Technical Manual CE-3x2 5K-T 48Vdc Telecom Generator PN-6x-T 7.
Power Alpha Technologies ®
TM CE-3x2 5K-T 48Vdc Telecom Generator PN-6x-T 7.5kW 48Vdc Telecom Generator Technical Manual 042-288-B0-001, Rev. A Effective Date: May 2008 Copyright © 2008 Alpha Technologies, Inc. member of The GroupTM NOTE: 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.
Table of Contents Safety Notes .......................................................................................................................... 8 1.0 System Overview ...................................................................................................... 13 1.1 PN-6x-T System Diagram .............................................................................. 14 1.2 CE3x2 5kW System Diagram ........................................................................ 15 1.
4.4 4.5 4.6 4.7 4.8 4.9 4.10 5.0 6.0 7.0 8.0 Control Functions ........................................................................................... 59 Alarm Classifications...................................................................................... 60 ECM Alarm Overview ..................................................................................... 62 Connecting the Alarm and Control Connections ............................................
List of Figures Fig. 1-1, PN-6x-T 7.5kW Telecom Generator ...................................................................... 13 Fig. 1-2, CE-3x2 5K-T Telecom Generator .......................................................................... 13 Fig. 1-3, PN-6x-T System Diagram ..................................................................................... 14 Fig. 1-4, CE3x2 System Diagram ........................................................................................ 15 Fig.
Fig. 4-1, Location of Engine Control Module (ECM) ........................................................... 54 Fig. 4-2 (a), ECM LED Indicators, Switches, and Interface Connections ............................ 55 Fig. 4-2 (b), ECM Printed Circuit Boards ............................................................................ 55 Fig. 4-3, LED Indicators and Control Functions................................................................... 59 Fig. 4-4, Terminal Block 1 ................................
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.
General Safety Precautions To avoid injury: • This enclosure and its associated hardware must be serviced only by authorized personnel. • Enclosure must remain locked at all times, except when authorized service personnel are present. • Remove all conductive jewelry or personal equipment prior to servicing equipment, parts, connectors, wiring, or batteries. • Read and follow all installation, equipment grounding, usage, and service instructions included in this manual.
Battery Safety Notes WARNING! Lead-acid batteries contain dangerous voltages, currents, and corrosive material. Battery installation, maintenance, service, and replacement must only be performed by authorized personnel. Chemical Hazards Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contain dilute sulfuric acid, which is harmful to the skin and eyes. Emissions are electrolytic, and are electrically conductive and corrosive.
Battery Maintenance Guidelines The battery maintenance instructions listed below are for reference only. Battery manufacturer’s instructions for transportation, installation, storage, or maintenance take precedence over these instructions. • • • • • • • • To prevent damage, inspect batteries every 3 months for: Signs of battery cracking, leaking or swelling. The battery should be replaced immediately by authorized personnel using a battery of the identical type and rating. Signs of battery cable damage.
Auxiliary Power Unit (APU) Notes 12 • While the engine is stopping, a small amount of unburned fuel may be present. Fans are used to expel these fumes from the enclosure, but fumes may be detected outside the enclosure for a short period of time after engine shutdown. This is a normal condition and does not present a hazard. • Most utilities add a chemical agent to the gas which produces a strong odor so leaks can be detected before they reach a dangerous or explosive level.
1.0 System Overview AlphaGen Telecom curb-side generator systems power outside plant communication networks. Every AlphaGen system incorporates industry leading power technology, including natural gas or propane fueling, exclusive audible noise baffling, remote status monitoring features, and a durable, weather resistant enclosure construction. This document describes the installation, operation, and maintenance of the CE-3x2 5K-T and PN-6x-T 7.5kW Telecom generators.
2 4 3 1 0 ECM ECM TB1-4 TB1-9 6 8 7 BLACK ORANGE GREEN NC NO COM OUTPUT CB AUX SW DOOR SW DOOR SW GAS HAZARD SENSOR 1 23 2 1 RED BLACK BLACK WHITE WHITE WHITE YELLOW COM L N NC NO AC FAIL RELAY TB2-2 TB2-1 TB2-8 TB2-7 ORANGE MAJOR MAJOR MAJOR MINOR ALM ALARM ALARM ALARM ALARM BY NC COM NC NO COM COM ALM BY NO ALM BY NC ENG RUN COM ENG RUN NO ENG MINOR MINOR MINOR Door RUN ALARM ALARM ALARM NO NC NO NO NC COM Door COM LPG ( -) LPG (12V ) AC/ FAIL NC AC/ FAIL NO AC/ FAI
2 4 3 1 0 ECM TB1-8 ECM TB1-7 DOOR SW ECM J5-6 ECM J5-5 ECM TB1-9 MAJOR MAJOR MAJOR ALARM ALARM ALARM NO COM NC MINOR ALARM NC COM ALM BY COM ALM BY NC ALM BY NO RUN NO ENG RUN COM ENG NC RUN ENG MINOR MINOR MINOR Door Door LPG AC/ AC/ LPG ALARM ALARM ALARM MON. FAIL FAIL COM MON.
