Alpha Technologies
Site Preparation and Installation
Effective: August 2015
Underground Battery Vault
Power
Alpha Technologies
®
031-040-B0-003 Rev. C1
3
Underground Battery Vault
Site Preparation and Installation
031-040-B0-003 Rev. C1
Effective Date: August 2015
Copyright © 2015
Alpha Technologies, Inc.
Contacting Alpha Technologies: www.alpha.com
or
For general product information and customer service (7 AM to 5 PM, Pacic Time), call
1-800-863-3930
For complete technical support, call
1-800-863-3364
7 AM to 5 PM, Pacic Time and24/7 emergency support
member of The Group
TM
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. If
there are questions regarding the safe operation of this powering system, please contact Alpha Technologies
or your nearest Alpha representative.
NOTE:
Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators,
batteries, or other hardware if used or operated in any manner or subject to any condition not consistent with
its intended purpose, or is installed or operated in an unapproved manner, or improperly maintained.
NOTE:
031-040-B0-003 Rev. C1
4
Contents
Safety Notes .......................................................................................................................... 5
Battery Safety Notes.............................................................................................................. 6
Mechanical Safety ................................................................................................................. 6
1. INTRODUCTION ............................................................................................................... 8
1.1 Underground Battery Vault ....................................................................................................... 8
2. INSTALLATION ................................................................................................................. 9
2.1 Site Prep and Installation .......................................................................................................... 9
2.2 Battery Placement .................................................................................................................. 10
2.3 Battery Connection ................................................................................................................. 12
2.4 Battery Covers ........................................................................................................................ 18
2.4.1 Installing the Battery covers ............................................................................................. 19
2.5 Temperature Sensor ............................................................................................................... 21
Figures and Tables
Fig. 1-1 Underground Battery Vault ................................................................................................. 8
Fig. 2-1 Typical site for UBV ............................................................................................................ 9
Fig. 2-2 Single 36Vdc Battery String ............................................................................................. 10
Fig. 2-3 Dual 36Vdc Battery String ................................................................................................ 10
Fig. 2-4 Single 48Vdc Battery String ..............................................................................................11
Fig. 2-5 Dual 48Vdc Battery String ................................................................................................. 11
Fig. 2-6 Terminal Connection with Battery Sense Wiring .............................................................. 12
Fig. 2-7 AG-CMT-3SC Wiring for Single 36V Battery String ......................................................... 14
Fig. 2-8 AG-CMT-3SC Wiring for Dual 36V Battery String ............................................................ 15
Fig. 2-9 AG-CMT-4SC Wiring for Single 48V Battery String ......................................................... 16
Fig 2-10 AG-CMT-4SC Wiring for Dual 48V Battery String ............................................................ 17
Fig. 2-11 165 GXL Battery Cover .................................................................................................... 18
Fig. 2-12 180 GXL Battery Cover .................................................................................................... 18
Fig. 2-13 165 AGM Battery with Cover in place .............................................................................. 20
Fig. 2-14 180 GXL Battery with cover in place ................................................................................ 20
Fig. 2-15 Location of Temperature Probe on Battery ...................................................................... 21
Fig. 2-16 Temp Probe Connector .................................................................................................... 21
Table 1 Available Options ............................................................................................................... 8
Table 2 Part Numbers, Charge Management Technology-related items ...................................... 13
031-040-B0-003 Rev. C1
5
Chemical Hazards
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. To avoid
battery contact, remove all metallic objects, (such as rings or watches), from your person.
• Batteries produce explosive gases. Keep all open ames 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).
• If any battery emission contacts the skin, wash immediately and thoroughly with water. 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 one pound bicarbonate of soda to one gallon of water. Report a 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.
• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have
developed on your body.
• Use special caution when connecting or adjusting battery cabling. An improperly or unconnected battery
cable can make contact with an unintended surface that can result in arcing, re, or a possible explosion.
• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by authorized
personnel using a battery of identical type and rating.
WARNING!
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.
Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contains dilute sulfuric acid,
which is harmful to the skin and eyes. Emissions are electrolytic and are electrically conductive and corrosive.
031-040-B0-003 Rev. C1
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Mechanical Safety
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components, especially sharp edges.
• Depending on the model, batteries can weigh anywhere from 25 to 100 pounds. Exercise care when
handling and moving batteries. Use proper handling equipment.
Safety Precautions, continued
• Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can result in a re
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.
