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Alpha Technologies BDFB 8x800A Installation & Operation Manual

Breaker distribution fuse bay
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Alpha Breaker Distribution Fuse Bay (BDFB)
Installation & Operation Manual
Part # 9400009-J0
Effective: 02/2016
Your Power Solutions Partner
member of The
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Summary of Contents for Alpha Technologies BDFB 8x800A

  • Page 1 Alpha Breaker Distribution Fuse Bay (BDFB) Installation & Operation Manual Part # 9400009-J0 Effective: 02/2016 Your Power Solutions Partner member of The Group ™...
  • Page 3 Canada and USA: 1-888-462-7487 International: +1-604-436-5547 Copyright Copyright © 2016 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technolo- gies. No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or transmit- ted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or otherwise without prior explicit written permission from Alpha Technologies.
  • Page 4 9400009-J0 Rev F...

  • Page 5: Table Of Contents

    Table of Contents 1. Safety ............................7 1.1 Safety Symbols .......................... 7 1.2 General Safety ........................... 7 1.4 Mechanical Safety ........................8 1.3 Electrical Safety ......................... 8 2. Introduction ...........................9 2.1 Scope of the Manual ........................9 2.2 Product Overview ........................9 2.3 Product Features ........................
  • Page 6 5. Maintenance ........................54 5.1 Breaker Panel Interface Replacement (alarm strip) ..............55 5.2 System Monitor and Display Replacement ................58 6. Warranty and Service Information ..................60 6.1 Technical Support ........................60 6.2 Warranty Statement ......................... 60 6.3 Limited Hardware Warranty ..................... 60 6.4 Battery Warranty ........................
  • Page 7 List of Figures Figure 1 — BDFB, 8-feed secondary distribution system, 24" ............9 Figure 2 — BDFB load bus arrangements ..................12 Figure 3 — Detailed view of load bus arrangement ................ 13 Figure 4 — Breaker / fuse holder distribution ................. 14 Figure 5 —...
  • Page 8 9400009-J0 Rev F...

  • Page 9: Safety

    Keep it in a safe place. Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference.

  • Page 10: Mechanical Safety

    1.4 Mechanical Safety • Use caution breakers and bus work can be hot. • Power supplies can reach extreme temperatures under load. • Use caution around sheet metal components and sharp edges. 1.3 Electrical Safety WARNING! The DC output from rectifiers and batteries, though not dangerous in voltage, has a high short-circuit current capacity that may cause severe burns and electrical arcing.

  • Page 11: Introduction

    2. Introduction 2.1 Scope of the Manual This instruction manual explains the features, installation, interconnection and startup of the Alpha Breaker Distri- bution Fuse Bay (BDFB) high capacity distribution system. Images contained in this document are for illustrative purposes only and may not exactly match your installation. 2.2 Product Overview Alpha's BDFB is a high capacity distribution system designed to be fed from a -48V power system, bringing power closer to the connected equipment and increasing the number of load distribution points.

  • Page 12: Specifications

    3. Specifications 3.1 Product Specifications Electrical System Voltage: -48V Output Current per Load/Panel: 640A max Number of Loads/Panels per bay: 2, 4, 6 or 8 Secondary Load Postions: 20 positions per panel Over Current Protection: TPS/TLS Plug in bullet up to 125A Single pole LEL breaker up to 125A Double pole LEL breaker up to 200A Triple pole LEL breaker up to 300A...

  • Page 13: Load Bus Arrangements

    3.2 Load Bus Arrangements A load bus is defined as one or more panels protected by a single circuit breaker or fuse at the power plant. Cable from the power plant is terminated at the input connector and goes through an 800A rated shunt. For currents larger than 500 amps, two 750 kcmil feeder cables are required per shunt.

  • Page 14: Figure 2 - Bdfb Load Bus Arrangements

    2 panel, 2 load 6 panel, 2 load 6 panel, 6 load Legend = Shunt = Link bar 8 panel, 2 load 8 panel, 4 load Figure 2 — BDFB load bus arrangements 9400009-J0 Rev F...