1.0 System Overview, continued 1.3 Natural Gas System Block Diagram CAUTION! Do not include the generator system as part of a local gas piping system test. Damage to the generator pre-regulator may result. The generator system is pressure tested in accordance with NFPA standards prior to shipment. ENGINE Demand Low-pressure Regulator CONTROLS 14" WC (max.) APU Enclosure CONTROL Solenoid S Engine must have 7" to 11" WC and 156 cubic feet/Hr.
1.0 System Overview, continued 1.4 Liquid Propane System Block Diagram LP PROPANE - VAPOR WITHDRAWAL BLOCK DIAGRAM ENGINE DEMAND CONTROLS LOW PRESSURE REGULATOR 8oz MAX S 11"WC APU ENCLOSURE SENSOR 11"WC OUTLET SOLENOID CONTROL LOW FUEL ALM LOW FUEL PRESSURE SWITCH PROPANE POST-REG PROPANE ENCLOSURE LPG TANK Fig. 1-7, LP Propane Vapor Withdrawal Block Diagram 042-288-B0-001, Rev.
1.0 System Overview, continued 1.5 Specifications Model CE-3x2 5.0kW PN-6x-T 7.5kW DC Output Voltage: -51.5 to -52V @ no load -51.5 to -52V @ no load DC Output Load Regulation: 0.5V 0.5V Output Current: 52V @96A max. 52V @ 144A max. <54dBrnc <54dBrnc Wideband: <100mVrms in any 3kHz bandwidth from 10k to 20mHz <100mVrms in any 3kHz bandwidth from 10k to 20mHz Broadband: <250mVp-p from 20 to 100mHz <250mVp-p from 20 to 100mHz Engine: 398cc, air-cooled, single OHV 10.
1.0 System Overview, continued 1.5 Specifications, continued Engine Specifications, PN-6x-T 7.5kW 48Vdc Generator Set Specification Manufacturer: Kohler Manufacturer: Kohler Make/model: CH20 Dimensions (in/mm): 21.5"L x 20"W x 21.8"H 546 x 508 x 554 Weight (lb/kg): 190/86 Rated* kW: 7.5 Rated Voltage: (after rectifier) 52 ± 0.5Vdc @ no load Rated Amps: 144 @ 52Vdc Stator Resistance: (ohms) 0.
1.0 System Overview, continued 1.5 Specifications, continued Engine Specifications, CE-3x2 5K-T 48Vdc Generator Set Specification Manufacturer: Kohler Manufacturer: Kohler Make/model: CV14 Dimensions (in/mm): 24"L x 26"W x 44"H 546 x 508 x 554 Weight (lb/kg): 395/179 Rated* kW: 5kW Rated Voltage: (after rectifier) 52 ± 0.5Vdc @ no load Rated Amps: 96 @ 52Vdc Stator Resistance: (ohms): 0.
2.0 Site Preparation 2.1 2.2 Site Considerations • Where possible, select a site away from houses, and above the 100-year flood plain. • Place in a shaded location to minimize the effects of solar loading. • Avoid locating the enclosure where it obstructs or inhibits visibility. • Locate the enclosure away from sprinkler systems, or other sources of forced water. • Locate the enclosure out of the prevailing wind to minimize the buildup of snow or windborne dust.
2.0 Site Preparation, continued 2.2 Acoustics, continued 20 Feet, (64 dBa) 50 Feet (56 dBa) Fig. 2-2, Acoustical Measurements in Relation to Placement Near Residences (generator sound levels at full load) 22 042-288-B0-001, Rev.
2.0 Site Preparation, continued 2.3 Enclosure Impact Protection The National Fire Protection Agency (NFPA) requires that equipment using natural gas or liquid propane be protected, based on good engineering practices, in areas where vehicle traffic is normally expected at that location. The required protection is based on the anticipated speed of the vehicles operated in that area. The NFPA does not provide specific guidelines for when protection is needed or the nature of the protection.
2.0 Site Preparation, continued 2.3 Enclosure Impact Protection, continued Generator Protection, Vehicular Areas, continued The remote located natural gas meter shown below may require two to four bollard posts depending on location, site survey, and traffic pattern. This is a typical installation design with gas meters supported by dual risers and located near the cabinet. ATTENTION: Install enclosure protection in compliance with local codes. Generator Fig.
