031-093-C0-001 © 3/99
CE-G Series
Propane Enclosures
Installation Manual
CE-3G / CE-9G
031-093-C0-001 © 3/99
i
Preface
031-093-C0-001 © 3/99
Preface
Topic page
Overview i
About this Manual i
Table of Contents ii
List of Figures iii
Safety Information iv
Installation Notes v
Battery Safety Notes vi
Overview: The purpose of the CE-G Enclosure Installation Manual is to
provide an overview of the system and to detail the
enclosure installation procedure.
Audience: This manual intended for the installers and operators of the
system.
Contents: Section 1, System Overview. This section describes the
CE-G Series Enclosure.
Section 2, Pre-Installation. This section describes
site selection and pad layout.
Section 3, Installation. This section describes the
procedures for installing the cabinet.
Section 4, Operation. This section describes the preparation of
the cabinet for initial turn-up and the conversion of the APU fuel
source from Natural Gas to Propane.
CE-G Series Enclosure
Installation Manual
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Preface
031-093-C0-001 © 3/99
CE-G Series Enclosure
Installation Manual
Table of Contents
Section 1, System Overview
1.1 Overview .................................................................................. 1-1
1.2 Block Diagram ............................................................................... 1-2
Section 2, Pre-Installation
2.1 Site Preparation............................................................................ 2-1
2.1.1 Site considerations.............................................................. 2-1
2.1.2 Concrete pad layout ............................................................ 2-2
2.1.3 Enclosure impact protection ................................................. 2-3
Section 3, Installation
3.1 Tools and materials ....................................................................... 3-1
3.2 Transportation.............................................................................. 3-2
3.3 Installation procedure .................................................................... 3-3
3.4 Enclosure impact protection ........................................................... 3-6
Section 4, Operation
4.1 Installation of tanks ...................................................................... 4-1
4.2 Installation of Regulator assembly ................................................... 4-2
4.3 Installation of HP/LP hoses ............................................................. 4-4
4.4 Converting the APU From Natural Gas To Propane Gas ........................ 4-5
4.4.1 Accessing the APU .............................................................. 4-5
4.4.2 Dual Fuel Load block conversion procedure ............................. 4-9
4.4.3 Conversion completion ....................................................... 4-10
4.5 Natural Gas To LP Gas conversion.................................................. 4-11
4.5.1 Pre-Regulator / Low Fuel-pressure switch conversion ............. 4-11
4.6 Remotely located CE-G enclosures................................................ 4-14
4.7 Converting Collocated enclosure for remote application ..................... 4-15
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List of Figures
Section 1, Introduction
Figure 1.1 Colocated CE-X, CE-G enclosures .................................... 1-1
Figure 1.2 System Block Diagram .................................................... 1-2
Section 2, Pre-Installation
Figure 2.1 Concrete Pad Layout ..................................................... 2-2
Figure 2.2 Impact post arrangement .............................................. 2-3
Section 3, Installation
Figure 3.1 Gas Utility Box cutout .................................................... 3-3
Figure 3.2 Impact post arrangement ............................................... 3-6
Section 4, Operation
Figure 4.1 Tank base locator tabs ................................................... 4-1
Figure 4.2 Vapor outlet orientation .................................................. 4-1
Figure 4.3 Stop nut ............................................................ 4-2
Figure 4.4 Regulator assembly ........................................................ 4-2
Figure 4.5 Tank securing bracket .................................................... 4-3
Figure 4.6 High Pressure Hose arrangement ...................................... 4-4
Figure 4.7 Low Pressure Hose connection ........................................ 4-4
Figure 4.8 Exhaust pipe access panel .............................................. 4-5
Figure 4.9 Exhaust pipe flange bolts ................................................ 4-6
Figure 4.10 Fuel hose fitting ............................................................ 4-6
Figure 4.11 APU housing connectors ................................................. 4-7
Figure 4.12 APU tray locking bolts .................................................... 4-7
Figure 4.13 APU tray ............................................................ 4-8
Figure 4.14 Dual fuel load block ........................................................ 4-9
Figure 4.15 Exhaust pipe flange gasket ............................................. 4-10
Figure 4.16 Fuel hose placement, APU............................................... 4-10
Figure 4.17 Nat Gas pre-regulator removal ......................................... 4-11
Figure 4.18 Low fuel pressure switch wire placement ........................... 4-12
Figure 4.19 Low fuel pressure switch placement ................................. 4-12
Figure 4.20 Low fuel pressure switch connector ................................. 4-13
Figure 4.21 Remote CE-G arrangemant .............................................. 4-14
Figure 4.22 Bolt hole locations ......................................................... 4-15
Figure 4.23 Remote gas utility box mounting location ........................... 4-15
Figure 4.24 Hose connection ........................................................... 4-16
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To reduce the risk of electrical shock, injury or death caused by explosion of
fuel or moving parts, and to ensure the safe operation of this unit, the follow-
ing symbols have been placed throughout the manual. Where these symbols
appear, servicing should be performed only by qualified personnel.
