CAT-1 Series 3. Installation Guide. The Valley Group, Inc. 871 Ethan Allen Hwy. Suite 104 Ridgefield, CT 06877

Transcription

1 CAT-1 Series 3 Installation Guide The Valley Group, Inc. 871 Ethan Allen Hwy. Suite 104 Ridgefield, CT (203) (203) FAX tvg@cat-1.com

2 Installation of Load Cells for CAT-1 Systems A load cell (Figure 1) is basically a machined stainless steel body, on which are mounted foil-type precision resistors (strain gauges). The stainless steel body, the strain gauges, compensating resistors, and protective elements are hermetically sealed inside a stainless steel canister. Although the load cells supplied to you are highly durable, certain handling and installation procedures must be followed to prevent possible damage. Figure 1: 10,000 lb (44,482N) Stainless Steel Load Cell with 80 ft (24m) cable and connector The load cells must not be subjected to bending or torsion. This may introduce errors, and in the case of serious bending or torsion, may permanently damage the load cell. The hardware used to mount the load cells between the dead-end insulator and the structure must allow sufficient freedom of movement to avoid these types of stresses. Y-clevis hardware is the preferred choice for installation of the load cells. The load cells should be handled carefully during installation. Do not lift the load cells by the cables. Avoid dropping or jarring the load cells, as the resulting severe shock can potentially damage the sensitive strain gauges contained within the canister body. Prevent water and other foreign substances from coming in contact with the load cell s threaded connector. The connector may be capped and placed inside a plastic bag and taped if installation is taking place in a wet or dirty environment.

3 Step-by-step Installation Instructions 1. Test assemble the load cells and mounting hardware prior to installation to ensure that it fits loosely enough to allow movement without bending. Measure the overall length of the load cell and associated hardware. (Note: for Load Cell dimensions see supplement 2) An equivalent length must be removed from the existing insulator and hardware arrangement to ensure that the slack in the line is not changed through the addition of the load cells. Options for achieving this are: removing unnecessary hardware links, reducing the amount of insulators used in the insulator string, pulling up an appropriate amount of conductor. 2. Depending on your company s work practices, load cell installation may or may not be possible during energized conditions. In either case, during installation, take care to prevent applying torque on the load cells. Y-clevis (Figure 2) or shackle (Figure 3) hardware Figure 2: Load cell and Y-clevis hardware is recommended to prevent torque and bending. The load cells are to be installed between the structure and the cold (un-energized) side of the insulator string Figure 3: Load cells with shackle hardware on steel structure.

4 3. (Optional: Additional protection for your Load Cells) Electrically bypass the load cell (for flashover protection) with a copper braid of at least 200 kcmil (100 sq. mm). In typical installations, ground rod clamps or stainless steel hose clamps are used to attach the ground strap to hardware on either side of the load cell. The ground strap and connectors are not provided with the load cells; having them selected and checked for fit prior to the installation of the load cells can save a significant amount of time. 4. At least one side of the load cell must be grounded. A solid path to ground through the attachment hardware to a grounded metal structure is adequate. On wood poles, it may be necessary to run a separate ground wire to the attachment hardware. Follow whatever grounding guidelines your company uses to determine the size of the structure ground and bonding wire to be used. 5. Make note of which load cell is installed on which line section. The load cells have been marked with the serial number and port number of the CAT-1 with which they are to be used. Make sure that the correct load cells are installed at each location, as the CAT-1 units have been pre-configured with the zero offsets associated with each load cell. Example: Data to record during Load Cell installation CAT-1 S/N Port Number Load Cell S/N Line Section Direction Brookfield NE Milford SW Wallingford N Naugatuck E 6. Mark the connector end of the load cell cable with the load cell port number. This can be done with a permanent marker on the amphenol connector body. This will make it easier to identify which cable goes in which port on the CAT-1 unit. 7. Secure the load cell cables to the structure to avoid damage that may occur if they are left to sway in heavy winds. Conduit may be used if available to provide a clean looking installation that will prevent damage from both sun and wind. Coil excess cable and fasten it to the structure near the main unit, leaving a drip loop in the cable below the main CAT-1 port connectors. 8. If the load cells are installed on the structure without the CAT-1 unit, the load cell connectors should be capped and placed inside a plastic bag and taped to prevent moisture ingress into the cable connector.

