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3.0 INSPECTION AND PRE-INSTALLATION SET UP
Several inspection and pre-installation setup steps should be performed at this time to assure
future trouble free operation and to allow the worker to become familiar with the controls and
functions.
The BT-D unit is shipped in a carton fully assembled with the mounting channel, decoupler and
safety cover in place. The unit is shipped with the output shaft in the closed position, set for 90°
of rotation turning clockwise to open as viewed from above unless specified otherwise by the
customer. Rotation travel and direction are easily changed in the field. The battery is in place, but
the fuse is removed and stored separately.
3.1 INITIAL INSPECTION
Upon receiving the unit, open and inspect the carton and its contents. Report any shipping
damage to the delivering carrier. Record the nameplate data on page 2.
3.2 CHECK BATTERY
Check the battery voltage with a voltmeter to make sure that it is healthy. If it is less than 12.4 volts,
the battery may already be damaged beyond repair. Contact the factory. Refer to section 7.0 -
ADMO™ BATTERY CARE AND STORAGE.
3.3 CHECK PLUG-IN CONNECTORS
Check and make sure that all plug-in connectors are fully seated before testing the motor.
3.4 TEST MOTOR OPERATION
Install the battery fuse in the fuse block. The fuse is found taped to the main battery cable. A spare
fuse will be clipped to the inside of the enclosure door.
NOTE: Wait five minutes for the unit to power up and perform a self-test. The motor will not
run until this sequence is complete.
Refer to section 5.1 - CONTROLS for instructions and then electrically operate the unit. This will
verify that the unit works before it is installed.
If the unit is to be installed immediately, the battery fuse may be left in place. If the battery is fully
charged and the unit is to be stored, remove the fuse.
Any problems should be reported to the factory at (724) 864-4177. Please refer to the serial and
style numbers on the nameplate when making inquiry.
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4.0 INSTALLATION
An installation, either new or replacement must begin with a completely installed and adjusted
overhead switch which is operating properly with a manual handle. The switch linkage, when
possible, should be adjusted so that the drive lever at the top of the vertical operating pipe goes
into toggle when the switch is closed. This provides a locking action to keep the switch closed
under short circuit conditions.
NOTE: Use discretion in lubricating the overhead switch. As the weather causes the lubricant to
deteriorate, operating friction increases thereby possibly reducing switch travel. Any significant
change in switch travel may affect auxiliary switch adjustment. See section 4.6 - 4.7.
4.1 DETERMINE LIMITS OF TRAVEL
Manually operate the overhead switch. Measure and record the approximate number of
degrees of vertical pipe rotation required to open and close the switch. You will need this
measurement when installing the decoupler in step 4.5.
4.2 DETERMINE AND PREPARE OPERATOR LOCATION
CLOSE THE SWITCH. If there is an existing operating device, remove it completely leaving the
vertical pipe in place. The only hardware needed from the original installation will be the vertical
pipe and the pipe ground strap. A new installation should have the vertical pipe in place but not
cut to length.
If this is a standard ground level installation, cut the bottom of the vertical pipe so that the end will
be 60" above ground level. If local practice requires mounting at a different height, cut the vertical
pipe to that length. Remember, the swing handle will be located
at the bottom end of the vertical pipe.
4.3 MOUNTING OPERATOR TO THE POLE
A. Refer to the attached drawings. Drill the two 11/16" (17mm)
diameter hanger bolt holes through the pole. The top hole
should be carefully drilled exactly even with the end of the
vertical pipe. The bottom hole should be 31"(787mm) down
from the top hole. Insert the top hanger bolt so the nut is on
the back side of the pole.
B. Slip the safety cover up high on the vertical pipe. Use tape
to temporarily hold it. Be sure the danger label is in front.
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C. Uncouple and set aside the top half of the decoupler.
Remove the crossbolt, but
leave the bottom half of
the decoupler on the output shaft
.
Do not remove the
rubber bands from around the decoupler half. They
are there to provide the correct spacing between the
decoupler halves.
Lift the operator unit into place (the
top hole in the back channel is provided for hoisting).
