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Alpha PowerBay BDFB Technical Manual

Secondary dc power distribution system
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PowerBay
Full Size BDFB
+™
Secondary DC Power Distribution System
Technical Manual
Effective: January 2020

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Summary of Contents for Alpha PowerBay BDFB

  • Page 1 PowerBay Full Size BDFB +™ Secondary DC Power Distribution System Technical Manual Effective: January 2020...
  • Page 2 Safety Notes Alpha Technologies Services, Inc. considers customer safety and satisfaction its most important priority. To reduce the risk of injury or death and to ensure continual safe operation of this product, certain information is presented differently in this manual. Alpha tries to adhere to ANSI Z535 and encourages special attention and care to information presented in ®...
  • Page 3 Alpha representative. 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.

  • Page 4: Table Of Contents

    Table of Contents 1.0 Purpose and Applicability ..........1.1 Product Model .
  • Page 5 Table of Contents (Continued) 6.4 BDFB Configurator ..............26 6.5 Breaker Settings .

  • Page 6: Purpose And Applicability

    Optional per-circuit current monitoring and RedundancyTracker™ 3.0 Unpacking and Inspection Unpacking and Inspection The Alpha PowerBay + Full-Size BDFB was carefully packaged and securely bolted to a pallet at the factory to withstand the normal rigors of shipping, however, you should carefully inspect all packaging and contents to confirm that no damage has occurred in transit.

  • Page 7: Installation

    4.0 Installation Installation 4.1 Installation Preparation Installation Preparation NOTICE: THIS PRODUCT MUST BE INSTALLED WITHIN A RESTRICTED ACCESS LOCATION WHERE ACCESS IS THROUGH THE USE OF A TOOL, LOCK AND KEY, OR OTHER MEANS OF SECURITY, AND IS CONTROLLED BY THE AUTHORITY RESPONSIBLE FOR THE LOCATION.

  • Page 8: Mounting

    4.2 Mounting Mounting The Full-Size BDFB will need to be securely mounted to the ground by the use of (4) Hilti concrete anchors. Step 1. Remove the rear covers of the BDFB. Step 2. Measuring the distance between the four slotted mounting locations found on the base of the rack, mark and drill holes into desired concrete location for rack placement (see Figure Step 3.

  • Page 9: Input Connections

    4.4 Input Connections Input Connections WARNING! ELECTRICAL HAZARD INPUTS MUST BE PROTECTED BY A LISTED CIRCUIT BREAKER OR BRANCH RATED FUSE. THE CIRCUIT BREAKER OR FUSE MUST BE RATED AT 1200A MAX. MULTIPLE POWER SOURCES ARE PRESENT. ENSURE ALL INPUT POWER FEEDS ARE NOT ENERGIZED BEFORE INSTALLING THEM.

  • Page 10: Dual-Bus Input Connections (With Internal Rtn)

    4.4.1 4.4.1 Dual-Bus Input Connections (with Internal Dual-Bus Input Connections (with Internal RTN) RTN) The hot and return buses on the dual-bus configuration are all equipped with interconnection jumpers, thus hot/return input cables are to be installed only on hot/return positions 1-2 on this configuration (see Figure 10).

  • Page 11: Quad-Bus Input Connections (With Internal Rtn)

    4.4.3 4.4.3 Quad-Bus Input Connections (with Internal Quad-Bus Input Connections (with Internal RTN) RTN) The hot and return buses on the quad-bus configuration are equipped with interconnection jumpers between hot/return positions 1-4 and positions 5-8, thus hot/return input cables are to be installed only on hot/return positions 1-2 and positions 5-6 on this configuration (see Figure 12).

  • Page 12: Eight-Bus Input Connections (With Internal Rtn)

    4.4.5 4.4.5 Eight-Bus Input Connections (with Internal Eight-Bus Input Connections (with Internal RTN) RTN) The hot and return buses on the eight-bus configuration each exist without interconnection jumpers, thus hot/return input cables are to be installed on all eight hot/return input connections for this configuration (see Figure 14).

  • Page 13: Output Connections

    4.5 Output Connections Output Connections CAUTION! DO NOT PERFORM THIS STEP ON CIRCUITS WITH BREAKERS OR FUSES INSTALLED. ENSURE NO POWER IS PRESENT ON THE CIRCUIT BEING WIRED BEFORE PROCEEDING. MAKE SURE THAT ALL CABLES HAVE INSULATED TERMINALS OR HEAT SHRINK APPLIED PRIOR TO TERMINATION, AND THAT NO-OXIDE COMPOUND IS APPLIED TO ALL COPPER- TO-COPPER CONNECTIONS.