  • Page 15: Figure 3 - Detailed View Of Load Bus Arrangement

    3.2.2 Shunt Assembly and Link Bar The BDFB load bus arrangements are factory configured, but they can be changed in the field while the system is operating live. The load bus details are installed at either the top or the bottom panels. These may be unbolted and moved if required.

  • Page 16: Distribution Panels

    3.3 Distribution Panels Each 20-position distribution panel accepts bullet-style circuit breakers and fuse holders. Single-pole through 125A, two-pole through 200A, three-pole through 300A and fuses through 125A. NOTE: Breakers or fuses in the distribution panels rated at 100A and greater shall have one empty space above and below for use in an operating ambient of 40°C.

  • Page 17: Figure 5 - Front View Breaker Distribution Panels, Left And Right Banks Shown

    Breaker trip status indication lights Green = power applied Red = breaker trip alarm Breaker trip status indication lights Green = power applied Red = breaker trip alarm Figure 5 — Front view breaker distribution panels, left and right banks shown 9400009-J0 Rev F...

  • Page 18: Installation

    4. Installation 4.1 Pre-Installation Preparation 4.1.1 Site Selection • Avoid areas that may be subjected to hot air exhaust from nearby equipment. • Provide adequate space for safe access for installation and maintenance personnel. • Rear: 3ft (1m) • Front: 3ft (1m) •...
  • Page 19 If any damage is observed contact the carrier immediately. Continue the inspection for any internal damage. In the unlikely event of internal damage, inform the carrier and contact Alpha Technologies for advice on the impact of any damage.

  • Page 20: Frame Installation

    4.2 Frame Installation The BDFB must be mounted in a clean and dry environment. Provide sufficient free space at the front and rear of the system to meet the cooling requirements and to allow for easy access. 4.2.1 Floor Drilling for Standard Anchoring NOTE: Earthquake anchoring is the type used in earthquake areas up to Zone 4.

  • Page 21: Figure 7 - Base Dimensions And Mounting Holes, 32" Wide Model

    Plan View 32" Bay FRONT 32" BAY .688 X 1.69 MOUNTING SLOTS Front of bay 2.285 20.030 1.285 Back of bay 1.285 29.030 1.285 Figure 7 — Base dimensions and mounting holes, 32" wide model Setting the Anchors 1. Before setting the anchor, review manufacturer's instructions. 2.

  • Page 22: Dc And Grounding Cables Installation

    4.3 DC and Grounding Cables Installation This section provides cabling details and notes on cable sizing for DC applications with respect to the Alpha BDFB secondary distribution system. • Only qualified personnel should install and connect the BDFB. • All wiring must be in accordance with applicable electrical codes. 4.3.1 Installation Notes Installer Responsibility The system arrives pre-wired, and the installer is responsible for connecting the following:...
  • Page 23 Table B — Cable size equivalents (AWG to Metric) Cable size Circular mils Square millimeters Equivalent metric cable 4 AWG 41740 21.15 2 AWG 66370 33.63 0 AWG (or 1/0) 105600 53.48 50 or 70 00 AWG (or 2/0) 133100 67.42 0000 AWG (or 4/0) 211600...
  • Page 24 Suggested Cabling Layouts 9400009-J0 Rev F...

  • Page 25: Figure 8 - Bdfb Frame Reference Ground Images (Back And Front)

    4.3.2 Connecting The Frame Ground A true, single point ground system means that everything is referenced to a single point which is tied to the external earth ground system. In reality each component and external source is effectively bonded to a single point, which is then bonded to the facility or the site external ground system.

  • Page 26: Figure 9 - Bdfb Auxiliary Wiring Connector

    NOTE: Both returns must be connected for accurate voltage measurement. 4.3.6 Auxiliary Power for the Monitor Interface NOTE: The return of the auxililary supply must be near the same potential as the returns for the load feeds. Alpha provides capability to connect an optional auxiliary supply. This allows the monitor to operated even if all feeds are disconnected.

  • Page 27: Figure 10 - Detail A, Top Termination 8 Panel, 8 Load

    DETAIL A Panel 2 Panel 1 Panel 4 Panel 3 Panel 6 Panel 5 Panel 7 Panel 8 Figure 10 — Detail A, top termination 8 panel, 8 load 9400009-J0 Rev F...