2.0 Site Preparation, continued 2.4 Natural Gas Meter Configurations The gas utility company should have the meter installed prior to generator arrival. Meter configurations must comply with local codes. The illustrations provided are for illustrative purposes only. Gas Utility Box Natural Gas Meter Street Regulator Manual Shutoff Excess Flow Valve (optional) Street Pressure Fig.
2.0 Site Preparation, continued 2.4 Natural Gas Meter Configurations, continued The gas utility company should have the meter installed prior to generator arrival. Meter configurations must comply with local codes. Examplesz provided are for illustrative purposes only. Street Regulator Manual Shutoff Gas Utility Box Natural Gas Meter Excess Flow Valve (optional) Street Pressure Fig.
2.0 Site Preparation, continued 2.5 Liquid Propane Systems For systems using liquid propane, the end user must provide a suitable LP tank. For collocated propane enclosures, see the CE-G Series Enclosure Installation Manual, Alpha P/N 031-093-C0-001, located at www.alpha.com. User-provided LP Tank Manual Shutoff Fig. 2-9, Liquid Propane Setup, CE-3x2 5K-T Manual Shutoff Location User-provided LP Tank (Most Common) Fig. 2-10, Liquid Propane Setup, PN-6x-T 7.5kW 042-288-B0-001, Rev.
2.0 Site Preparation, continued 2.6 Grounding Requirements, CE-3x2 5K-T The ground rod system is typically used in remote applications where the generator is located away from the power supply enclosure and exposed to lightning strikes, or coincidental surges. The wiring interface between the DC Genset and system carries a system ground to ensure common ground between both cabinets and communication devices. The remote APU cabinet ground rod serves only as an alternate discharge path.
2.0 Site Preparation, continued 2.7 Grounding Requirements, PN-6xT 7.5kW The ground rod system is typically used in remote applications where the generator is located away from the power supply enclosure and exposed to lightning strikes, or coincidental surges. The wiring interface between the DC Genset and system carries a system ground to ensure common ground between both cabinets and communication devices. The remote APU cabinet ground rod serves only as an alternate discharge path.
3.0 Installation 3.1 Installing the CE-3x2 5K-T or PN-6x-T 7.5kW Pad Template To ease the installation of the generator enclosure, use the pad mounting template to accurately locate the mounting holes for the generator cabinet mounting hardware. The installation instructions for the two types of generator pad templates are the same, only the dimensions vary. Site Considerations: • Where possible, select a site that is above the 100-year flood plain, and away from houses.
3.0 Installation, continued 3.1 Installing the CE-3x2 5K-T or PN-6x-T 7.5kW Pad Template, continued 1. Determine the size of the pad you need. Typically it is best to leave at least 6 inches of space between the outside of the cabinet and the edge of the pad. Occasionally, you might want to extend the pad in one or more directions for ease of access during maintenance. 2.
3.0 Installation, continued 3.1 Installing the CE-3x2 5K-T or PN-6x-T 7.5kW Pad Template, continued A Backfill trenches over conduit. B Concrete pad. C Stagger or nest conduits for passage through the three inch pad sweep opening on CE-3x2. D A B C When pouring the pad the sweeps may extend to a maximum of 4 inches above the finished pad to prevent concrete from filling the sweep openings.
3.0 Installation, continued 3.2 Installation, CE-3x2 5K-T Prior to installation verify the following: • All necessary grounding rods and materials are in place. • Utility power was run to site in accordance with the NESC (National Electric Safety Code). • Obtained local safety practices for working with high-voltage systems. • Gas piping, hardware, supports, and other gas carrying components to the pad location conform to NFPA standard and local requirements.
3.0 Installation, continued 3.2 CE-3x2 5K-T Installation 3.2.1 CE-3x2 5K-T Transportation and Lifting The generator weighs approximately 395 lbs. A safe means of transporting to the site, and unloading the generator must be arranged. Do not transport, lift, or place the generator on a surface unable to fully support its weight. The generator is shipped bolted to a pallet. Remove the protective outer wrapping material, and inspect the outside of the generator for shipping damage.
3.0 Installation, continued 3.2 CE-3x2 5K-T Installation, continued 3.2.1 CE-3x2 5K-T Transportation and Lifting, continued The enclosure is lifted via the attached lifting ears. The lifting ears are attached to the cabinet with 1/4-20 x 3/8” stainless steel SAE J429 Grade 8 hex head bolts, torqued 80 to 90 in-lbs. 1 A1 1 A1 1/4-20 x 3/8” stainless steel SAE J429 Grade 8 hex head bolts. 4 places per ear. 1 B1 1 B1 Bolts torqued 80 to 90 in-lbs. Fig. 3-5, Lifting Ear Attachment 042-288-B0-001, Rev.