As the unit is lifted into place, guide the lower end of
the vertical pipe over the output shaft and hang the
operator on the top hanger bolt using the keyhole
shaped mounting hole.
Insert the bottom hanger bolt from the back side of
the pole. The nut must go against the face of the
mounting channel. Tighten but do not overtighten the
hanger bolts. Install two lag bolts in the holes next to
the bottom hangar bolt. This will assure the unit does
not loosen as the pole shrinks with age.
Reinstall the crossbolt.
Note: A 1/8" gap is required between the end of the vertical pipe and the crossbolt. This is to
prevent the pipe from dragging on the bolt during an uncoupled motor operation.
4.4 ESTABLISH DIRECTION OF ROTATION
As received from the factory, the BT-D is wired according to customer specifications. Normally
it will be wired to run clockwise to open as viewed from above. If rotation as shipped is correct, go
to step 4.5. If opposite rotation is required, the change is done in two steps.
A. CHANGE THE PLUG-IN MOTOR CONNECTORS
Two small plug-in connectors will be found just below the motor. The male connectors are
labeled CW and CCW. One female end will have an arrow. Connect the end with the arrow
to the end labeled with the direction required to OPEN the switch.
B. RESET THE LIMIT SWITCH CAMS.
Changing the motor plug changes the limit switch orientation 180°. If the limit switches are not
changed, the decoupler will rotate to the rear of the cabinet and will damage the safety cover
if it is in place.
Fine adjustment of the limit cams is covered in steps 4.6 and 4.7. For now, they must be reset
to allow the unit to rotate the correct direction and stop close to the correct location.
Loosen the locking knob on the bottom of the auxiliary switch. (See the figure in step 4.6.) BE
CAREFUL TO ONLY MOVE ONE CAM AT A TIME. Turn the #2 (open position) cam (second
from the top) until the recess matches the recess of the #1 (top, closed position) cam. Rotate the
#1 cam until the recess matches the recess of the #4 (bottom) cam. Tighten the locking knob.
The #3 and #4 cams, which control the status signal to the RTU, will also need to be reset; but it
is best to leave this until final limit switch setting is done.
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4.5 INSTALL THE DECOUPLER
A. With the overhead switch closed, loosely clamp
the top decoupler half to the vertical pipe. A
gap is required between the decoupler halves.
A pair of rubber bands are placed around the
bottom half serving as an installation spacer to
provide this gap. DO NOT remove the rubber
bands until the decoupler is completely in-
stalled. DO NOT couple the two halves at this
time. Using the total travel distance noted
before the old operator was removed, position
the top decoupler so that the travel stroke is
evenly divided on each side of the centerline.
Refer to sketch 1.
NOTE: If a fiberglass or very long steel vertical
pipe is in use, operator travel will have to be biased
as much as 20° towards the open position to allow
for “wind up” of the vertical pipe. Refer to sketch
2 and slip the decoupler toward the open position.
(Sketch #2 shows clockwise to open example.)
B. When the decoupler is located in its operating position, tighten the clamp bolts to 60 ft.-lbs.
Remove the rubber bands. Verify that a gap is present between the decoupler halves. Set
(pierce the pipe) ONE of the piercing screws. DO NOT TRY TO COUPLE THE TWO HALVES
AT THIS TIME. More information about the decoupler is found in sections 5.3 and 5.4,
however, no adjustment should be done at this time.
C. If not already done, install the battery fuse in the fuse block.
D. Put the selector switch in the “LOCAL” mode and electrically run the motor operator (still
uncoupled) to its “OPEN” position and back to “CLOSED.” Be sure the decoupler halves do
not interfere with each other and that the vertical pipe does not drag on the crossbolt causing
partial switch operation. If the decoupler halves are out of alignment more than 1/8" either way,
the auxiliary switch must be reset.
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4.6 SET CLOSED POSITION LIMIT SWITCH
The auxiliary switch cams controlling the open and closed positions of the operator are set for
about 90° of rotation at the factory. The FINAL start and stop positions will have to be adjusted
to suit the individual overhead switch.
