PME. Series Enclosures. Battery Enclosure (BE) Field Upgrade Installation Instructions. Effective: January, Alpha Technologies

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1 PME Series Enclosures Battery Enclosure (BE) Field Upgrade Installation Instructions Effective: January, 2004 Alpha Technologies

2 Power Alpha Technologies. Protecting The Power in Communications.

3 Preface PME Series Enclosures Battery Enclosure (BE) Field Installation Instructions C0-001 Rev. A January, 2004 Copyright 2004 Alpha Technologies, Inc. NOTE: This manual covers the installation of the PME Battery Enclosure. Always work with the local utilities when connecting the enclosure to these utilities and observe all local and national laws which may be applicable for your area. NOTE: Photographs contained in this manual are for illustrative purposes only. These photographs may not exactly match your installation. NOTE: Review the drawings and illustrations contained in this manual before proceeding. If there are questions regarding the safe installation and operation of this enclosure or powering system, please contact Alpha Technologies or your nearest Alpha representative. Contacting Alpha Technologies: For general product information and customer service (7:00 AM to 5:00 PM Pacific Time ) For complete technical support (7:00 AM to 5:00 PM Pacific Time, or 24/7 emergency support) Save these instructions for future reference C0-001 Rev. A 3

4 Preface PME Series Enclosures Table of Contents BE Installation... 9 BE Kit Contents Mounting Bracket Installation Installing the Battery Enclosure (BE) on the PME Battery Installation Cable Connections Final Assembly List of Figures Fig. 1-1 The BE Kit Fig. 1-2 Placing Template Fig. 1-3 Mounting Bracket Spacing Fig. 1-4 Detail of Bracket Installation Fig. 1-5 Lid and Door Removed Fig. 1-6 Mounting BE Enclosure onto the PME Fig. 1-7 BE Enclosure in place Fig. 1-8 Battery and RTS Placement and Connection Fig. 1-9 Cable Routing Fig Door and Lid in Place Fig Grounding Lug C0-001 Rev. A

5 Preface IMPORTANT SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL CAUTION HAZARDOUS CONDITION Become familiar with the power supply s front panel. Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of the XM Series 2 Uninterruptible Power Supply, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference. To reduce the risk of injury or death caused by electrical shock, explosion of fuel or moving parts; 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. DANGEROUS VOLTAGE This symbol indicates a dangerous voltage may exist 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 may exist in this area of the product. Use caution whenever working in the area to prevent possible inhalation of harmful (fuel or exhaust) vapors. NO MATCHES OR OPEN FLAMES This symbol indicates a fire or explosive hazard may exist in this area of the product. Use caution whenever working in the area to prevent possible combustion of fuel vapors. MECHANICAL OR MOVING PARTS HAZARD These symbols indicate a mechanical or moving parts hazard may exist in this area of the product. Use caution whenever working in the area to prevent possible injury to the operator or service personnel. LEAK HAZARD This symbol indicates a leak hazard may exist in this area of the product. Use caution whenever working in this area to prevent and correct any leaks detected. ATTENTION This symbol indicates important installation, operation or maintenance instructions. Always follow these instructions closely. NOTE: 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 C0-001 Rev. A 5

6 Preface General Safety Precautions A Warning identifies conditions and actions that pose a hazard to the user. A Caution identifies conditions and actions that may damage the power supply or associated equipment. Warnings NOTE: This enclosure and its associated hardware (power supply, batteries, cabling) may contain equipment, batteries or parts which have accessible hazardous voltage or currents. To avoid injury: This enclosure and its associated hardware must be serviced by authorized personnel only. 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. An improperly connected battery cable or an unconnected battery cable 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 which is explosive. Proper venting of the enclosure is required. Follow the battery manufacturer s approved transportation and storage instructions C0-001 Rev. A

7 Preface General Safety Precautions NOTE: 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 does 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 on your body. Alpha Technologies is not responsible for unit damage due to enclosure or installation temperatures which exceed the operating temperature of the product C0-001 Rev. A 7

8 Preface Battery Safety Notes Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery installation, maintenance, service and replacement must be performed by authorized personnel only. Chemical Hazards NOTE: Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contain dilute sulfuric acid, which is harmful to the skin and eyes. Emissions are electrolytic, which are electrically conductive and corrosive. To avoid injury: Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel knowledgeable of batteries and the required safety precautions. Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all metallic objects from hands and neck. Batteries produce explosive gases. Keep all open flames and sparks away from batteries. Use tools with insulated handles, do not rest any 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. If any battery emission contacts the eye, wash immediately and thoroughly with water for 10 minutes with pure water or a special neutralizing eye wash solution and seek immediate medical attention. 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 1 lb. Bicarbonate of soda to 1 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 C0-001 Rev. A