3.0 Installation, continued 3.2 CE-3x2 5K-T Installation, continued 3.2.2 Enclosure Installation, CE-3x2 5K-T 1. Lift the enclosure with a lifting appararatus rated in excess of 500 lbs. Configure the lifting arrangement so the distance from the top of the cabinet to the lift ring or hook is at least twice the distance between the lifting ears (Fig. 3-2). 2. Position the enclosure above the concrete pad, and slowly lower it into position over the pad’s 3/8" (or 1/2") anchor or J-bolts.
3.0 Installation, continued 3.3 PN-6x-T 7.5kW Installation Prior to installation verify the following: • All necessary grounding rods and materials are in place. • Utility power run to site in accordance with the NESC (National Electric Safety Code). • Obtained local safety practices for working with high-voltage systems. • Gas piping, hardware, supports, and other gas carrying components to the pad location conform to NFPA standard and local requirements.
3.0 Installation, continued 3.3 PN-6x-T 7.5kW Installation, continued 3.3.1 PN-6x-T 7.5kW Transportation and Lifting, The enclosure as shipped contains the Auxiliary Power Unit (APU) and weighs approximately 338 lbs. A safe means of transporting 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. The system is shipped bolted to a pallet.
3.0 Installation, continued 3.3 PN-6x-T 7.5kW Installation, continued 3.3.1 PN-6x-T 7.5kW Transportation and Lifting, continued The enclosure is lifted via four lifting plates included with the generator. The lifting plates are attached to the cabinet with 1/4-20 x 3/8" stainless steel SAE J429 Grade 8 hex-head bolts, torqued 80 to 90 in-lbs. WARNING! To prevent injury or death, do not walk, or allow personnel to walk, beneath the suspended unit. Use steel-toe work shoe protection.
3.0 Installation, continued 3.3 PN-6x-T 7.5kW Installation, continued 3.3.2 Enclosure Installation Procedure, PN-6x-T 7.5kW 1. Position the enclosure above the concrete pad and slowly lower it into position over the pad’s 3/8" (or 1/2") anchor or J-bolts. A 25+ year vapor barrier MUST be used between the concrete and enclosure base to inhibit moisture ingress, and to prevent possible corrosion caused by metal to concrete contact.
3.0 Installation, continued 3.4 Enclosure Grounding, CE-3x2 5K-T Run the chassis and earth grounding wires through the one-inch opening in the bottom of the generator enclosure. Using a 7/16" nutdriver or socket, secure the ground leads to the grounding stud located on the enclosure wall. See Fig. 3-12 below. ATTENTION: It is the responsibilty of the system installer to verify applicable grounding requirements, and to ensure that system grounding complies with all state, local, or regional requirements.
3.0 Installation, continued 3.5 Enclosure Grounding, PN-6x-T 7.5kW Run the chassis and earth grounding wires through the one-inch opening in the bottom of the generator enclosure. Using a 7/16" nutdriver or socket, secure the ground leads to the grounding stud located on the enclosure wall. See Fig. 3-13 below.
3.0 Installation, continued 3.6 Natural Gas Utility Fuel Hookup, CE-3x2 5K-T These general instructions apply to either remote or collocated systems. • Connection to the utility fuel line is made using a 3/4" shear point union, 1/2" black iron pipe, and the appropriate pipe thread sealant suitable for use with natural gas or propane vapor. • Use approved pipe thread sealant on all fuel line connections (except flare fittings). • Thoroughly check the fuel system for vapor leaks.
3.0 Installation, continued 3.7 Natural Gas Utility Fuel Hookup, PN-6x-T 7.5kW These general instructions apply to either remote or collocated systems. • Connection to the utility fuel line is made using a 3/4" shear point union, 1/2" black iron pipe, and the appropriate pipe thread sealant suitable for use with natural gas or propane vapor. • Use approved pipe thread sealant on all fuel line connections (except flare fittings). • Thoroughly check the fuel system for vapor leaks.
3.0 Installation, continued 3.8 Liquid Propane Utility Fuel Hookup, CE-3x2 5K-T For collocated propane enclosures, see the CE-G Series Enclosure Installation Manual, Alpha P/N 031-093-C0-001, located at www.alpha.com. • Connection to the LP fuel line is made using a 3/4" shear point union, 1/2" black iron pipe, and the appropriate pipe thread sealant suitable for use with propane vapor. • Approved pipe thread sealant must be used on all fuel line connections (except flare fittings).
3.0 Installation, continued 3.9 Liquid Propane Utility Fuel Hookup, PN-6x-T 7.5kW • Connection to the LP fuel line is made using a 3/4" shear point union, 1/2" black iron pipe, and the appropriate pipe thread sealant suitable for use with propane vapor. • Approved pipe thread sealant must be used on all fuel line connections (except flare fittings). • Thoroughly check the fuel system for vapor leaks.