5 CAT-1 and CAT-PAC Installation The Load Cells are necessarily mounted close to the phase conductors, but the remaining structure mounted equipment should be kept as far from the energized conductors as is practical. Utility personnel normally install CAT-1 systems high enough on the structure to prevent public access but low enough to provide easy access by utility personnel. Attachment hardware is not included with the CAT-1 Main Unit. The typical installation on lattice and wood structures is done by attaching unistrut to the structure, and then attaching the CAT-1 Main Unit and CAT-PAC to the unistrut. The CAT-1 and the CAT-PAC may be mounted side-by-side or vertically stacked with the CAT-1 Main Unit in the top position. The vertically stacked arrangement is usually the most convenient for wood pole installations (Figure 1). Figure 1: CAT-1 and CAT-PAC vertically stacked installation. The solar panels must be mounted so that they are facing south. The position of the CAT-1 and CAT-PAC should be selected to accommodate this requirement. Make note of the surrounding structures and foliage to ensure that the proposed location of the units will not result in shading from the sun on either the solar panels or the NRS. (Note: CAT-1 Series 3 cellular units do not make use of the CAT-PAC unit. In such installations there will be just a single NEMA-4X enclosure to mount on the structure.)

6 Step-by-step Installation Instructions 1. Locate the CAT-1 system on the south side of the structure. Compasses do not work well under transmission lines. Check the orientation of the transmission line on your plan and profile drawings or transmission maps, and use the conductors as a direction reference for finding the south side of the pole. 2. The unistrut may be attached to the pole via thru-bolts or pole bands, or any other convenient method commonly used by your company for attaching equipment to wood structures. The unistrut should be mounted far enough down the pole to minimize shadowing of the CAT-1 components from the conductor and insulator assemblies. Placement of the CAT-1 Main unit and CAT-PAC is limited by the Load Cell cable length (80 ft, 24m) and the antenna cable length (30 ft, 9m). Allow for a minimum of 18 (457mm) and a maximum of 36 (914mm) separation between the CAT-1 Main Unit and the CAT-PAC. (For CAT-1 Main Unit and CAT-PAC dimensions, see supplement 3) 3. Mount the CAT-1 Main Unit to the unistrut. Check the position of mounting tabs on the bottom of the unit enclosure and verify that they are oriented so that the solar panels may be connected to them and face to the south. 4. Mount the CAT-PAC to the unistrut. Do not install the batteries into the unit prior to mounting to the structure. The battery restraint system within the CAT-PAC is designed to hold them in place only after the unit has been mounted. Installing the batteries prior to mounting may result in the batteries shifting during mounting which can cause damage to equipment or wiring in the enclosure. 5. After having secured the CAT-PAC to the structure, remove the fuses from the battery terminal leads. Install the batteries into the CAT-PAC, carefully noting polarity, RED to positive, BLACK to negative. Both batteries should be placed so the terminal lugs are facing the center of the box and face toward the front of the box (Figure 2). Secure the batteries with the battery retainer bar and tighten the wing nuts. Figure 2: Battery orientation (Note: Do not install the fuses into the battery terminal leads until after having finished the antenna installation. Steps 4 & 5 not applicable for CAT-1 Series 3 cellular installations)

7 6. The NRS must be mounted parallel to the monitored conductor in a location that will not be subject to shadowing. The NRS can typically be installed on the upper mounting lug of the CAT-1 Main Unit. Inspect the installation location to insure that it will remain free of shadows during the day. If it appears that shadowing may occur in this position, an alternate location for the NRS must be found. If an alternate location must be selected, an optional NRS mounting bracket can be supplied. The cable supplied with the NRS will allow it to be located up to 10 ft. (3m) away from the CAT-1 Main Unit (NRS units with 20 ft. (6m) cables are available on request). The NRS mounting bracket should be bolted to the south side of the pole out of the path of whatever obstructions prevented the NRS from being located on the mounting lug. The NRS is mounted using the thermal isolation bolt and thermal washers supplied with the unit. The thermal washers are placed beneath the NRS so that it remains free of direct contact with the mounting lug. After attaching the nuts and washers, align the NRS parallel to the monitored conductor. Avoid over-tightening the hardware, as it is possible to break the fiberglass bolt supplied. If the bolt is broken during installation, a spare has been included with the system. Attach the free end of the NRS lead cable to the bulkhead connector (five pin) on the CAT-1 Main Unit marked NRS or NRS1. Push the connector firmly into place and hand tighten. Do not use a wrench or other tool to tighten the connector. (Note: If this location has a second NRS in lieu of an ambient sensor, the second NRS should be connected to the bulkhead connector (five pin) marked NRS2, and aligned parallel to the second monitored conductor. The second NRS can be mounted to the same mounting lug as the first NRS. If a second NRS has been specified for this location, the thermal isolation bolt provided should have adequate length to accommodate installing both sensors. For each NRS sensor, note the line direction and tension port associated with it.)

