© 2002 TM

®

CESC-3X Compact AlphaGen System Sidecar

Installation Manual

Effective: March, 2002

2031-099-C0-001 Rev. A © 2002 TM

3 031-099-C1-001 Rev. A© 2002 TM

NOTE: Photographs contained in this manual are for illustrative purposes only. Thesephotographs may not exactly match your installation.

CESC-3X SidecarInstallation Manual

031-099-C1-001 Rev. AMarch, 2002

© 2002 Alpha Technologies

NOTE: Review the drawings and illustrations contained in this manual beforeproceeding. If there are questions regarding the safe installation of thissystem, please contact Alpha Technologies or your nearest Alpharepresentative

TM

R

4031-099-C0-001 Rev. A © 2002 TM

1. Introduction

5 031-099-C1-001 Rev. A© 2002 TM

Pads can either be poured on site, or precast by Alpha Technologies. The mountingholes on the bottom of the side car will fit both a standard PN-3 pad, and a CE3X pad.Precast pad model number PCD-SC-3X, Alpha P/N 641-064-10 is available for thissystem.

2.1 Concrete Pad Preparation

2. Installation

A 25+ year continuous vapor barrier must be used between the enclosureand the pad to prevent moisture ingress and possible corrosion caused bymetal to concrete contact. The vapor barrier material (such as 30 lb felt,neoprene pond liner, or heavy grade tar paper) must be initially extended atleast 6" in all directions around the perimeter of the enclosure. After theenclosure is secured to the pad, the material can be cut closer to theenclosure, using the appropriate knife or cutting tool.

5.5

9.2

3.5

3.5

22.0

CESC-3X

Generator

10.25

6.8

All Measurmentsin Inches

19.5

14.7 1

23

4

5

6

Indicates enclosure matingsurface

1 All measurements indixed to theleft-front generator mounting stud

2

3 Alpha standard, recomended distance,between edge of pad and enclosure

4 4" diameter through-hole for AC Powersweep (non-metered installation)

5 All mounting hardware must be stainlessor galvanized to prevent corrosion

6 5" X 8" cutout for internal connectionsto generator, and coaxial cable sweeps

2. Installation

6031-099-C0-001 Rev. A © 2000 TM

2.2 Utility Power Connection

Table 2-1; Service Entrance Circuit Breaker Requirements

noitpircseDahplA

rebmuNtraPDerauqS

rebmuNtraP)A51(citengaMnoN-noitallatsnIV042 01-422-074 5120Q

)A02(citengaMhgiH-noitallatsnIV021 01-710-074 MH9210Q

)A51(citengaMhgiH-noitallatsnIV021 01-310-074 MH5110Q

tcennocsiDecivreSlanretxE-XBB 01-580-020 BR07L4-20Q

CAUTION: The “Utility Power Connection” procedure must ONLY beperformed by qualified service personnel and in compliancewith local electrical codes and common safety practices.Connection to utility power must be approved by the localutility before installing the power supply.

NOTE: UL and NEC require that a service disconnect switch (UL listed) beprovided by the installer and be connected between the powersource and the ALPHA power supply. Connection to the powersupply must include an appropriate service entrance weather head.

Wiring the Utility Service

Utility power enters the enclosure through the side or bottom of the UPE. Theenclosure accepts a standard electrical fitting. The UPE Series can be equipped with anoptional circuit breaker assembly located in the enclosure’s module compartment.

NOTE: A “high-magnetic” trip circuit breaker must be used in order toaccommodate the high-inrush currents normally associated with thestart-up of ferroresonant transformers (400 Amp, no-trip, first-halfcycle). Do not replace this circuit breaker with a conventional serviceentrance circuit breaker. Alpha recommends Square D circuit breakersONLY, because of increased reliability in this powering application.

Alpha Technologies offers a high-magnetic Square D circuit breaker and a BBX option (aUL Listed service entrance). Contact your local sales representative for more information.

In most cases, the following configurations (see next page) qualify for serviceentrance use, however, other codes may apply. Always contact your local utility toverify that the wiring conforms to applicable codes.

2. Installation

7 031-099-C1-001 Rev. A© 2000 TM

240VAC Service (XM Series 2 915-240 Power Supply; XM Series 2 922-48 for UPE-4 and UPE-8): Enclosures used with the XMSeries 2 915-240 or 922-48 are equipped with a 240VACduplex receptacle to provide power to the power supplyand peripheral equipment. The receptacle, NEMA 6-15R, is protected by a single, 2-pole, common trip 15Amp circuit breaker located inside the service entrance.Wiring is typically 14AWG per NEC code, a groundingclamp, located on the enclosure, facilitates dedicatedgrounding.

120VAC 20A Service (XM Series 2 915-120 Power Supply): Enclosures usedwith the XM Series 2 915-120 are equipped with a120VAC duplex receptacle to provide power to thepower supply and peripheral equipment. The receptacle,NEMA 5-20R, is protected by a single, 2-pole, commontrip 20 Amp circuit breaker located inside the serviceentrance. Wiring is typically 12AWG per NEC code, agrounding clamp, located on the enclosure, facilitatesdedicated grounding.

120VAC 15A Service (XM Series 2 615): Enclosures used with the XM Series2 615 are equipped with a 120VAC duplex receptacleto provide power to the power supply and peripheralequipment. The receptacle, NEMA 5-15R, is protectedby a single-pole, 15 Amp High Magnetic circuit breakerlocated inside the service entrance. Wiring is typically14AWG per NEC code, a grounding clamp, located onthe enclosure, facilitates dedicated grounding.

NOTE: Alpha recommends wiring with 12AWG, in case the enclosureis to be upgraded to use 90V power supplies in the future.