• Spent or damaged batteries are environmentally unsafe. Always recycle used batteries. Refer to
local codes for proper disposition of batteries
Battery Safety Notes
• Always refer to the battery manufacturer’s recommendation for selecting correct “FLOAT” and “ACCEPT”
charge voltages. Failure to do so can damage the batteries.
• Verify the Power Supply’s battery charger “FLOAT” and “ACCEPT” charger voltage settings.
• Batteries are temperature sensitive. During extremely cold conditions, a battery’s charge acceptance is
reduced and requires a higher charge voltage; during extremely hot conditions, a battery’s charge
acceptance is increased and requires a lower charge voltage. To compensate for changes in temperature,
the battery charger used in the power supply is temperature compensating. Refer to Section 2.5 for
instructions on connecting the Remote Temperature Sensor (RTS).
• If the batteries appear to be overcharged or undercharged, rst check for defective batteries and then
verify the correct charger voltage settings.
• To ensure optimum performance, inspect batteries every three to six months for signs of cracking,
leaking, or unusual swelling (note that some swelling is normal).
• Check battery terminals and connecting wires. Clean battery terminal connectors periodically and
retighten to approximately 50 inch-pounds. Spray the terminals with an approved battery terminal
coating such as NCP-2.
031-040-B0-003 Rev. C1
7
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). REBAR SHOULD
BE PLACED IN A CROSSHATCH PATTERN FOR PAD REINFORCEMENT.
IF THE PAD IS TO BE LOCATED IN AN AREA WITH A DEEP FROST LINE OR UNSTABLE SOIL, CONCRETE
PYLON FOOTINGS (4” DIA. X 4’ DEEP, OR 1’ DEEPER THAN THE REGIONAL FROST LINE) SHOULD BE
PLACED BELOW THE CONCRETE PAD, IN FRONT OF AND BELOW THE (6) MOUNTING FEATURES.
THE HEIGHT OF THE PAD MUST BE AT LEAST 4” ABOVE GRADE TO REDUCE THE BUILDUP OF DEBRIS
AROUND THE BASE OF THE CABINET.
ADEQUATE SPACE SHOULD BE ALLOWED FOR CABLE TV INPUT / OUTPUT CONDUIT; PLANT GROUNDING
ELECTRODE CONDUCTOR(S); RF CABLE ENTRANCE VIA (1) 4”, (2) 3” OR (3) 2 1/2” RIGID CONDUIT
SWEEP(S) WITH 2’ BEND RADIUS (MINIMUM); AND FIBER OPTIC CABLE ENTRANCE (REFER TO FIBER
MANUFACTURER’S SPECIFICATION FOR MINIMUM BEND RADIUS REQUIREMENTS).
PRIOR TO POURING CONCRETE, ANY WIRE RUNNING THROUGH THE PAD MUST HAVE A THERMAL
EXPANSION JACKET (I.E., PVC) TO PREVENT CRACKING OF THE CONCRETE DURING LIGHTNING
STRIKES.
ALPHA TECHNOLOGIES IS NOT RESPONSIBLE FOR BROKEN WELDS OR OTHER DAMAGE TO THE
CABINET CAUSED BY IMPROPER INSTALLATION.
CONCRETE FILLED, 6” DIAMETER STEEL POSTS (OR EQUIVALENT) SHOULD BE PLACED AT THE
CORNERS OF THE PAD TO REDUCE EXPOSURE TO ACCIDENTAL TRAFFIC DAMAGE. POSTS MUST ALSO
BE PLACED IN FRONT OF THE GAS UTILITY RISER TO PROTECT THE GAS REGULATOR FROM IMPACT
AND / OR DAMAGE FROM LAWN EQUIPMENT.
ALL DIMENSIONS ARE GIVEN IN INCHES.
FOR FURTHER INFORMATION REGARDING THIS INSTALLATION, CONTACT APLHA TECHNOLOGIES OR
YOUR NEAREST ALPHA REPRESENTATIVE.
031-040-B0-003 Rev. C1
8
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.