  • Page 28: Figure 11 - Detail B, Top Termination 8 Panel, 4 Load

    6 & 8 2 & 4 5 & 7 1 & 3 DETAIL B Panel 2 Panel 1 Panel 4 Panel 3 Panel 6 Panel 5 Panel 7 Panel 8 Figure 11 — Detail B, top termination 8 panel, 4 load 9400009-J0 Rev F...

  • Page 29: Figure 12 - Left Hand Bank

    4.3.7 Wiring the Distribution Panels Refer to guidelines supplied with the load equipment. Distribution cables are typically sized to provide a 0.5V loop drop at full load as well as meeting the ampacity requirements of the protection fuse or circuit breaker. Before You Begin: 1.

  • Page 30: Figure 14 - Top Front Of The Bdfb, Removing The Alarm Panel

    4.3.8 Alarm Connection Wiring See the section BDFB LED Status Indicators (on page 31) for a description of available alarm relays. The wiring connection for the BDFB alarm indicator is routed through the top of the unit. To wire the alarm panel: 1.

  • Page 31: Figure 15 - Alarm Relay Board (Back View)

    TB1= over current TB2 = under voltage TB3 = Breaker trip Figure 15 — Alarm relay board (back view) 4.3.9 Top Cover (optional) The BDFB system can be ordered with an optional Kydex top cover. If using a top cover you will need to create an access entryway for the cables: 1.

  • Page 32: Figure 16 - Bdfb Breaker Panels

    4.3.10 Panel Positions and Labelling The BDFB cabinet is factory configured for top feed cable entry, however this can be reconfigured if required. The following image shows the location of BDFB's side by side banks of 8 panels as well as the BDFB Monitor. Load bus designations are stamped on the labels and installed by the user.
  • Page 33 4.3.11 BDFB LED Status Indicators The BDFB has multiple modes to indicate panel and system functionality. The equipment comes with a factory installed LCD monitor interface to monitor the system and make adjustments. In addition to the information available via the monitor there are system alarm LEDs and panel alarm LEDs. System System alarm indication combine alarms for all panels, it is located at the top of the unit and includes three dry con- tacts (see section on Alarm Connection Wiring, on page 28).

  • Page 34: Bdfb Monitor

    4.4 BDFB Monitor Overview Each BDFB has up to 8 panels. The current, voltage and breaker trip status are monitored and displayed via the BDFB monitor interface (MI). The MI features both a display mode for monitoring status, and a configuration mode which is used for navigating menus and making adjustments.
  • Page 35 4.4.2 Display Mode When in display mode, the up and down arrow keys allow operators to scroll through the status of each panel. Each panel's status displays on the LCD screen which is divided into two portions. The left portion indicates which panel is selected as well as panel alarms. Each of the eight panels are represented by a 5 by 3 pixel grid.
  • Page 36 Alarm Messages The alarm error messages are as follows: • Over Current • Loss of Input Feed • Breaker Trip If more than one error exists the message scrolls between errors. 1. To monitor the BDFB, use the up and down buttons to scroll through the individual panels. 2.
  • Page 37 4.4.4 Configuration Mode The MI configuration menu is used to set configurations and change parameters. Operators can adjust the parame- ters until desired functionality is reached, and then save them. Adjusted or restored parameters are not "permanent" until saved at the top level configuration menu (see the Configuration Menu map, on page 38). From the configu- ration menu the operator can do any of the following: •...
  • Page 38 4.4.5 To Configure a Panel 1. From Display Mode, use the up and down arrows to scroll to the panel to be configured. 2. Press and hold the left and right buttons simultaneously to enter the Configuration mode. Config Menu displays on the top line, and the first option, Panel Config displays on the second line.
  • Page 39 4.4.6 To Configure System (Alarms or Display) 1. From Display Mode, press and hold the left and right buttons simultaneously to enter Configuration mode. Config Menu displays on the top line of the display, and the first option, Panel displays on the second line. 2.

  • Page 40: Configuration Menu

    4.5 Configuration Menu 9400009-J0 Rev F...

  • Page 41: Separating Panels

    4.6 Separating Panels The load bus details can installed at either the top or the bottom panels. The BDFB load bus arrangements are fac- tory configured, but they can be changed in the field. The basic procedure to separate two panels is to add a shunt bus connector kit to the panel to be separated, connect the shunt kit and then remove the link bar between panels.