2.2 Utility Power Connection, continued

2. Installation

8031-099-C0-001 Rev. A © 2000 TM

ISE 120 VAC 15 Amp

ISE 120 VAC 20 Amp

ISE 240 VAC 15 Amp

2.2 Utility Power Connection, continued

Ground

Neutral

Line

ON

OFF

Ground

Neutral

Line

ON

OFF

Ground

Line 2

ON

OFF

Line 1

2. Installation

9 031-099-C1-001 Rev. A© 2000 TM

ON

OFF

NeutralLine 1Ground From Utility

To Enclosure

240 VAC ServiceEntrance

120 VAC ServiceEntrance

2.2 Utility Power Connection, continued

ON

OFF

ON

OFF

NeutralLine 1Line 2Ground From Utility

To Enclosure

2. Installation

10031-099-C0-001 Rev. A © 2000 TM

OFF

20

ON

GroundLine 2Neutralline 1

OFF

ON

GroundNeutralline 1

2.2 Utility Power Connection, continued

240 VAC Meter Base

120 VAC Meter Base

2. Installation

11 031-099-C1-001 Rev. A© 2000 TM

GeneratorEnclosureSide Wall

SidecarEnclosureBack Wall

DC Output From Generator

LineNeutralGround

PositiveNegative

120 VAC From Service Entrance

ECM Interface

3" PVCCoupling

The following cables must be routed either through a 3" sweep or coupling:

#4 AWG DC Output from the generator

120 VAC power from the CESC sidecar service entrance

ECM or ACU Interface cable

2.3 Generator / Sidecar Inter-connecting Cables

12031-099-C0-001 Rev. A © 2002 TM

Input Power Panel (IPP)

SPI

EnclosureGrounding Rail

A cooling fan is required any time aPower Supply is housed in the side car.The fan is thermostatically controlled toturn on at 140 deg F and off at 110 degF. The fan cable has a 'T' connectorthat attaches to the Power Supplyoutput connection. Replace fuse onlywith a 1/4” X 1-1/4”, 5 Amp, 250 Volt(Alpha P/N 460-025-10).

2.4 Internal Components

2. Installation

Cooling Fan

Fuse

AC Power Connections

Thermostat

The Sidecar enclosure contains anInput Power Panel (IPP), one or twoService Power Inserters (SPI),and theEnclosure Grounding Rail. The PowerSupply rests on the upper shelf, and a48 VDC battery pack on the lower twoshelves.

2. Installation

13 031-099-C1-001 Rev. A© 2000 TM

1

2

4

3

1

3

2

Upper Shelf

Lower Sheff

48 VoltBattery Pack

36 VoltBattery Pack

2.5 Battery Pack Wiring

14031-099-C0-001 Rev. A © 2002 TM

XM2 Power Supply

Output to SPIand Fan Battery Pack Input

AC Power Cord

2.6 Power Supply Placement

1. Place the XM2 power supply onto the top shelf of the side car.

2. Verify that the AC Input Breaker in the service entrance is in the OFF position.

3. Verify that the Battery Breaker on the front of the power supply is in the OFFposition.

4. Plug the AC power cord into the Input Power Panel on the side of the enclosure.

5. Plug the Battery Input Cable from the battery pack into the Battery Inputconnection on the front of the power supply.

6. Plug the wire leading from the fan into the OUTPUT 1 connection on the front ofthe power supply.

7. Plug the wire leading from the top SPI into the other set of plugs on the wirefrom the fan.

8. If a second SPI is installed, plug it into the OUTPUT 2 connection on the front ofthe power supply.

2. Installation

15 031-099-C1-001 Rev. A© 2002 TM

2. Installation

2.7 Battery Remote Temperature Sensor (RTS)

Tools Needed:

Adhesive Tape

Procedure:

For enclosures with multiple battery strings, the RTS must be locatedwith the WARMEST battery string. This ensures proper operation ofthe battery charger’s temperature compensation circuit. Failure tolocate the RTS with the warmest battery string could result inovercharging and premature battery failure. In this application, the RTSMUST be attached to a battery in the upper tray of the side-car.

1. Attach the RTS Probe to the inner side of one of the batterieson the upper tray of the side-car with adhesive tape.

2. The other side of the RTS Probe is attached to the front panel of theXM2 power supply, in the jack labeled TEMP PROBE

16031-099-C0-001 Rev. A © 2002 TM

2. Installation

2.8 Service Power Inserter

1. The SPI box(es) are mounted on the shelf support bracket.

2. Remove the two screws on the face of the SPI and lift offthe cover to gain access to the Seizure Screw Assembly.Loosen the Seizure Screw several turns so that the stingerwill pass through the clamp. (Fig 2-3)

3, Insert the Coaxial Termination into the outputport on the bottom of the SPI. Ensure that thestinger goes through the Seizure Screw Assembly.Tighten the Coaxial Termination.

4. Tighten the seizure screw to 35.0 Inch-Pounds.Replace the SPI cover and screws.

Ensure that the switch on the top or the SPI isin the ON position, the AUX position is used onlywhen an alternate power source is connected tothe 'Jones" connector on the top of the SPI.

Seizure ScrewAssembly

CoaxTermination

SeizureScrew

CoaxStinger

UNITED STATESASIA PACIFICLATIN AMERICAAlpha Technologies3767 Alpha WayBellingham, WA 98226Tel: (360) 647-2360Fax: (360) 671-4936Web: www.alpha.com

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GERMANYAlpha TechnologiesHansastrasse 8D-91126 SchwabachTel: +49-9122-79889-0Fax: +49-9122-79889-21

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AUSTRALIAAlpha Technologies8 Anella Ave., Unit 6Castle Hill, NSW 2154Tel: +61 (0)2 9894-7866Fax: +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. ATM

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© 2002