The sketch below identifies the cams used in the BT-D auxiliary switch to control operating travel.
All directions are as viewed from above. Adjustments are always made by turning the cams
in the OPPOSITE DIRECTION OF THE CORRECTION YOU NEED TO MAKE.
A. Loosen the auxiliary switch locking knob.
B. If the bottom decoupler half ran more than 1/8" past the top half (too far closed), the operating
stroke must be decreased by rotating the #1 cam toward the closed position.
C. If the bottom half stops short of the top half, the operating stroke must be increased by rotating
the #1 cam toward the open position.
D. Tighten the auxiliary switch locking knob and run the operator open and closed again with the
decoupler released. Recheck and repeat until the alignment is within 1/8".
E. Be cautious when moving the cam. Shaft rotation will change about the amount that the cam
is moved and is easy to over compensate. Take care not to move any cam but the one involved
in adjustment.
4.7 SET OPEN POSITION LIMIT SWITCH
Use the detachable swing handle (see sect. 5.3) to fully open the overhead switch. Replace
the handle in its hanger clip. Run the operator around to its open position. Just as with the closed
position, the operator will have to be adjusted until the decoupler halves align.
If the bottom decoupler half travels beyond the top half, decrease the operating stroke by
turning the #2 cam towards the open position. If the unit stops short of the top half, increase the
stroke by turning the cam toward the closed position. Operate the unit open and closed and adjust
until the decoupler halves align within 1/8".
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4.8 ELECTRICALLY OPERATE OVERHEAD SWITCH
Couple the decoupler and electrically operate the switch open and closed. Carefully inspect
the switch to make sure that it is traveling through its full range of motion, and is closing completely
without excessive strain on the linkage. The installer should check the overhead switch stops and
contacts to determine if the overhead switch is fully closed. Inspection must be done at the level
of the switch by climbing the pole or using a bucket truck. Ground level observations are not
accurate. Make adjustments of the auxiliary switch until the switch has proper travel. Adjust the
overhead switch if necessary.
Verify the open gap. Open gaps are usually determined by utility operating standards, however
ANSI standard C37.32 - 1990 recommends the following open switch dimensions according to
switch voltage ratings. See chart below.
Example -- A switch with a 110 BIL rating should have an open gap of
approximately 10 inches but not less than 7 inches.
When the cams are set and the unit operates in a satisfactory manner, set the second piercing
screw on the decoupler pipe clamp.
4.9 SET AUXILIARY CAMS
Once the limit switch cams are set, the auxiliary cams controlling the RTU status input must be
set. The #3 cam (closed status) must match the #1 cam (closed limit switch). The #4 cam (open
status) must match the #2 cam (open limit switch). Once the auxiliary switch cams are set in
position to match the limit switches, turn them a little bit more in the SAME direction that the switch
was operating so they trip a little ahead of the limit switches.
Rated
Voltage -
kV Max.
BIL Rating
kV
Recommended
Open Gap --
Inches
Flash Over
Distance
8.3 95 7 6
15.5 110 10 7
25.8 150 12 10
38.0 200 18 13
48.3 250 22 17
72.5 350 32 25
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4.10 INSTALL AC POWER AND OTHER CONNECTIONS
Install the RTU and radio/phone equipment, if not already done.
NOTE: RTU / Radio power sources for both 2.5 Amps @ 12 Volts and .75 Amps @ 24 Volts are
provided. For maximum efficiency use the 12 volt source whenever possible.
A removable access plate is provided in the bottom of the enclosure for entry of external wires.
Refer to section 5.7 for an explanation of AC-DC scheme Vs. DC scheme operation.
An adequate power supply must be provided for AC - DC scheme units. A minimum of #12
AWG wire should be used. See chart at below for requirements.
If the AC power supply is not adequate, change
from AC/DC scheme to DC scheme by unplug-
ging the 4 position Molex jumper connector found
in the center of the power module board mounted
on the back of the cabinet. See photo below. The
DC scheme requires a power source of at least 1
Amp for battery charging plus the radio and RTU
loads.