  • Page 42: Combining Panels

    4.7 Combining Panels BDFB load bus arrangements are factory configured, when the system is ordered, but they can be changed in the field. The basic procedure to combine two panels is to install a link bar between the panels, and then remove one shunt feed.

  • Page 43: Installing/Changing The Load Shunt Bus Kit

    4.8 Installing/Changing the Load Shunt Bus Kit The BDFB comes factory configured for top fed installation. Each bank of panels can be reconfigured to meet cus- tomer equipment power needs as required. To reconfigure the BDFB, a load shunt bus kit, as well as a link bar kit and the necessary hardware are needed.

  • Page 44: Installing/Changing The Inter Link Bar Kit

    4.9 Installing/Changing the Inter Link Bar Kit To reconfigure the BDFB, a shunt and or interlink bar kits and the necessary hardware will be needed. Install the shunt load kit and then install inter link bar between the panels. NOTE: When converting the BDFB, unscrew the bolts to remove the inter link bar between panels, and then reinstall the bolts on the existing PEM studs to ensure connection be- tween the laminate bar and the input bus bar.

  • Page 45: Converting The Bdfb System

    4.10 Converting the BDFB System The following diagram shows the connection for a top feed, 8 panel, 2-load BDFB system. Load shunt bus kit Load shunt bus kit Breaker/fuse loads Breaker/fuse loads 1 through 20 1 through 20 to the equipment to the equipment Link bars connect Link bars connect the 4 panels, on...

  • Page 46: Figure 20 - Top Fed, 4-Load System

    4.10.1 Converting from a 2-load to a 4-load To convert the BDFB from a 2-load to a 4-load system do the following: 1. Remove the interlink bars between panels 3 and 5, and between panels 4 and 6. See page 44. 2.

  • Page 47: Figure 21 - Converting A 4-Load System

    4.10.2 Converting from a 4-load to a 8-load To convert the BDFB from a 4-load to and 8-load system do the following: 1. Remove the interlink bars between panels 1 and 3, 2 and 4, 5 and 7, and between panels 6 and 8. See page Load shunt bus kit Load shunt bus kit Panel 1...

  • Page 48: Figure 22 - Top Fed 8-Load System

    2. Install a load shunt bus kit on panels 3, 4, 7 and 8. See following figure. Load shunt bus kit Load shunt bus kit Panel 1 Panel 2 Panel 3 Panel 4 Panel 5 Panel 6 Panel 7 Panel 8 Figure 22 —...

  • Page 49: Internal Return

    4.11 Internal Return The BDFB internal return bus (if ordered) comes factory configured in either 2 or 8-load configuration which can be field upgraded to suit the specific needs of the installation. The internal return load bus kits can be ordered as follows: •...

  • Page 50: Converting The Internal Return From 2-Load To A 4-Load

    4.12 Converting the Internal Return from 2-load to a 4-load To convert from a 2-load to a 4-load system, add booster bar with the supplied hardware. See "Booster Bar Instal- lation" on page 50. Booster bar 1/4 - 20 screws supplied Figure 24 —...

  • Page 51: Converting The Internal Return To A 6- Or 8-Load System

    4.13 Converting the Internal Return to a 6- or 8-load System To covert to a 6- or 8-load system, add booster bars with the supplied hardware. See "Booster Bar Installation" on page 50. Booster bar 1/4 - 20 screws supplied Booster bar Figure 25 —...

  • Page 52: Booster Bar Installation

    4.14 Booster Bar Installation 4.14.1 Installing a 24" booster bar If possible, in an A-B system it is recommended to turn off the side in which the booster bar is being installed. 1. There are a total of six nuts which hold the main internal return and the input connector together (only two should be removed).
  • Page 53 4.14.2 Installing a 48" Booster Bar If possible, in an A-B system it is recommended to turn off the side in which the booster bar is being installed. 1. There are a total of six nuts which hold the main internal return and the input connector together (only four should be removed).