3.0 Installation, continued 3.10 Making the DC Output Connection, CE-3x2 5K-T Verify proper polarity with a digital voltmeter, and connect the Load to the DC output connector. Fig, 3-18, DC Output, CE-3x2 5K-T 042-288-B0-001, Rev.
3.0 Installation, continued 3.11 Making the DC Output Connection, PN-6x-T 7.5kW 1. Locate and remove the safety shroud. The shroud is held in place with two thumb screws. Shroud Location Fig. 3-19, DC Output Safety Shroud 2. Strip the user-supplied DC load wires 3/4". Loosen the 3/16" Allen screws and insert the DC load wires. Torque to 120 in-lbs and replace the safety shroud. Positive DC Load Connection Negative DC Load Connection Fig. 3-20, DC Output Connections, PN-6x-T 7.
3.0 Installation, continued 3.12 Connecting the Ignition Battery, CE-3x2 5K-T WARNING! For further information regarding the safe handling of batteries, refer to the Battery Safety Notes at the beginning of this manual. 1. Set the RAS switch on the ECM to the STOP position. 2. Using a voltmeter, check ignition battery voltage. Battery voltage should be at least 12.5Vdc. If low, recharge before placing into operation. 3. Coat the battery terminals with battery corrosion preventative compound (NCP-2).
3.0 Installation, continued 3.13 Connecting the Ignition Battery, PN-6x-T 7.5kW The ignition battery is calcium/silver chemistry, 585 CCA , group 55 battery (Alpha P/N 181076-10). WARNING! For further information regarding the safe handling of batteries, refer to the Battery Safety Notes at the beginning of this manual. 1. Set the RAS switch on the ECM to the STOP position. 2. Using a voltmeter, check ignition battery voltage. Battery voltage should be at least 12.5Vdc.
3.0 Installation, continued 3.14 Terminal Block 2 (AC Line) Connections, CE-3x2 5K-T Terminal Block 2 is above the ignition battery, located in the rear of the enclosure. Connect the user-supplied wiring using a #1 flat-head screwdriver. Strip wires 3/8" (9.5mm) and torque to 7 in-lbs (0.8 Nm). Refer to the table and photo below for alarm definitions. Terminal Block 2 Position 1 Fig.
3.0 Installation, continued 3.15 Terminal Block 2 (AC Line) Connections, PN-6x-T 7.5kW Terminal Block 2 is located on the bulkhead next to the convenience outlet. Connect the usersupplied wiring using a #1 flat-head screwdriver. Strip wires 3/8" (9.5mm) and torque to 7 in-lbs (0.8 Nm). Refer to the table and photo below for alarm definitions. Terminal Block 2 Terminal Block 2 Position 1 Fig. 3-22, Terminal Block 2 (TB2), PN-6x-T7.
3.0 Installation, continued 3.16 Final Inspection Checklist CAUTION! Set the ECM Run/Auto/Stop (RAS) switch to the STOP position before initially powering up the ECM. This allows the operator to manually control the START and STOP functions of the APU until the system is set up. This also prevents the APU from starting unexpectedly. Once the installation is complete, verify the following: 1. Engine oil at proper level 2. All electrical connections securely made 3.
4.0 The Engine Control Module The Engine Control Module (ECM) controls and monitors the generator’s Auxiliary Power Unit (APU). The ECM is a two part assembly made up of the ECM Printed Circuit Board (ECM PCB) and the Generator Remote Interface (GRI) board. The GRI is attached to the ECM PCB with three ribbon cables. The ECM provides interface connectors for the enclosure sensors, engine controller, battery sense, line sense, and other equipment.
4.
4.0 The Engine Control Module, continued 4.1 Theory of Operation Under normal operating conditions (no alarms) the ECM Run-Auto-Stop (RAS) switch is in the AUTO (center) position. The ECM has control of the APU while in the Auto mode. When the RAS switch is switched from the STOP position to the AUTO position the ECM will run the APU for a one minute self-test after a short delay. This indicates the ECM is in the Auto mode and is capable of starting and stopping the APU automatically.
4.0 The Engine Control Module, continued 4.1 Theory of Operation, continued 4.1.3 Normal APU Shutdown The ECM initiates a normal APU shutdown when the AC line is within normal limits, the DC bus alarm is not active, the 12 minute cool-down period has elapsed, and the Engine Run command is not active. If started due to low DC Bus voltage, the ECM continues to run the APU until specific conditions are met (see below) or a major alarm occurs.
4.0 The Engine Control Module, continued 4.2 ECM Operating Mode Summary, continued The following conditions cause immediate engine shutdown: 1. Manual engine stop switch is activated. 2. Software engine stop switch is received. 3. Any of the following engine alarms become active: • Low oil • Engine over-temperature • Low fuel • Over-speed • Over-crank • Over-voltage 4. Any of the following system alarms become active: 4.