Hex-head bolts (standard)
Penta-head hardware optional)
Cover
Battery compartment
Box, High density polyethelyne
1” thick grate
2.5” PVC Conduit
1. INTRODUCTION
1.1 Underground Battery Vault
Fig. 1-1 Underground Battery Vault (UBV)
Alpha Underground Battery Vault (UBV)
Specications
HDPE Vault (accommodates up to 8 batteries)
(in): 43.5L x 31.75W x 18H
(mm): 105L x 806W x 457H
HDPE Lid
(in): 35.6L x 24.1W
(mm): 904L x 612W
Available Options
Part Number Model Description
870-180-26 BCK-UBV3 Fused Battery Cable Kit - 3 batteries
874-194-21 BCK-UBV4 Fused Battery Cable Kit - 4 batteries
874-194-22 BCK-UBV6 Fused Battery Cable Kit - 6 batteries
874-194-23 BCK-UBV8 Fused Battery Cable Kit - 8 batteries
875-730-20 Replacement Inline Fuse, 100A
874-195-22 BCK-Extension, 25’ For XM Series 2 Power Supply
874-165-26 BCK-Extension, 25’ Shielded version for XM Series 2 Power Supply*
600-646-C2 6 Battery Tray
630-335-10 UBV-SH Penta Head Hardware
964-028-10 Lifting Hook, Universal, 36"
964-029-10 7/8" Penta Head Socket
744-524-20 UBV-BC-180 Battery Cover for 180 series batteries
745-778-20 UBV-BC-165 Battery Cover for 160 series batteries
740-162-20 RTS-4 Remote Temperature Sensor, 4’ length (supplied with XM2)
744-423-20 RTS-25 Remote Temperature Sensor, 25’ length
*Shielded cables provide EMI Supression required for above-ground XM2 applications where the BCK is routed through
an exposed plastic conduit.
Table 1 Available options
031-040-B0-003 Rev. C1
9
Vault & Lid
Optional concrete pad
(4” to 6” thick)
Compacted backll
Compacted
backll
Drainage gravel
(6” deep typical)
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 ush
with grade.
3. Finish installation by adding backll and compacting.
For installations where the optional concrete pad is 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 ush
with grade.
3. Install shims on each side and end to prevent deection.
4. Add backll and compact to a depth of 8” below grade.
5. Build form around vault to make a 6” wide collar around the vault.
6. Once concrete sets, nish backll to grade.
Undisturbed soil
2” PVC conduit for wiring
(provided by installer),
broken out of enclosure at
appropriate location for
installation.
2. INSTALLATION
2.1 Site Prep and Installation
Fig. 2-1 Typical site for UBV
031-040-B0-003 Rev. C1
10
Fig. 2-2 Single 36Vdc battery string
Fig. 2-3 Dual 36Vdc battery string
2. INSTALLATION, continued
underground battery vault (ubv)
intercell connection
to power supply: red (+), black (-)
intercell connection
underground battery vault (ubv)
inline fuse
inline fuse
to power supply: red (+), black (-)
parallel link
3
1
2
36V
24V
12V
inline fuse
intercell connection
parallel link
remote temperature sensor – rts
(connects to power supply)
remote temperature sensor – rts
(connects to power supply)
36V
24V
12V
3A
1A
2A
12V
24V
36V
1B
3B
2B
2.2 Battery Placement
underground battery vault (ubv)
to power supply: red (+), black (-)
intercell connection
intercell connection
remote temperature sensor – rts
(connects to power supply)
inline fuse
to power supply: red (+), black (-)
intercell connection
underground battery vault (ubv)
inline fuse
intercell connection
intercell connection
intercell connection
inline fuse
parallel link
parallel link
remote temperature sensor – rts
(connects to power supply)
4 23
48V
36V
24V
1
12V
031-040-B0-003 Rev. C1
11
48V
4A
36V
3B
24V
2A
12V
1B
24V
2B
36V
3A
12V
1A
48V
4B
2.2 Battery Placement, continued
Fig. 2-4 Single 48Vdc battery string
Fig. 2-5 Dual 48Vdc battery string
2. INSTALLATION, continued
031-040-B0-003 Rev. C1
12
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. Connect batteries in as shown in the accompanying diagrams, and tighten harware to
battery manufacturer's specications.
4. Tape Remote temperature sensor (RTS) to side of battery.
5. If an optional AlphaGuard Battery Sense Monitor is incorporated into the battery system,
connect the battery sense wires as shown.
6. Apply corrosion inhibitor to terminal assembly after tightening.
Route the battery cable connectors from the enclosure, ring lugs rst to the UBV.
NOTE:
Verify the battery voltage and polarity are correct before proceeding.
NOTE:
2. INSTALLATION, continued
2.3 Battery Connection
3/4" x1/4-20 bolt
split washer
battery sense wire
(from optional alphaguard)
battery cable
flat washer
Fig. 2-6 Terminal Connection with Battery Sense Wiring
031-040-B0-003 Rev. C1
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2. INSTALLATION, continued
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.