  • Page 54: External Return Installation

    4.15 External Return Installation 4.15.1 Mounting the External Return Base Kit (optional) The external return base kit is an option for return connections for the loads. It serves as the common connecting point for the positive side of the power section. The external return kit has a capacity of 640A per kit.

  • Page 55: Figure 28 - External Return, 4-Bar, Horizontal Configuration

    Figure 28 — External return, 4-bar, horizontal configuration 4.15.2 Landing Cables on External Return When landing cables on the bus bar for the external return bar kit follow the instructions in the Figure 21. Return Bar to Loads Wiring Always start system and load wiring from the same side. When wiring the system always space the input and output cables evenly across the entire length of the bar to ensure the load current is evenly distributed.

  • Page 56: Maintenance

    5. Maintenance Although very little maintenance is required with Alpha systems, routine checks and adjustments are recommended to ensure optimum system performance. Qualified service personnel should do the repairs. The following table lists a few maintenance procedures for this system. These procedures should be performed at least once a year.

  • Page 57: Breaker Panel Interface Replacement (Alarm Strip)

    5.1 Breaker Panel Interface Replacement (alarm strip) This procedure outlines how to remove and replace the breaker panel interface boards (P/N 7050244-001). The alarm strip boards are difficult to install when the breakers are in place. It is recommenced that all breakers be removed before installing the alarm strips.
  • Page 58 NOTE: The alarm boards are calibrated to specific inputs on the monitor interface labelled 1 through 8. Do not swap locations. The frame is always pre-wired to all locations. Recali- brate the board after installation (use kit available from Alpha). To remove the interface connections: These wires have insulated quick connectors to reduce chance of shorting as there is -48Vdc with high current potential on the leads.
  • Page 59 2. Remove the cover from the breaker panel interface as follows: a. Gently hold the cover with one hand. b. Push up on the bottom of the cover for the right side. Push Unlocked down on the top for the left side. c.

  • Page 60: System Monitor And Display Replacement

    5.2 System Monitor and Display Replacement This procedure outlines how to remove and replace the system monitor display interface (P/N 705244-001). WARNING! Hazardous voltages are present at the input of power systems. The DC output from rec- tifiers and batteries, though not dangerous in voltage, has a high short-circuit current capacity that may cause severe burns and electrical arcing.

  • Page 61: Figure 30 - Cable Assignment

    4. Remove the MI board assembly and place it on a flat working surface. 5. Remove the two mounting screws and set aside, and then remove the old board. 6. Replace with the new MI board. Follow these steps in reverse order (from step 6 to step 1) to insert the new MI board. Step 5 System alarm connections...

  • Page 62: Warranty And Service Information

    6. Warranty and Service Information 6.1 Technical Support In Canada and the USA, call toll free 1-888-462-7487. Customers outside Canada and the USA, call +1-604-436-5547. 6.2 Warranty Statement For full information details review Alpha's online Warranty Statement at http://www.alpha.ca/warranty. 6.3 Limited Hardware Warranty Alpha warrants that for a period of two (2) years from the date of shipment its products shall be free from defects under normal authorized use consistent with the product specifications and Alpha’s instructions, unless otherwise specified in the product manual, in which case, the terms of the manual will take precedence...

  • Page 63: Acronyms And Definitions

    7. Acronyms and Definitions Alternating current ANSI American National Standards Institute American Wire Gauge British thermal unit Controller area network Canadian Electrical Code Canadian Standards Association Cordex™ series; e.g., CXC for Cordex System Controller Direct current DHCP Dynamic Host Configuration Protocol Electronic Industries Alliance Electromagnetic compatibility Electromagnetic interference Electromagnetic Compatibility and Radio Spectrum Matters...

  • Page 64: Certification

    8. Certification About CSA and NRTL CSA (Canadian Standards Association also known as CSA International) was established in 1919 as an independent testing laboratory in Canada. CSA received its recognition as an NRTL (Nationally Recognized Testing Laboratory) in 1992 from OSHA (Occupational Safety and Health Administration) in the United States of America (Docket No.
  • Page 66 Canada and USA: 1-888-462-7487 International: +1-604-436-5547 Visit us at www.alpha.ca Due to continuing product development, Alpha Technologies reserves the right to change specifications without notice. Copyright © 2016 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.

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