4.0 The Engine Control Module, continued 4.4 Control Functions The Run-Auto-Stop (RAS) switch controls the Auxiliary Power Unit (APU). Typically the RAS switch is in the AUTO position so the ECM has control of the generator. When the RAS is not in the AUTO position a minor alarm is displayed. The STOP position is used to stop or prevent APU operation during maintenance.
4.0 The Engine Control Module, continued 4.5 Alarm Classifications Major Alarms: A major alarm indicates a critical failure or situation that causes the system to go off-line. Major alarms cause the engine to shutdown immediately and generally prevent further operation. Most major alarms are latched by the ECM. Placing the RAS switch to the STOP position for three seconds, then switching back to AUTO clears any latched alarms and starts the generator (if the cause of the alarm has been corrected).
4.0 The Engine Control Module, continued 4.5 Alarm Classifications, continued Minor Alarms: Minor alarms indicate a system fault which, though not indicative of imminent system failure or shutdown, requires service attention before the condition worsens. A site check by service personnel is recommended. • Control Fail (Latching – after five activations): A control failure between the ECM and the generator set. Typically this means the engine did not start or stop when commanded to do so.
4.0 The Engine Control Module, continued 4.6 ECM Alarm Overview Alarms are indicated in three ways: ECM LEDs, RS-485 communications, and alarm contact closures on the ECM transponder interface. Alarm indications on the ECM LEDs are displayed by pressing the service reset button momentarily. Pressing the service reset switch again will reveal the next alarm in the list. When the alarm list has been exhausted, all LEDs will flash several times and then return to their normal functions.
4.0 The Engine Control Module, continued 4.7 Connecting the Alarm and Control Connections Alarm output and communication connections are located on Terminal Block 1.
4.0 The Engine Control Module, continued 4.8 ECM DIP Switch and Fuse Configuration The ECM PCB has an eight-position DIP switch (SW5) used to configure the generator interface, APU output voltage (AC or DC), and utility voltage. The GRI board has three fuses, F1, F2, and F3. SW5 F2: 12V Output to APU Fan and Enclosure Gas Detector (2A, 250V Slo-Blo) Alpha P/N 460-205-10 F1: 12V Input from APU (2.
4.0 The Engine Control Module, continued 4.
4.0 The Engine Control Module, continued 4.9 ECM Interface Block Diagram and Connectors The Generator Remote Interface provides power conditioning to the ECM PCB, and connection between cabinet sensors and the APU control. The interface supplies all necessary signals, alarms, logic power, and analog voltages required for telemetry at the central office or relevant monitoring station, and allows the ECM to start and stop the engine alternator as part of the network controlled periodic test sequence.
4.0 The Engine Control Module, continued 4.10 ECM Self-test Generator testing consists of starting and running the generator for a duration of 10 minutes. Generator testing can be initiated two ways: 1. The ECM is configured to periodically run an automatic test. 2. A one-minute automatic test is performed when the manual control switch is returned to Auto from Stop.
4.0 The Engine Control Module, continued 4.10 ECM Self-test, continued The following programmable, internal ECM variables control automatic self-tests. • Autotest Interval: The number of days between automatic tests. • Autotest Countdown: • Autotest Duration: Each Autotest is measured in minutes. The test duration is 10 minutes. Manually Enabling the Autotest Feature: Use SW5-8 to enable the Autotest feature with a 14-day test interval.
5.0 Turn-up and Test 5.1 Appearance and Condition of Components Prior to applying power, open each door of the enclosure. Observe and note the condition of the following: 5.2 • Doors and locking mechanisms • Seals • Door intrusion switches System Preparation The following procedure involves starting and stopping the engine using the Engine Control Module (ECM).
5.0 Turn-up and Test, continued 5.3 Performing a Local APU Test Procedure: 1. Locate the ECM and set the Run/Auto/Stop (RAS) switch to the STOP position. 2. Verify ignition battery and AC line sense connection to ECM. 3. Verify all alarms on ECM are OFF, except Tamper Alarm & Auto Mode Disabled. 4. Remove gas port plug from input side of demand regulator, install brass manometer port connection fitting and connect manometer to fitting (see Section 7-9 for details). 5.
5.0 Turn-up and Test, continued 5.4 Generator System Sensor Verification The ECM has a built-in self-test feature. Each time the ECM’s RAS (Run-Auto-Stop) switch is placed in the AUTO position, a one minute self-test is performed and any failures are reported as major or minor alarms. Latched alarms can be reset after the fault has been cleared by placing the RAS switch to the STOP position for three seconds and then back to the AUTO position. 5.4.1 Enclosure Alarm Verification 1.
5.0 Turn-up and Test, continued 5.4 Generator System Sensor Verification, continued 5.4.2 AC and DC Line Sense Verification The ECM monitors the AC line and DC bus status to determine when to start and stop the APU. In the event of an extended power outage or low battery bus voltage the ECM will start the APU. The following test verifies these functions. 1.