8 7. Attach the umbilical connector (Figure 3) to the appropriate bulkhead connectors on both the CAT-1 Main Unit and the CAT-PAC. Push the connector firmly into the receptacle and hand tighten. Enough cable length has been supplied to support either vertical or horizontal positioning of the enclosures. The maximum vertical and horizontal separation of the CAT-1 Main unit and the CAT-PAC is 36 and 60, respectively (914 and 1524mm). Figure 3: CAT-1 Main Unit and CAT-PAC umbilical cable (Note: Step 7 is not applicable to CAT-1 Series 3 cellular installations) 8. Attach the Load Cell connectors to the appropriate bulkhead connectors marked PORT 1 and PORT 2. The Load Cell connectors should have been marked with the correct port number during the Load Cell installation. 9. Coil any excess cable lengths and secure to a convenient location using tie-wraps or electrical tape. 10. Ground both the CAT-1 Main Unit and the CAT-PAC to the structure ground. This can be easily accomplished using appropriate hardware attached to the unistrut of each enclosure. Use whatever gauge bonding wire is typically used within your company for grounding pole-top equipment.

9 11. Attach the smaller 10W solar panel (silver frame) to the lower mounting lug on the CAT-1 Main Unit. Secure the panel to the mounting lug with the hardware provided. Make sure that the panel is facing due south. Loosen the hardware allowing the panel to tilt. The angle of the panel with respect to vertical should be set according to the following table: Latitude (degrees) Angle 0 to to 25 Same as latitude 25 to 30 Lat to 35 Lat to 40 Lat Lat +20 (Note: the proper angle for the panel may have been pre-marked with permanent marker on the bracket. Adjust the panel s angle as necessary) Attach the lead from the solar panel to the bulkhead connector (four pin) marked SOLAR on the CAT-1 Main Unit. Connect the other lead coming from the ambient temperature sensor attached to the solar panel mounting bracket to the bulkhead connector (five pin) marked AMB (Dual NRS installations will not have an ambient sensor mounted on the 10W solar panel). To install the connectors push them into the receptacle firmly and hand tighten. Do not use a wrench or any other tool to tighten the connectors. 12. Attach the two 20W solar panels to the lower mounting lugs on the CAT-PAC enclosure. These panels should be aligned to face south and then tilted out from each other by about degrees. The vertical tilt of the panels should be set as instructed in the step 12. Attach the solar panel leads to the bulkhead connectors (four pin) on the CAT-PAC. Use the same precautions mentioned earlier in previous connector attachments. (Note: Step 12 is not applicable for CAT-1 Series 3 cellular installations.)

10 Yagi Antenna Installation The Yagi antenna supplied with the CAT-1 system is not furnished with a mounting bracket, as most utilities have standard mounting arrangements for pole mounted antennas. An example (Attachment 1) of a mounting bracket assembly has been included to provide some idea on how to mount the antenna if your company does not already have a standard mounting arrangement. The minimum and maximum diameters permitted for the outside diameter of the antenna mast are 1.25 and (31 and 60mm) respectively The antenna cable provided is 30 feet (9m) in length. Depending on the location of the CAT-1 Main Unit in relationship to the phase wires, it may not be possible to use the entire length of cable provided. Consult with your company s communications and transmission personnel to determine what the NESC and corporate code clearance requirements are for placement of communications facilities at the kv level of the line on which the antenna is being placed. In general, the antenna and mounting bracket assemblies should be located below the pole top and the static wire, (Figure 1) if one exists, to prevent the likelihood of lightning strikes on the antenna. Whether the antenna may be placed above or below the phase wires depends on the structure design and your company s standard practice for communications facility placement. (Note: CAT-1 Series 3 cellular units are either supplied with a whip antenna that is mounted directly to the CAT-1 enclosure, or with a 10dB cellular Yagi antenna which is physically identical to the antenna used with the Real-Time systems. The steps outlined below apply to Yagi installations of either cellular or Real-time systems.) Figure 1: Typical antenna placement

11 Step-by-step Installation Instructions 1. Attach the mounting bracket assembly to the pole at the location indicated by your communications personnel. 2. Bolt the yagi antenna to the antenna mast using the U-bolts provided. The antenna should be mounted with the vanes of the antenna oriented vertically. If the antenna must be mounted in the horizontal plane, ensure that the antenna at the master location is also mounted horizontally. The recommended vertical arrangement provides the best propagation of signal as well as reducing the surface area exposed to ice buildup. The antenna should be aligned vertically and horizontally to point in the direction of the receiving antenna at the master location. 3. Use the weatherproofing kit provided to prevent water from entering the connector at the antenna end of the cable. For details on use of the weatherproofing kit, see the documentation provided in the kit. 4. Ground the antenna mounting bracket assembly to the structure ground. 5. Secure the antenna cable to the structure to prevent it from swaying in the wind. Use of a conduit is suggested to provide a clean installation, which provides a high level of protection from the elements. 6. Attach the N-male connector to the corresponding bulkhead connector on the CAT- PAC. Hand tighten the connector. Do not use a wrench or other tool to tighten the connector. 7. Coil any excess cable and secure to a convenient location using tie-wraps or electrical tape.