DANGEROUS VOLTAGE
This symbol indicates a dangerous voltage exists in this area of the
product. Use caution whenever working in the area to prevent
electrical shock.
INHALATION HAZARD - DONT BREATHE VAPORS
This symbol indicates an inhalation hazard exists 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 exists in this area of
the product. Use caution whenever working in the area to prevent
possible combustion fuel vapors.
MECHANICAL OR MOVING PARTS HAZARD
These symbols indicate the presence of a mechanical or moving parts
hazard in this area of the product. Use caution whenever working in
the area to prevent possible injury to the operator or servicepersonnel.
LEAK HAZARD
This symbol indicates a leak hazard exists in this area of the product.
Use caution whenever working in the area to prevent and correct any
leaks detected.
ATTENTION
This symbol indicates important installation, operation or maintenance
instructions. Always follow these instructions closely.
IMPORTANT SAFETY INSTRUCTIONS
CONTAINED IN THIS MANUAL
SAVE THESE INSTRUCTIONS
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.
HAZARDOUS CONDITION
CAUTION
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Preface
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IMPORTANT INSTALLATION NOTES
It is important that the installation procedures be followed as outlined in this
manual. The procedures have been developed to facilitate the installation of
the equipment and for the safety of the installation and service personnel.
Read the documentation thoroughly before proceeding with the installation.
The system should be installed ONLY by qualified service personnel.
Consult local utility codes for additional cabinet grounding and utility
requirements.
ALPHA TECHNOLOGIES is not responsible for broken welds of 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.
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Propane Safety Notes
1. Never overfill your LP-gas container. LPgas containers not
containing a fixed liquid level gauge must be filled by
weight to 80% of their total capacity. Propane expands
1.5% for each 10 °F increase in temperature. 20% of the
container must remain available for expansion. Some tanks
supplied by Alpha Technologies come equipped with auto-
matic stop fill valves. Tanks must be filled in accordance
with manufactures, D.O.T, NFPA Code 58, state and local
regulations.
2. Do not use pliers to close the POL valve on your tank.
These valves are designed to be closed leak tight by hand or
screwdriver as appropriate. If pliers are needed to stop a
leak , the valve needs replacement.
3. When tightening the POL Nut (left-hand thread) on the
service valve, draw it up snug with a proper wrench do not
jam it. No thread sealant is necessary. Check for leaks
after connecting, by using a leak detection solution or soapy
water.
4. If you take your LP-gas tank to a LP-gas dealer for filling,
transport it in the proper position in which it is used (verti-
cal for all Alpha Technologies supplied tanks), with the
valves closed and the POL plug inserted. Secure the tank
against falling or rolling.
5. The outside of the tank should be kept corrosion free by
periodic checks and a coat of paint should be used if needed
(light reflective color).
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Preface
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Propane Safety Notes
6. Do not store LP-gas tanks indoors or in enclosed areas. Do
not expose the tanks to heat, relief valve may open. Al-
ways store with the service valve closed tight and plugged.
7. Do not attempt to repair LP-gas containers or valves or
regulators.
8. When using make sure that the tank is level, securely fas-
tened down, and vertical.
9. Check all tank and line connections periodically to be sure
they are tight. When testing for leaks use soapy water or a
leak detect solution. Do not use any open flame for leak
testing.
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1-1
1. System Overview
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1.1 Overview
The CE-X series of enclosures from Alpha Technologies has been
designed to meet the needs of todays outside plant powering requirements.
When an alternate fuel source is not available, the CEG propane natural gas
option can provide up to 16 hours of continuous operation.
The procedures described in this document describe the installation of a
CE-G Series Propane Enclosure. The installation procedures are identical for
the CE-3G and the CE-9G. The cabinet footprint (and mounting hole location)
is identical for each enclosure. The only physical difference between the
enclosures is that the CE-3G is 44 tall and the CE-9G is 52 tall.
