Underground Battery Vault Site Preparation and Installation Effective: August 2006 Alpha Technologies
Alpha Technologies Power ®
Underground Battery Vault Site Preparation and Installation 031-040-B0-002 Rev. B Effective Date: August 2006 Copyright © 2006 Alpha Technologies, Inc. member of The GroupTM NOTE: Photographs contained in this manual are for illustrative purposes only. These photographs may not match your installation. NOTE: Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding.
Contents Safety Notes .......................................................................................................................... 5 Battery Safety Notes.............................................................................................................. 6 Mechanical Safety ................................................................................................................. 6 1. INTRODUCTION ..................................................................................
Safety Notes Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of 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.
Safety Precautions, continued • Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can result in a fire or possible explosion. • 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. • Remove all rings, watches and other jewelry before servicing batteries.
IMPORTANT INSTALLATION NOTES THE SYSTEM SHOULD BE INSTALLED ONLY BY QUALIFIED SERVICE PERSONNEL. ALWAYS CONSULT LOCAL CODES FOR CONCRETE PAD REQUIREMENTS. CONSULT LOCAL UTILITY CODES FOR ADDITIONAL CABINET GROUNDING AND UTILITY REQUIREMENTS. CONSULT THE LOCAL GAS COMPANY FOR CORRECT METER TYPE AND RISER LOCATION. THE ENCLOSURE SHOULD BE INSTALLED ABOVE FLOOD ZONES WHENEVER POSSIBLE. THE PAD MUST BE AT LEAST 6” THICK AND CAPABLE OF HOLDING 4,000 LBS (MINIMUM).
1. INTRODUCTION 1.1 Underground Battery Vault Alpha’s UBV Series Underground Battery Vaults and BVE enclosures meet municipal and state regulations involving line of sight restrictions. These utility approved vaults are manufactured from high density polyethylene (HDPE) and can house up to eight batteries. Several options are available including combinations with ground and pole mount power supply enclosures. UBV Underground Battery Vaults Standard Features HDPE Vault (in): 43.5L x 31.
2. INSTALLATION 2.1 Site Prep and Installation For installations where the optional concrete pad is not used: 1. Excavate the site approximately 6” deeper than the overall height of the vault. The length and width of the hole should be 4” to 6” more than the width and depth of the vault. 2. Use 6” of compacted gravel as a base for the vault. Level the gravel so the top of the vault is flush with grade. 3. Finish installation by adding backfill and compacting.
2. INSTALLATION Battery Placement + - + - + - + 2 + 3 - + - 1 - - + + 2.2 2 1 To install two 48 VDC battery strings in the UBV, load them in this order (observe indicated orientation with respect to battery polarity): 10 1. Install batteries in the corners. 2. Install either of these pairs of batteries next. 3. Install this pair last. 031-040-B0-002 Rev.
2. INSTALLATION 2.2 Battery Placement, continued + - - + + Single 36V battery string with AG-CMT-3SC-P - + - + - - + + Dual 36V battery string with one AG-CMT-3SC-P per string (2 total) - - + - + - + - + Single 48V battery string with AG-CMT-4SC-P + + - + - + + - + + - 031-040-B0-002 Rev.
2. INSTALLATION 2.3 Battery Connection Depending on the size of the vault, strings of 3, 4, 6, or 8 batteries may be installed, along with an optional AlphaGuard Battery Monitoring system. After securing the UBV, and installing the batteries, make the wire connections to the batteries as shown. Installation and Connection Procedure: 1. Label the batteries. 2. Install the batteries into the underground battery vault. 3. Spray terminal and hardware with battery corrosion inhibitor before assembly, 4.
2. INSTALLATION 2.3 Battery Connection, continued 2.3.1 Charge Management Technology (CMT) The AlphaGuard monitors and protects the batteries by spreading the charge voltage equally across all the batteries in a string, ensuring that every battery in the string, whether old or new, is properly charged. With an ideal voltage always across each battery, life and runtime are optimized. Individual batteries in a string can be replaced as they fail, allowing batteries to be left in service longer.
2. INSTALLATION 2.3 Battery Connection, continued 2.3.1 Single 36V Battery String Wiring Diagram To BATTERY INPUT connector + - To TEMP PROBE connector Remote temperature sensor - - - Fuse on battery terminal + Black Brown Locate this connection above high water mark or source of high humidity + To Status Monitoring Card 24V 36V + 12V Orange Yellow AG-CMT-3SC-P-C Battery Monitoring cable Fig. 2-4 AG-CMT-3SC-P-C Wiring for Single 36V Battery String 14 031-040-B0-002 Rev.
2. INSTALLATION 2.3 Battery Connection, continued 2.3.
2. INSTALLATION 2.3 Battery Connection, continued 2.3.3 Single 48V Battery String Wiring Diagram To BATTERY INPUT connector Remote temperature sensor attached to side of central battery To TEMP PROBE connector + 36V - + 24V - - - + 12V 48V + + Fuse on battery terminal Yellow To Status Monitoring Card Orange Black Brown Battery Monitoring cable 9’ cable : Alpha p/n 875-510-20 35’ cable: Alpha p/n 875-510-23 AG-CMT-4SC-P-C shown Fig.
2. INSTALLATION 2.3 Battery Connection, continued 2.3.
2. INSTALLATION 2.4 Battery Covers Battery covers for the 165 and 180 series batteries are available and protect the batteries from water, dirt and corrosion. The battery covers for the 165 GXL and 180 GXL batteries are different sizes. The 180 GXL battery cover is the larger of the two. The battery specific covers are not interchangeable. Fig. 2-8 165 GXL Battery Cover Group 27 (Alpha p/n 745-778-20) 18 Fig. 2-9 180 GXL Battery Cover Group 31 (Alpha p/n 744-524-20) 031-040-B0-002 Rev.
2. INSTALLATION 2.4 Battery Covers, continued 2.4.1 Installing the Battery covers For the 165GXL battery, the cover locking mechanism fits under the battery handle tab molded into the battery case. To properly seat the cover, the battery handle must be pushed down as shown to allow space for the cover latch to engage at “X”. X For the 180 GXL battery, the carry strap does not need to be pushed down. The cover will latch at “X”.
2. INSTALLATION 2.4 Battery Coovers, continued 2.4.1 Installing the Battery Covers, continued Fig. 2-10 165 AGM Battery with Cover in Place Fig. 2- 11 180 GXL Battery with Cover in Place 20 031-040-B0-002 Rev.
2. INSTALLATION 2.5 Temperature Sensor Temp Probe Connector: The Remote Temperature Sensor (RTS) plugs directly into the temperature probe (RJ-11C type) connector. The sensor end of the RTS is routed to the battery compartment and taped directly to the side of the center battery (See Fig. 2-12). The RTS provides battery temperature measurements used to adjust the battery charge voltage. Attach the probe to the side of the battery so that it is protected by the cover. Fig.
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