  • Page 14: Output Adapters

    4.5.1 4.5.1 Output Adapters Output Adapters Output adapters are an available option for the AM and GJ breaker panels. These adapters are offered in straight, 45, and 90 degree angled orientations. Table 4. Output Adapter Options (see Figures 19-23) PART DESCRIPTION NUMBER C590-2267-10 2 pole output adapter;...

  • Page 15: Safety Cover Installation

    4.6 Safety Cover Installation Safety Cover Installation WARNING! ELECTRICAL HAZARD FAILURE TO INSTALL/REINSTALL THE SAFETY COVERS WILL CREATE AN ELECTRICAL HAZARD. 4.6.1 4.6.1 Bus Safety Covers Bus Safety Covers The BDFB will ship from the factory with plastic safety covers either mounted in place or packaged inside the rack.

  • Page 16: Gj Circuit Breakers

    4.7.2 4.7.2 GJ Circuit Breakers GJ Circuit Breakers For a list of compatible GJ breakers, see Appendix E on Page 50. Step 1. Ensure that breaker is in the OFF position before installing into panel (see Figure 27). Step 2. Remove breaker shield(s) from GJ breaker panel by loosing the captive thumbscrews (see Figure 28).

  • Page 17: Bus Reconfiguration

    4.8 Bus Reconfiguration Bus Reconfiguration WARNING! ELECTRICAL HAZARD MULTIPLE POWER SOURCES ARE PRESENT. ELECTRICAL INSTALLATION SHOULD ONLY BE PERFORMED BY QUALIFIED PERSONNEL WITH PROPER TOOLS AND PROTECTIVE SAFETY EQUIPMENT. NOTICE: MAKE SURE THAT NO-OXIDE COMPOUND IS APPLIED TO ALL COPPER-TO-COPPER CONNECTIONS. Table 6. Interconnection Jumper Specifications TERMINATION HOLE/STUD CENTER...

  • Page 18: Return Bus Interconnection Jumper Installation (Models With Internal Rtn)

    4.8.1 4.8.1 Return Bus Interconnection Jumper Installation Return Bus Interconnection Jumper Installation (Models with Internal RTN) (Models with Internal RTN) Step 1. Depending on the selected configuration, align the return jumper in place between the return buses. Step 2. For each return jumper, insert the six 3/8 in. bolts with flat and lock washers through the pems located on the return buses.

  • Page 19: Distribution Panel Installation

    4.9 Distribution Panel Installation Distribution Panel Installation Depending on the configuration ordered, the BDFB may have empty panel positions that are covered with blanking plates. If extra distribution is needed anytime in the future, these plates can be easily removed and replaced with breaker panels by following these instructions.

  • Page 20: Product Specifications

    5.0 Product Specifications Product Specifications 5.1 PowerBay+ Full-Size BDFB Specifications PowerBay+ Full-Size BDFB Specifications Table 7. Mechanical Width 26 in. Height 84 in. Depth 28 in. Weight 775 lbs. Table 8. Electrical Voltage -48VDC Load Current Per Bus 960A Max. Continuous Number of Busses 2, 4, 6, or 8 Alarm Contacts Form-C, 60VDC @ 0.5A Max.

  • Page 21: Gj Breaker Panel Specifications

    Table 12. Electrical (AM800 Breaker Panel) Total Load Current 640A Continuous Load Current Per Pole 100A Continuous Supported Protection Devices Single-Pole AM Circuit Breaker Up to 125A; Double-Pole AM Circuit Breaker Up to 200A; Triple-Pole AM Circuit Breaker Up to 300A; TPS/TLS Plug-In Fuse Holder Table 13.

  • Page 22: Operation

    6.0 Operation Operation The Full-Size BDFB is available with an optional supervisory controller module to allow for precise monitoring of bus, panel, and breaker alarms. 6.1 Menu Icons Menu Icons Navigation within the supervisory controller is performed by tapping the icons located at the top of the screen.

  • Page 23: Alarm Severity

    6.2.1 6.2.1 Alarm Severity Alarm Severity If an alarm occurs, a caution triangle will appear at the top of the screen on the left side. The triangle will appear orange if there is a minor alarm or red if there is a major alarm. Table 19.

  • Page 24: Settings Menu

    6.3 Settings Menu Settings Menu The Settings menu ( ) allows the user to monitor and fine-tune the BDFB system settings. Refer to interface map below for menu layout. Settings ┣  Volts Calibration ┣  Display ┃  ┣  Brightness ┃  ┗  Touch Calibration ┣ ...