The battery fuse should be installed before con-
necting AC power. AC power connections are
made at the fuse block terminals. Be sure to
observe correct wiring terminal identification on
these connections as labeled. If a power supply
ground wire is present, connect it to the ground
lug below the fuse block.
Note: It is very important that the incoming power supply leads inside the cabinet
be kept as short and direct as possible. Magnetic pulses generated by high voltage
spikes, switching transients and power surges can and do affect the internal
electronic control components. When possible the supply leads should also be
twisted to minimize these magnetic fields.
A green LED light is located on the lower right corner of the power module board. It indicates that
AC voltage is present. Battery voltage should increase almost immediately when AC power is
connected. Use a voltmeter connected to the battery terminals to verify charger operation.
120 VOLT CURRENT
REQUIREMENTS
CONTINUOUS 4 AMPS.
1 SECOND 15 AMPS.
PEAK 30 AMPS.
AC/DC to DC
Jumper
LED
Indicator
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4.11 INSTALLATION OF GROUNDS (EARTH CONNECTIONS) and SURGE SUPPRESSION
Extensive testing and field study have determined that proper grounding of all components used
in an ADMO™™ installation is essential for proper operation, personnel safety and equipment
protection.
Electrical transients (surges) on utility systems can be caused by lightning, faults, switching lines,
spill gaps and by quick break whips that restrike. These surges can have serious side effects
ranging from reduced life expectancy of electronic components up to and including operation of
the motorized switch when not commanded to operate.
Take note that it is essential that all grounded components be solidly connected to a common
terminal on the pole ground (ground bus, downcomer, etc.). Any distance between these
connections can result in a significant rise in voltage potential during a surge, which in turn can
cause a heavy current flow in places where it is not wanted.
When installing grounds on the ADMO™™, follow your company standards and guidelines as to
wire gauge and connectors.
The following illustrations show do’s and don’ts regarding grounding practices. The arrowheads
on the conductors represent current flow during a surge.
A. Approved Practices.
1. All grounds MUST be connected to a single, common
connection on the pole ground. This common point can be
at any convenient location on the pole ground as long as all
individual grounds go DIRECTLY to it.
2. Whenever a ground strap from the operating rod is used,
it MUST GO DIRECTLY to the common point on the pole
ground. Be sure to leave enough slack in the ground strap
to allow full operating rod travel. Follow your company
guidelines about use of a ground strap on nonconductive or
insulated operating rods.
3. The ADMO™ ground must be connected from the factory
installed grounding lug to the common ground terminal on
the downcomer.
4. All communications wiring should be installed in properly
connected metal conduit. If metal conduit is not used, then
shielded twisted pair cable must be used. The shield must be
grounded to the cabinet at BOTH ends.
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B. Poor Practices
The illustrations below show commonly used schemes which perform poorly. These should never
be used and if they are in place should be changed to one of the approved methods described.
C. Obsolete Practices
The schemes below were formerly specified by C/P Inc. Testing and field experience have shown
that these schemes do not perform as expected. These schemes should not be used for a new
installation.
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C. Other Considerations.
1. An antenna surge arrestor should be used when installing a coaxial cable from a remote
antenna to the radio.
2. The ADMO™ 12 Volt DC power supply should`, whenever possible, be used to operate any
RTU/Radio mounted outside the ADMO™ cabinet. This power supply wire should also be installed
in metal conduit or use shielded twisted pair cable with shield grounded at BOTH ends. (Section
4.11A-4).
3. Incoming AC power supply wires should be sufficiently heavy to carry the ADMO™ operating
load. They should be twisted, and there should be only a very small loop in the wire inside the
cabinet. See section 4.10.
4. When an external RTU is mounted on a different pole from the ADMO™ and/or is controlling
more than one ADMO™, an optional 10 point surge suppressing terminal block is recommended.
Consult the factory for installation advice.
5. Every installation is subject to different conditions and has to operate according to a variety of
utility practices. We therefore strongly recommend that any apparent surge related damage to
electronic components or any unwanted operations be reported to the factory for surge analysis.
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