Fig.1.1, Collocated CE-X/CE-G enclosures
1-2
1. System Overview
031-093-C0-001 © 3/99
Fig. 1.2, System block diagram
DEMAND
REGULATOR
LOW PRESSURE
SOLENOID
8oz
ENGINE
LP PROPANE - VAPOR WITHDRAWAL
LOW FUEL
PRESSURE
S
HIGH PRESSURE
CONTROL
CONTROLS
PROPANE
11"WC
PROPANE 150 PSI
10 PSI TO 11"WC
PROPANE
POST-REG
PRE-REGULATOR
OUTLET
PROPANE
VALVE
AUTO/MANUAL
DUAL TANK
SENSOR
ENCLOSURE
APU
BLOCK DIAGRAM
SWITCH
GAS
BOX
UTILITY
PROPANE
ENCLOSURE
11"WC
MAX
LOW FUEL ALM
1.2 Block Diagram
The block diagram shown illustrates the overall system interconnection
between the CE-X enclosure with Auxiliary Power Unit, and the CE-G enclosure
with supplemental propane supply.
1-3
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1-4
1. System Overview
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2. Pre-Installation
2-1
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2.1 Site Preparation
2.1.1 Site considerations
The site for the collocated CE-G will be predetermined by
the location of the CE-X enclosure.
The site for the remotely located CE-G should be planned so
that the enclosure will receive good air flow. If possible, in areas
of extreme heat, the enclosure should be positioned so that it
will be shaded from the afternoon sun. In areas of prevailing
winds, the enclosure should be located so that the side of the
cabinet face into the direction of the prevailing wind. This will
greatly reduce the amount of wind borne matter (dirt, snow, and
debris) which may enter the enclosure through the louvers or
vents.
In areas of flooding, the geographical site and concrete pad
should be located above the flood plane.
Place the front of the enclosure facing the street, where
component access will be curbside. In most instances,
landscaping such trees, shrubs, or wooden fences serve to
provide a more acceptable appearance in keeping with
surrounding neighborhood designs.
The enclosure should be placed where it will be free of
obstructions.
2. Pre-Installation
2-2
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1
1
2
2.1.2 Concrete Pad Layout
The illustration below shows the general dimensions for a poured
in place concrete pad. When placing the pad, allow at least 36
inches of clearance to allow the front and rear doors to fully
open.
3/8" diameter (4 places) bolts (which should extend
1"-1 1/2" above the surface of the pad). All mounting hardware
must be stainless steel to prevent corrosion.
A 25+ year continuous vapor barrier must be used between the
enclosure and pad to prevent moisture ingress and corrosion
caused by metal-to-concrete contact. The vapor barrier material
(such as 30 lb. felt, neoprene pond liner, or heavy grade tar
paper) should initially extend at least 6" in all directions around
the perimeter of the enclosure. After the enclosure is in place, the
material should be cut closer to the enclosure, using the
appropriate knife or cutting tool.
1
2.1 Site Preparation, continued
Fig.2-1, Concrete pad layout (all dimensions shown in inches)
1
1
2
2. Pre-Installation
2-3
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TRAFFIC
TRAFFIC
SIDEWALKSIDEWALK
PAD
POSTS
CURB
STREET
CE-X CE-G
PROPANEAPU
FRONT
2.1.3 Enclosure Impact Protection
As described in the NFPA Technical Compliance Statement,
the cabinet must be protected by impact posts, placed in
strategic locations according to traffic patterns. The illustration
below shows the general arrangement of the 6 diameter,
concrete-filled posts. The actual positioning of the posts may
vary by location.
2.1 Site Preparation, continued
Fig.2-2, Impact post arrangement (typical)
2. Pre-Installation
2-4
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3-1
3. Installation
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The following procedure will allow for installation of the Collocated CE-G with
the CE-X/ CE-X2. The CE-G enclosure re is bolted to the concrete pad using
7/16 bolts and to the CE-X APU enclosure by carriage bolts. Also this
procedure will explain step by step how to install the two 40 LB propane tanks
and the regulator /control valve.
Tools:
(2) Pipe wrench 10
7/8 combination box and open ended wrench
Straight slot screw driver
Multimeter
Adjustable crescent wrench 10
1/2 open ended wrench
Materials
QTY
(1) Regulator hold down bracket assembly
(2) 40 pound DOT approved propane tanks
(1) CE-G Enclosure
3.1 Tools and Materials
3-2
3. Installation
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3.2 Transportation
The enclosure is shipped bolted to a shipping pallet. It should be
transported, loaded, and unloaded while bolted to the shipping pallet. A safe
means of transportation to the site and unloading the enclosure must be
considered. Do not transport, lift, or place the unit on any surface unable to
fully support its weight.
NOTE:
The enclosure should only be transported, lifted, and
installed as shipped from the factory. Do not install the
propane tanks until the enclosure is installed on the pad.
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