  • Page 25: System

    6.3.3 6.3.3 System System The System menu allows adjustment to the buzzer volume, ON/OFF power to the accent lighting, and a readout of the current bus/panel ampacity. The firmware version is located at the bottom of this screen. To access this feature, select the System button in the Settings menu (see Figure 48).

  • Page 26: Bdfb Configurator

    6.4 BDFB Configurator BDFB Configurator The BDFB supervisory controller allows for flexible configuration and reconfiguration of distribution panels and bus layouts at the touch of a button. The following illustrations depict a quad-bus BDFB configuration, however these instructions are applicable for all other panel/jumper configurations offered.

  • Page 27: Breaker Settings

    6.5 Breaker Settings Breaker Settings To access breaker settings (calibration/ampacity/inventory), select a panel from the Home screen. Once selected, breaker load and ampacity data will be displayed along with any breaker alarms (see Figure 60). Refer to alarm key shown on this screen for alarm severity.

  • Page 28: Breaker Ampacity

    6.5.2 6.5.2 Breaker Ampacity Breaker Ampacity To access breaker ampacity settings, select the breaker ampacity icon ( ) at the top of the screen. The Set Brkr screen will appear Table 20. AM Breaker Max Ampacity Value with up to 22 breakers shown (see Figure 65). Select the breaker NUMBER OF MAX RATING that is to be adjusted, then select pole count (1-3) using the (+) or...

  • Page 29: How To Review System Status Via The Embedded Webserver

    6.6 How to Review System Status via the How to Review System Status via the Embedded Webserver Embedded Webserver The optional embedded ethernet module provides remote monitoring via IP-based ethernet networks and a web browser. By default, the ethernet module is configured at the factory with static network settings.

  • Page 30: Realtime Status

    6.8 Realtime Status Realtime Status By clicking on the Realtime Status tab located at the top of the home page, BDFB bus and panel detail will be shown (see Figure 70 & 71). For bus detail, a table will display: y Bus number y Load y Feeder fuse size...

  • Page 31: Email & Snmp Settings

    6.9.2 6.9.2 Email & SNMP Settings Email & SNMP Settings This page allows the user to configure the SNMP source address (IP address of the ethernet module) and the SNMP trap destination address (IP address of SNMP data receiver). Once all settings have been entered, click Save SNMP Settings.

  • Page 32: Upload Firmware

    6.9.5 6.9.5 Upload Firmware Upload Firmware This page allows the user to upgrade the firmware on the embedded ethernet module. Follow the on-screen instructions to upload/upgrade firmware (see Figure 76). 6.9.6 6.9.6 Reboot Device Reboot Device This page allows the user to reboot the embedded ethernet module.

  • Page 33: Appendix A: Mechanical Drawings

    Appendix A: Appendix A: Mechanical Drawings Mechanical Drawings A.1 PowerBay+ Full BDFB Isometric View PowerBay+ Full BDFB Isometric View C048-740-30 R02, Rev. C (01/2020)

  • Page 34: Powerbay+ Full Bdfb Dimensions

    A.2 PowerBay+ Full BDFB Dimensions PowerBay+ Full BDFB Dimensions C048-740-30 R02, Rev. C (01/2020)

  • Page 35: Powerbay+ Full Bdfb Grounding Locations

    A.3 PowerBay+ Full BDFB Grounding Locations PowerBay+ Full BDFB Grounding Locations C048-740-30 R02, Rev. C (01/2020)

  • Page 36: Am Breaker Panel Isometric Views

    A.4 AM Breaker Panel Isometric Views AM Breaker Panel Isometric Views (Left mount panel configuration shown) C048-740-30 R02, Rev. C (01/2020)

  • Page 37: Gj Breaker Panel Isometric Views

    A.5 GJ Breaker Panel Isometric Views GJ Breaker Panel Isometric Views (Left mount panel configuration shown) C048-740-30 R02, Rev. C (01/2020)

  • Page 38: Appendix B: Bus Layout And Jumper Configurations

    Appendix B: Appendix B: Bus Layout and Jumper Configurations Bus Layout and Jumper Configurations B.1 HOT/RTN Input Bus Locations HOT/RTN Input Bus Locations C048-740-30 R02, Rev. C (01/2020)

  • Page 39: Dual-Bus Hot/Rtn Jumper Configuration (W/Internal Rtn)

    B.2 Dual-bus HOT/RTN Jumper Configuration (w/Internal RTN) Dual-bus HOT/RTN Jumper Configuration (w/Internal RTN) C048-740-30 R02, Rev. C (01/2020)

  • Page 40: Quad-Bus Hot/Rtn Jumper Configuration (W/Internal Rtn)

