Fax: (360) 671-4936
Web: www.alpha.com
CANADA
Alpha Technologies
7033 Antrim Ave.
Burnaby, B.C. V5J 4M5
Tel: (604) 430-1476
Fax: (604) 430-8908
UNITED KINGDOM
Alpha Technologies
Cartel Business Estate
Edinburgh Way
Harlow, Essex CM20 2DU
Tel: +44-1279-422110
Fax: +44-1279-423355
GERMANY
Alpha Technologies
Hansastrasse 8
D-91126 Schwabach
Tel: +49-9122-997303
Fax: +49-9122-997321
MIDDLE EAST
Alphatec
P.O. Box 6468
3307 Limassol, Cyprus
Tel: +357-5-375675
Fax: +357-5-359595
AUSTRALIA
Alpha Technologies
8 Anella Ave., Unit 6
Castle Hill, NSW 2154
Tel: +61 (0)2 9894-7866
Fax: +61 (0)2 9894-0234
Due to continuing product improvements, Alpha reserves the right to change specifications without notice.
Copyright © 2000 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies. 031-099-C0-001 Rev. A.
4.14
4.14.1
10.
2.
4.14.2
Lifting Straps
CAUTION: 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.
The 5kW APU enclosure may be lifted
via the overhangs at the top of the
cabinet. Use straps rated for loads of
at least 500 lbs.
1
A1
Do not attempt to force the
cabinet to a level position
during this procedure; the
cabinet will right itself once
placed on the pad.
Cabinet Lifting Procedures
1.
Addendum
Lifting Bar
Notice the rearward tilt of the
cabinet indicating the Center of
Gravity is slightly behind center.
This is normal and prevents the
lifting bar from resting on the gas
hazard sensor.
NOTE:
4.
Cabinet Lifting Procedures
3.
When routing the straps, use OSHAapproved protective sleeves over the
straps to prevent damage due to
chafing from edges of the cabinet
overhangs, or the lodging of the straps
in the spaces between the roof
overhang and the side(s) of the
cabinet.
4.
1
A1
Position the system over the pad (refer to
the installation instructions in section 3.2)
and lower into place.
1
A1
Once the lifting straps are in place, lift
slowly to take up any slack in the straps.
CAUTION: Do not allow fingers or
hands to get between the strap(s)
and the lifting ring. This is a pinch
hazard!
Remove the front and rear doors of
the enclosure, and remove the bolts
which secure the enclosure to the
pallet.
031-099-C0-001 Rev. A.
4-15