6.0 Operation 6.1 Normal Operating Condition Under normal operating conditions (no alarms) the ECM’s RAS switch is in the AUTO position. The ECM has control over the APU while in Auto mode. Each time the RAS switch is moved from the STOP position to the AUTO position, the ECM, after a short delay, runs the APU for one minute. This indicates that the ECM is in the Auto mode, and is capable of starting and stopping the APU automatically.
6.0 Operation, continued 6.2 Alpha Ignition Battery Charger Overview The Alpha Ignition Battery Charger (Alpha P/N 744-870-21)) keeps the ignition battery charged to start the Auxiliary Power Unit (APU) in the event of an extended power outage. The charger is active when the yellow LED on the face of the unit is lit. When the generator starts, the Alpha Ignition Battery Charger (IBC) shuts off and internal engine charger takes over ignition battery charging.
7.0 Maintenance The engine/alternator requires maintenance at regular intervals to remain reliable and ready to provide backup power when needed. Please refer to the following table for general maintenance guidelines. For specific recommendations regarding maintenance intervals, please refer to the supplied engine manufacturer’s operator’s manual.
7.0 Maintenance, continued 7.1 Servicing the APU Required Tools and Equipment: • Phillips screwdriver • 10mm socket wrench • 3/8" open-end wrench • Digital Voltmeter (DVM) capable of displaying true RMS • Battery operated frequency counter (or DVM with this function) Prior to Performing Maintenance Activities: 1. For routine engine maintenance procedures, refer to the Kohler Power Systems COM7.5 Operation Manual included with your generator. 2.
7.0 Maintenance, continued 7.2 Filter Cleaning, CE-3x2 5K-T The air intake filter (Alpha P/N 561-216-10) is located on the rear door of the enclosure. CAUTION! Failure to keep the filter clean, or using improperly installed filters, may cause system failure due to dirt buildup or lack of cooling air. Equipment failures caused by filter blockage, incorrect filter substitution, or dirt ingress due to clogged or improperly installed filters are not covered under warranty.
7.0 Maintenance, continued 7.3 Filter Cleaning, PN-6x-T 7.5kW The air intake filter (Alpha P/N 561-216-10) is located inside the air intake vent on the side of the enclosure. CAUTION! Failure to keep the filter clean, or using improperly installed filters, may cause system failure due to dirt buildup or lack of cooling air. Equipment failures caused by filter blockage, incorrect filter substitution, or dirt ingress due to clogged or improperly installed filters are not covered under warranty.
7.0 Maintenance, continued 7.4 Pad Shear Magnetic Switch Replacement Required Tools: #2 Phillips screwdriver 1. Unlock and remove rear enclosure door. 2. Locate the pad shear switch on the left side of the enclosure floor. 3. Remove the two screws holding the switch bracket to the floor. 4. Disconnect electrical connections, and remove the switch assembly (inset). 5. Unbolt the switch from the bracket, and replace with a new unit. 6. Reinstall in reverse order.
7.0 Maintenance, continued 7.5 Replacing Gas Hazard Sensor 1. Unlock and remove the front enclosure door. 2. Locate and remove the gas hazard sensor. The gas hazard sensor is located to the left of the ECM cage and above the hour meter. It is attached to the sheet metal with a hook and loop fastener. Disconnect the wire harness. 3. Verify the selector switch of the new sensor is in the proper position for your fuel source. 4. Reconnect wire harness. 5. Place new sensor on the hook and loop pad.
7.0 Maintenance, continued 7.6 Replacing Ignition Battery Charger Module Assembly Required Tools: #2 Phillips screwdriver The 48Vdc charger module is located above the ECM housing. 1. Disconnect the connectors from the front of the module. 2. Remove the Phillips screw holding the front of the charger to the ECM housing. 3. The back of the charger is held in place by a tab that fits into a slot on to the ECM housing. Slide the charger free and lift it out of the enclosure. Remove Screw Fig.
7.0 Maintenance, continued 7.7 Replacing Engine Control Module 1. Set RAS to STOP. 2. Turn OFF the 200A DC circuit breaker (PN-6x-T) or disconnect the output connector (CE-3x2). 3. Disconnect wire harnesses on ECM top to bottom. 4. Release the ECM captive latch and slide the ECM out of its housing. 5. Check new ECM DIP switch configuration per Table 4.4 (page 61). 6. Verify 120V/240V jumpers in the 120V position. 7. Install new ECM card. Verify card edges are in rails and latch card in place. 8.