    B.3 Quad-bus HOT/RTN Jumper Configuration (w/Internal RTN) Quad-bus HOT/RTN Jumper Configuration (w/Internal RTN) C048-740-30 R02, Rev. C (01/2020)

  • Page 41: Eight-Bus Hot/Rtn Jumper Configuration (W/Internal Rtn)

    B.4 Eight-bus HOT/RTN Jumper Configuration (w/Internal RTN) Eight-bus HOT/RTN Jumper Configuration (w/Internal RTN) C048-740-30 R02, Rev. C (01/2020)

  • Page 42: Appendix C: Input Cable Configurations

    Appendix C: Appendix C: Input Cable Configurations Input Cable Configurations C.1 Dual-bus Input Cable Positions (w/Internal RTN) Dual-bus Input Cable Positions (w/Internal RTN) C048-740-30 R02, Rev. C (01/2020)

  • Page 43: Dual-Bus Hot Input Cable Positions (W/O Internal Rtn)

    C.2 Dual-bus HOT Input Cable Positions (w/o Internal RTN) Dual-bus HOT Input Cable Positions (w/o Internal RTN) C048-740-30 R02, Rev. C (01/2020)

  • Page 44: Quad-Bus Hot/Rtn Input Cable Positions (W/Internal Rtn)

    C.3 Quad-bus HOT/RTN Input Cable Positions (w/Internal RTN) Quad-bus HOT/RTN Input Cable Positions (w/Internal RTN) C048-740-30 R02, Rev. C (01/2020)

  • Page 45: Quad-Bus Hot Input Cable Positions (W/O Internal Rtn)

    C.4 Quad-bus HOT Input Cable Positions (w/o Internal RTN) Quad-bus HOT Input Cable Positions (w/o Internal RTN) C048-740-30 R02, Rev. C (01/2020)

  • Page 46: Eight-Bus Hot/Rtn Input Cable Positions (W/Internal Rtn; All Hot/Rtn Positions Cabled)

    C.5 Eight-Bus HOT/RTN Input Cable Positions Eight-Bus HOT/RTN Input Cable Positions (w/Internal RTN; All HOT/RTN Positions Cabled) (w/Internal RTN; All HOT/RTN Positions Cabled) C048-740-30 R02, Rev. C (01/2020)

  • Page 47: Eight-Bus Hot Input Cable Positions (W/O Internal Rtn; All Hot Positions Cabled)

    C.6 Eight-Bus HOT Input Cable Positions Eight-Bus HOT Input Cable Positions (w/o Internal RTN; All HOT Positions Cabled) (w/o Internal RTN; All HOT Positions Cabled) C048-740-30 R02, Rev. C (01/2020)

  • Page 48: Appendix D: Supported Lugs For Termination

    Appendix D: Appendix D: Supported Lugs For Termination Supported Lugs For Termination Table 22. Supported Lugs for Input Connections WIRE GAUGE PART DESCRIPTION MANUFACTURER MANUFACTURER CRIMP DIE SUPPORTED NUMBER PART NUMBER REQUIRED 4/O AWG C538-102-10 Lug; Long Barrel; 3/8" Burndy YAZV282TC38FX Burndy U28RT, holes;...
  • Page 49 Table 25. Supported Lugs for Output Connections (GJ breaker panel) WIRE PART DESCRIPTION MANUFACTURER MANUFACTURE CRIMP DIE GAUGE NUMBER PART NUMBER REQUIRED SUPPORTED 4/O AWG C538-102-10 Lug; Long Barrel; 3/8" Burndy YAZV282TC38FX Burndy U28RT, holes; 1" CTC W28VT, W28RT, X28RT 4/O AWG C538-133-10 Lug;...

  • Page 50: Appendix E: Supported Circuit Breakers

    Appendix E: Appendix E: Supported Circuit Breakers Supported Circuit Breakers Table 26. AM Circuit Breakers PART NUMBER AMPERAGE C470-401-10 5A; Single-pole C470-235-10 10A; Single-pole C470-409-10 15A; Single-pole C470-402-10 20A; Single-pole C470-403-10 30A; Single-pole C470-267-10 35A; Single-pole C470-407-10 40A; Single-pole C470-408-10 45A;...
  • Page 52 Tel.: Toll Free North America: +1 800 322 5742 | Outside US: +1 360 647 2360 | Technical Support: +1 800 863 3364 For more information visit our website at: www.alpha.com © 2020 Alpha Technologies Services, Inc. All Rights Reserved. Trademarks and logos are the property of Alpha C048-740-30 R02, Rev C B (01/2020)

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