DCX3000 Portable Generator Operation Manual 3.
Power Alpha Technologies ®
AlphaGen DCX3000 3.0kW, 36/48V DC Portable Generator Operation Manual 041-028-B0-003, Rev. C Effective Date: September 2006 Copyright© 2006 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 .......................................................................................................................... 6 1.0 Introduction ................................................................................................................. 8 2.0 Specifications.............................................................................................................. 9 3.0 Battery Cable Connections .........................................................
List of Figures Fig. 1-1, DCX3000 Overview ................................................................................................. 8 Fig. 1-2, Basic Block Diagram ............................................................................................... 8 Fig. 3-1, Generator Access Door and Battery Pack Adapter Cable ..................................... 10 Fig. 3-2, Enclosure without Generator Access Door.............................................................11 Fig.
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 this product, 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 Information • The manufacturer cannot anticipate every circumstance that may involve a hazard, therefore, these warnings are not all inclusive. • Do not use the generator or any of its parts as a step. • Generator must be properly grounded. • Do not place or operate the generator in standing water, or expose to a forced spray of water. • Do not make or break any connections while generator is running.
1.0 Introduction The Alphagen DCX3000 portable DC generator supplies DC power to a power node battery bus during AC line interruptions. Upon loss of commercial AC power, the existing battery strings supply the power supply inverters. After some interval of battery discharge, the operator deploys the portable generator at the site to supply power to the DC bus. The generator delivers continuous, high-quality power throughout the commercial AC interruption period.
2.0 Specifications Engine Honda GX 200 6.5 hp, air-cooled, OHV, single cylinder, manual recoil starting, manual choke Fuel/Fuel Tank Unleaded gasoline/3.5 gallon metal tank with level gauge Rated Power 2800W continuous, 3000W maximum Alternator Permanent magnet, brushless, bearingless Output Voltage Dual range selector 36V: 39.5VDC, nominal at generator output connector 48V: 52.
3.0 Battery Cable Connections 3.1 Enclosures with Generator Access Door Tools and Materials Needed: • Portable Generator Battery Cable Kit • DC Multimeter Procedure: 1. Open the enclosure’s battery compartment and locate the battery pack connections for the positive and negative battery cables leading to the power supply. 2. Observing polarity (red to positive, black to negative), connect the Battery Pack Adapter Cable to the connections located in Step 1.
3.0 Battery Cable Connections, continued 3.2 Enclosures without Generator Access Door Tools and Materials Needed: • 2.5" Punch Tool Kit for Enclosures (Alpha P/N 745-131-20) • 2.5" Enclosure Upgrade Kit (Alpha P/N 745-131-21) • Electric drill • #7 Drill bit (.2010”) or #9 drill bit (.1960”) • #2 Phillips screwdriver WARNING! Disconnect all sources of service power to the enclosure before drilling holes. Ensure the area is clear of wires and electrical boxes.
3.0 Battery Cable Connections, continued 3 Extension Cable Set, 50’ P/N 875-324-21 30’ P/N 875-324-20 10’ P/N 875-324-22 Red 2 Fuse 1 Alligator Clamp-style Battery Pack Adapter Cable, P/N 874-946-20 Black Ensure clamps lay flat against batteries, facing inward Fig. 3-3, Alligator Clamp-style Connection 12 041-028-B0-003, Rev.
3.0 Battery Cable Connections, continued Extension Cable Set, 50’ P/N 875-324-21 30’ P/N 875-324-20 10’ P/N 875-324-22 3 Red 2 Fuse Ring Lug-style Battery Pack Adapter Cable, P/N 874-946-21 1 Black Cable rings connect directly to the battery terminals Fig. 3-4, Ring Lug-style Connection 041-028-B0-003, Rev.
3.0 Battery Cable Connections, continued Circuit Breaker must be CLOSED OUTPUTS GENERATOR BREAKER CONVENIENCE FROM XT1 UPS BYPAS S EXT GENERATOR LA-P Plus 60A HEATING PADS Novus Power Panel BLACK RED Novus-style Battery Pack Adapter Cable P/N 875-324-23 Extension Cable Set, 50’ P/N 875-324-21 30’ P/N 875-324-20 10’ P/N 875-324-22 Fig. 3-5, Novus-style Connection 14 041-028-B0-003, Rev.
3.0 Battery Cable Connections, continued Y-style Battery Pack Adapter Cable P/N 874-946-22 Extension Cable Set, 50’ P/N 875-324-21 30’ P/N 875-324-20 10’ P/N 875-324-22 3 2 Fuse 1 Fig. 3-6, Y-style Connection 041-028-B0-003, Rev.
3.0 Battery Cable Connections, continued 3.3 Grounding Tools and Materials Needed: #8AWG copper ground wire and clamps Procedure: 1. Read and thoroughly understand the Engine Owner’s Manual before operating this equipment. 2. Before starting the generator, follow all instructions outlined in the BEFORE OPERATION section of the Engine Owner’s Manual. 3. Attach #8AWG copper grounding wire between the generator grounding lug and the service entrance grounding bar, or directly to the utility grounding rod.
3.0 Battery Cable Connections, continued Ground Wire To prevent injury, the generator MUST share a common ground with the enclosure service entrance. Power Meter Ground Stake Ground Wire Fig. 3-8, Overview of PWE Installation 041-028-B0-003, Rev.
4.0 Starting the Engine Prior to starting the generator, review the Safety Information on page 6 of this manual. Set the generator on a flat, level surface, free of standing or running water, or combustible materials. Operating the generator at an angle of more than 15 degrees may result in the oil level dropping below a safe level. This may cause the low oil sensor to trip, or failure of the generator to shut down. This generator runs very quietly.
4.
5.0 Engine Shut-Down and Cable Removal WARNING! Engine block and muffler become extremely hot during normal operation. Procedure: 1. Press the OUTPUT SW to remove voltage from the battery pack. 2. Turn the ENGINE SW OFF. 3. Turn the FUEL VALVE OFF. 4 Disconnect the battery pack adaptor from the extension cable. 5. Remove the extension cable from the front panel of the generator. 6. Remove the battery pack adaptor from the battery pack. 7. Remove #8AWG copper ground wire. 5.
5.0 Engine Shut-Down and Cable Removal, continued 5.4 Fuse Replacement Tools and Materials Needed: • 10mm and 8mm socket • Ratchet handle • Torque wrench • Replacement fuse: Alpha P/N 460-273-10, Hinode Electric Co. P/N 350GH-80 Procedure: 1. Set the ENGINE SW to OFF. Disconnect the extension cable from the DC Out jack. 2. Remove the four 10mm nuts from the front plastic housing, and remove the housing. 3. Locate the fuse cover below the OUTPUT SW. 4.
6.0 Maintenance Record Use the following form to log maintenance and repair of your DCX3000. Maintenance Record (Refer to engine owners manual for service requirements and intervals) Model Number Date 22 Hour Meter Serial Number Action Initials 041-028-B0-003, Rev.
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