The AlphaGuard unit installs directly on top of one of the batteries in the string. A wire harness connects the
AlphaGuard to each of the batteries in the string. Both 36V (3 battery) and 48V (4 battery) versions are available.
One AlphaGuard is required per battery string. The AlphaGuard performs electrical compensation for differences
in individual batteries in the string.
AlphaGuard Charge Management System (AG-CMT)
Part Number Model Description
012-306-32 AG-CMT-3SC-P
AlphaGuard Charge Management SC, CMT-3SC-P 36Vdc
Potted without sense wires
012-306-33 AG-CMT-4SC-P
AlphaGuard Charge Management SC, CMT-4SC-P 48Vdc
Potted without sense wires
Table 2 Part Numbers, Charge Management Technology-related items
+
-
+
-
+
-
12V24V36V
3 12
031-040-B0-003 Rev. C1
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2. INSTALLATION, continued
2.3 Battery Connection, continued
2.3.2 Single 36V Battery String Wiring Diagram
orange
yellow
AG-CMT-3SC-P
Fig. 2-7 AG-CMT-3SC-P Wiring for Single 36V Battery String
remote temperature sensor – rts
(connects to power supply)
to power supply: red (+), black (-)
brown
black
inline fuse
Brown
+
-
+
-
+
-
12V
24V
36V
+
-
+
-
+
-
12V
24V
36V
1A
2A
3A
3B
2B
1B
black
031-040-B0-003 Rev. C1
15
orange
yellow
inline fuse
inline fuse
yellow
orange
AG-CMT-3SC-P
AG-CMT-3SC-P
2. INSTALLATION, continued
2.3 Battery Connection, continued
2.3.3 Dual 36V Battery String Wiring Diagram
Fig. 2-8 AG-CMT-3SC-P Wiring for Dual 36V Battery String
remote temperature sensor – rts (connects to power supply)
to power supply: red (+), black (-)
black
A
B
4
2
3
48V
36V
24V
1
12V
AG-CMT-4SC-P
031-040-B0-003 Rev. C1
16
2. INSTALLATION, continued
2.3 Battery Connection, continued
2.3.4 Single 48V Battery String Wiring Diagram
Fig. 2-9 AG-CMT-4SC-P Wiring for Single 48V Battery String
remote temperature sensor – rts
(connects to power supply)
to power supply: red (+), black (-)
brown
orange
yellow
red
inline fuse
black
48V
4A
36V
3B
24V
2A
12V
1B
24V
2B
36V
3A
12V
1A
48V
4B
brown
orange
yellow
red
AG-CMT-4SC-P
AG-CMT-4SC-P
orange
inline fuse
031-040-B0-003 Rev. C1
17
2. INSTALLATION, continued
2.3 Battery Connection, continued
2.3.5 Dual 48V Battery String Wiring Diagram
Fig. 2-10 AG-CMT-4SC-P Wiring for Dual 48V Battery String
to power supply: red (+), black (-)
inline fuse
remote temperature sensor – rts
(connects to power supply)
yellow
black
red
brown
black
A
B
031-040-B0-003 Rev. C1
18
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
specic covers are not interchangeable.
2. INSTALLATION, continued
2.4 Battery Covers
Fig. 2-11 165 GXL Battery Cover
Group 27
(Alpha p/n 745-778-20)
Fig. 2-12 180 GXL Battery Cover
Group 31
(Alpha p/n 744-524-20)
031-040-B0-003 Rev. C1
19
For the 165GXL battery, the cover locking mechanism ts
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
X
For the 180 GXL battery, the carry strap does not need to be
pushed down. The cover will latch at “X”.
Place the cover over the battery, route the battery cables and
battery sense wires down through the molded channels in the
cover.
Flex the side panels out and place the cover over the battery.
The cover will snap into place.
Press down evenly and rmly on the cover to fully seat it in place.
Repeat for the rest of the batteries in the string.
To ensure the battery covers are properly seated, pull up on
the center of the cover. If the cover comes off, repeat the above
steps.
2. INSTALLATION, continued
2.4 Battery Covers, continued
2.4.1 Installing the Battery covers
031-040-B0-003 Rev. C1
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2. INSTALLATION, continued
2.4 Battery Covers, continued
2.4.1 Installing the Battery Covers, continued
Fig. 2-13 165 AGM Battery with Cover in Place
Fig. 2-14 180 GXL Battery with Cover in Place
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