7.0 Maintenance, continued 7.8 Fuel Conversion, Natural Gas to LP 7.8.1 PN-6x-T Pre-regulator Removal with Low Pressure Switch Installation WARNING! The following procedure must only be performed by qualified personnel. To prevent injury, disable generator and disconnect gas supply prior to beginning the gas conversion procedure. Required Tools: 7/8" open-end wrench In this procedure, the pre-regulator is removed, and a low pressure switch is installed in its place.
7.0 Maintenance, continued 7.8 Fuel Conversion, Natural Gas to LP, continued 7.8.2 Switching the LP Port to the NG Port, PN-6x-T WARNING! The following procedure must only be performed by qualified personnel. To prevent injury, disable generator and disconnect gas supply prior to beginning the gas conversion procedure. Required Tools: • 7/8" open-end wrench • NFPA-approved pipe sealant In this procedure, the gas inlet hose is switched from the LP port to the NG port.
7.0 Maintenance, continued 7.8 Fuel Conversion, Natural Gas to LP, continued 7.8.3 Switching the NG Port to the LP Port, CE-3X2 WARNING! The following procedure must only be performed by qualified personnel. To prevent injury, disable generator and disconnect gas supply prior to beginning the gas conversion procedure.
7.0 Maintenance, continued 7.9 Maxitrol Pre-regulator Calibration Required Tools and Materials: • Flat Tip Screwdriver • DWYER # 1212 water column (0-16") gas pressure test kit • Allen head wrench set • NFPA-approved pipe sealant (i.e. Megaloc Multipurpose Thread Sealant) • Leak detector compound (soapy water) The Maxitrol 325-3 regulator has a maximum inlet pressure of 10 PSI. Alpha Technologies recommends all installations range between 1-2 PSI for consistent of gas flow.
7.0 Maintenance, continued 7.9 Maxitrol Pre-regulator Calibration, continued Fig. 7-14, Pre-regulator Calibration Secondary Regulator Secondary Regulator Calibration Tap Calibration Tap Fig. 7-15, Secondary Demand Regulator 042-288-B0-001, Rev.
7.0 Maintenance, continued 7.9 Maxitrol Pre-regulator Calibration, continued WARNING! • No matches or open flame or sparks. Use caution whenever working in the area to prevent possible combustion of fuel vapors. • Leak Hazard: Use caution whenever working in the area to prevent and correct any leaks detected. Calibration Procedure: 1. Set the ECM Run/Auto/Stop (RAS) switch to the STOP position. 2. Remove the Allen-head screw located on the secondary or demand regulator. 3.
8.0 Interconnection 8.1 Gas Hazard Alarm Interface Connector The Gas Hazard Detector Interface Connector is connected between the wire harness and detector unit as shown. The interface control is a 3-pin (1x3 row) Universal Mini Mate-’N’-Lok style male connector.
8.0 Interconnection, continued 8.3 Gas Solenoid Interface Connector Pin Description Function 1 Gas Solenoid +12V +12Vdc supplied to gas solenoid only when APU is ON (running). APU Shuts OFF gas supply to cabinet during any fail safe or fault condition. 2 Gas Solenoid Common Return path for gas solenoid. Fig. 8-3, Gas Solenoid Interface Connector 8.
8.0 Interconnection, continued 8.5 ECM Enclosure Alarm Interface Connector The Alarm Interface Connector (J10) is connected to the Power PCBA. The interface control is a 14-pin (2x7 row) Universal Mini Mate-’N’-Lok style male connector.
8.0 Interconnection, continued 8.7 Charger Control Interface Connector The Battery Charger Control Interface Connector is connected between the charger module and ECM as shown. The interface control is a terminal block 2-position plug-in connector. Pin Description Function 1 Control Positive Connects pin 1 & 2 together, turning the Charger ON, i.e. Closed (LOW signal) 2 Control Negative Charger control common return Pin 1 Pin 2 Fig. 8-7, 48Vdc Charger Control Interface Connector 8.
8.0 Interconnection, continued 8.9 ECM APU Control Interface The interface control is a 12-pin (2x6 row) Mini Mate-’N’-Lok style connector. Pin Description Function 1 +12V Ignition Battery Ignition Battery Fused 12V from APU 2 Neg. Ignition Battery Ignition Battery Negative from APU 3 Low Oil Pressure Active LOW signal denotes low oil pressure. 4 Over-temp Active LOW signal indicates Over-temp. 5 Start Command Active LOW from ECM activates APU Start relay.
Power Alpha Technologies ® Alpha Technologies 3767 Alpha Way Bellingham, WA 98226 USA Tel: +1 360 647 2360 Fax: +1 360 671 4936 Web: www.alpha.com Alpha Technologies Ltd. 4084 McConnell Court Burnaby, BC, V5A 3N7 CANADA Tel: +1 604 430 1476 Fax: +1 604 430 8908 Alpha Technologies Europe Ltd.