9 Installation BE Installation Overview The PME Battery Enclosure was designed to allow the customer to add additional batteries in the field for additional standby/run time. Upon receipt, the enclosure should be unpacked and inspected for shipping damage. The following items should be enclosed: 1. Battery Enclosure (Alpha P/N ) 2. Battery Cable Y Adapter (Alpha P/N ) 3. Battery Cable Kit (Alpha P/N ) 4. Pole Mounting Bracket 5. Bracket Hole Drilling Template 6. New PME Door 7. New PME Lid 8. Mounting Hardware Tools and Materials Needed: Digital Volt-Ohm Meter Hand Operated Rivet Gun with.156 nosepiece 3/4 Drill Motor 3/4 Auger Bit (long enough to drill through pole) 7/16 Wrenches and Sockets Torque Wrench 3 Batteries (manufacturer and type to match existing batteries) IMPORTANT INSTALLATION NOTES NOTE: The total combined weight of a fully-populated PME and BE is approximately 600 pounds. Verify stability of the mounting pole before installation. The system must be installed ONLY by qualified service personnel. 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. Secure permission of pole owner for mounting of enclosure. Obtain, review, and follow all appropriate electrical, building and installation codes the local area and utilities. Verify lifting equipment is safe and capable of weight requirements. and practices of Verify area around, above and below is clear of all obstructions which may pose a hazard during installation. Post necessary hazard warnings for the work area C0-001 Rev. A 9

10 Installation BE Installation, continued BE Kit Contents PME-BE Door Drilling Template Mounting Bracket Fig. 1-1 The BE Kit C0-001 Rev. A

11 Installation BE Installation, continued Mounting Bracket Installation WARNING: Follow all manufacturer s operating and safety instructions for the use of power tools and punch drivers. Set BATTERY BREAKER on the power supply to the OFF position. Secure service power to the enclosure for the duration of the installation. 1. Place the drilling template on top of the upper pole bracket, and hold flush against the pole. Use the lower hole for the PME. 2. Mark the hole location, and remove the template. Drill a 3/4 hole through the pole. 13 1/2" 12 1/2" Fig. 1-2 Placing Template C0-001 Rev. A 11

12 Installation BE Installation, continued Mounting Bracket Installation, continued 3. Install the mounting bracket using a 1/2 bolt, washers, and nut. 12.5" 18" REF. Fig. 1-3 Mounting Bracket Spacing Fig. 1-4 Detail of Bracket Installation C0-001 Rev. A

13 Installation BE Installation, continued Installing the Battery Enclosure (BE) on the PME 1. Remove the PME door and lid. NOTE: Service personnel may encounter either of two styles of lids for the PME series enclosure. After removing the door, the pinned lid may simply be lifted away from the enclosure. If the lid is hinged (piano-style), it will be necessary to drill out the rivets securing the lid to the enclosure. Fig. 1-5 Lid and Door Removed C0-001 Rev. A 13

14 Installation BE Installation, continued Installing the Battery Enclosure (BE) on the PME, continued 2. Align the pole mount strap on the BE-PME with the mounting plate on the pole. Lower the BE enclosure onto the top of the PME (Fig. 1-6). Verify the flange on the bottom of the BE enclosure fits over the OUTSIDE of the PME enclosure on both sides and the back. Tighten the retaining bolt on the BE-PME pole mount strap to secure the BE enclosure to the mounting plate. Fig. 1-7 BE Enclosure in place Fig. 1-6 Mounting BE Enclosure onto the PME C0-001 Rev. A

15 Installation BE Installation, continued Battery Installation 1. Remove the BE enclosure lid, and hang to the side on the lanyard. Install three batteries as shown below. Attach Battery Cable Kit and remote temperature sensor according to the diagram. 2. Using a multimeter, verify that the battery pack has at least 36 VDC at the connector. Verify polarity is correct (red = pos, black = neg). 3A - 2A - 1A POS Remote Temp Sensor (RTS) NEG Fig. 1-8 Battery and Remote Temperature Sensor (RTS) Placement and Connection C0-001 Rev. A 15

16 Installation BE Installation, continued Cable Connections 1. Verify the BATTERY BREAKER on the power supply is in the OFF position. Unplug the existing battery pack and RTS from the front of the power supply. Verify polarity prior to making any connections. 2. Plug the Y adapter into the front of the power supply. Connect both battery packs to the remaining plugs of the Y adapter. Power Supply Fig. 1-9 Cable Routing C0-001 Rev. A

17 Installation BE Installation, continued Final Assembly 1. Reinstall the BE enclosure lid 2. Install the new front door 3. Run a new #6 solid copper grounding wire from the grounding lug on the back of the BE enclosure to the grounding rod at the base of the pole (Fig. 1-11). Fig Door and Lid In Place Fig Grounding Lug C0-001 Rev. A 17

20 Power Protecting The Power in Communications. Alpha Technologies 3767 Alpha Way Bellingham, WA USA Tel: (360) Fax: (360) Alpha Technologies Ltd McConnell Court Burnaby, BC, V5A 3N7 CANADA Tel: (604) Fax: (604) Alpha Technologies Europe Ltd. Cartel Business Estate Edinburgh Way Harlow, Essex CM20 2TT UNITED KINGDOM Tel: Fax: Alpha Technologies Hansastrasse 8 D Schwabach GERMANY Tel: Fax: Alphatec 339 St. Andrews Street Suite 101 Andrea Chambers Limassol, Cyprus CYPRUS Tel: Fax: Alpha Technologies Unit R5-R7 Regents Park Estate Corner Park Rd and Prince s Rd East Regents Park, NSW 2143 AUSTRALIA Tel: Fax: Due to continuing product improvements, Alpha reserves the right to change specifications without notice. Copyright 2004 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies C0-001 Rev.A.

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