Alpha AlphaGen Curbside Technical Manual

Technical Manual

CE-3x2 5K-T 48Vdc Telecom Generator

PN-6x-T 7.5kW 48Vdc Telecom Generator

Effective: January 2015

Alpha Technologies

®

Power

Alpha Technologies

Contacting Alpha Technologies: www.alpha.com

or

For general product information and customer service (7 AM to 5 PM, Pacic Time), call

1-800-863-3930,

For complete technical support, call

1-800-863-3364

7 AM to 5 PM, Pacic Time or 24/7 emergency support

3

CE-3x2 5K-T 48Vdc Telecom Generator

PN-6x-T 7.5kW 48Vdc Telecom Generator

Technical Manual

042-288-B0-001, Rev. A3

Effective Date: January 2015

Alpha Technologies, Inc.

member of The Group

TM

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.

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. If

there are questions regarding the safe operation of this powering system, please contact Alpha Technologies

or your nearest Alpha representative.

NOTE:

4

042-288-B0-001, Rev. A3

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

1.3 Natural Gas System Block Diagram .............................................................. 16

1.4 Liquid Propane System Block Diagram ......................................................... 17

1.5 Specications ................................................................................................. 18

2.0 Site Preparation ........................................................................................................ 21

2.1 Site Considerations ........................................................................................ 21

2.2 Acoustics ........................................................................................................ 21

2.3 Enclosure Impact Protection .......................................................................... 23

2.4 Natural Gas Meter Congurations ................................................................. 25

2.5 Liquid Propane Systems ................................................................................ 27

2.6 Grounding Requirements, CE-3x2 5K-T ........................................................ 28

2.7 Grounding Requirements, PN-6xT 7.5kW ..................................................... 29

3.0 Installation................................................................................................................. 30

3.1 Installing the CE-3x2 5K-T or PN-6x-T 7.5kW Pad Template ........................ 30

3.2 Installation, CE-3x2 5K-T ............................................................................... 33

3.2.1 CE-3x2 5K-T Transportation and Lifting .............................................. 34

3.2.2 Enclosure Installation, CE-3x2 5K-T ................................................... 36

3.3 PN-6x-T 7.5kW Installation ........................................................................... 37

3.3.1 PN-6x-T 7.5kW Transportation and Lifting, ......................................... 38

3.3.2 Enclosure Installation Procedure, PN-6x-T 7.5kW .............................. 40

3.4 Enclosure Grounding, CE-3x2 5K-T .............................................................. 41

3.5 Enclosure Grounding, PN-6x-T 7.5kW ........................................................... 42

3.6 Natural Gas Utility Fuel Hookup, CE-3x2 5K-T .............................................. 43

3.7 Natural Gas Utility Fuel Hookup, PN-6x-T 7.5kW .......................................... 44

3.8 Liquid Propane Utility Fuel Hookup, CE-3x2 5K-T ......................................... 45

3.9 Liquid Propane Utility Fuel Hookup, PN-6x-T 7.5kW ..................................... 46

3.10 Making the DC Output Connection, CE-3x2 5K-T ......................................... 47

3.11 Making the DC Output Connection, PN-6x-T 7.5kW ...................................... 48

3.12 Connecting the Ignition Battery, CE-3x2 5K-T ............................................... 49

3.13 Connecting the Ignition Battery, PN-6x-T 7.5kW ........................................... 50

3.14 Terminal Block 2 (AC Line) Connections, CE-3x2 5K-T ................................. 51

3.15 Terminal Block 2 (AC Line) Connections, PN-6x-T 7.5kW ............................. 52

3.16 Final Inspection Checklist .............................................................................. 53

4.0 The Engine Control Module ..................................................................................... 54

4.1 Theory of Operation ....................................................................................... 56

4.1.1 Standby Operating Condition Less Than Three Minutes .................... 56

4.1.2 Standby Operating Condition More Than Three Minutes .................... 56

4.1.3 Normal APU Shutdown ....................................................................... 57

4.1.4 Abnormal APU Shutdown.................................................................... 57

4.2 ECM Operating Mode Summary .................................................................... 57

4.3 LED Indicators ............................................................................................... 58

042-288-B0-001, Rev. A3

5

4.4 Control Functions ........................................................................................... 59

4.5 Alarm Classications ...................................................................................... 60

4.6 ECM Alarm Overview ..................................................................................... 62

4.7 Connecting the Alarm and Control Connections ............................................ 63

4.8 ECM DIP Switch and Fuse Conguration ...................................................... 64

4.9 ECM Interface Block Diagram and Connectors ............................................. 66

4.10 ECM Self-test ................................................................................................. 67

4.11 Maintenance Functions ................................................................................. 68

5.0 Turn-up and Test ....................................................................................................... 69

5.1 Appearance and Condition of Components ................................................... 69

5.2 System Preparation ....................................................................................... 69

5.3 Performing a Local APU Test ......................................................................... 70

5.4 Generator System Sensor Verication ........................................................... 71

5.4.1 Enclosure Alarm Verication ............................................................... 71

5.4.2 AC and DC Line Sense Verication .................................................... 72

6.0 Operation .................................................................................................................. 73

6.1 Normal Operating Condition .......................................................................... 73

6.1.1 AC Line Fail ......................................................................................... 73

6.1.2 Low DC Bus Level............................................................................... 73

6.2 Alpha Ignition Battery Charger Overview ....................................................... 74

7.0 Maintenance ............................................................................................................. 75

7.1 Servicing the APU .......................................................................................... 76

7.2 Filter Cleaning, CE-3x2 5K-T ......................................................................... 77

7.3 Filter Cleaning, PN-6x-T 7.5kW ..................................................................... 78

7.4 Pad Shear Magnetic Switch Replacement..................................................... 79

7.5 Replacing Gas Hazard Sensor ...................................................................... 80

7.6 Replacing Ignition Battery Charger Module Assembly ................................... 81

7.7 Replacing Engine Control Module ................................................................ 82

7.8 Fuel Conversion, Natural Gas to LP .............................................................. 83

7.8.1 PN-6x-T Pre-regulator Removal with Low Pressure Switch Installation ...... 83

7.8.2 Switching the LP Port to the NG Port, PN-6x-T .................................. 84

7.8.3 Switching the NG Port to the LP Port, CE-3X2 ................................... 85

7.9 Maxitrol Pre-regulator Calibration .................................................................. 86

8.0 Interconnection ......................................................................................................... 89

8.1 Gas Hazard Alarm Interface Connector ......................................................... 89

8.2 Low Fuel Pressure Interface Connector ........................................................ 89

8.3 Gas Solenoid Interface Connector ................................................................ 92

8.4 Charger Module Control Interface Connector ............................................... 90

8.5 ECM Enclosure Alarm Interface Connector ................................................... 91

8.6 Inverter Battery DC Sense Interface Connector ............................................ 91

8.7 Charger Control Interface Connector ............................................................. 92

8.8 ECM AC Line Sense 120/240V Interface ....................................................... 92

8.9 ECM APU Control Interface ........................................................................... 93

8.10 ECM Alarm Interface ...................................................................................... 93

6

042-288-B0-001, Rev. A3

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. 1-5, Arrangement of Metered, Nominal Pressure (1-2psi) Natural Gas System........... 16

Fig. 1-6, Excess Flow Valve ............................................................................................... 16

Fig. 1-7, LP Propane Vapor Withdrawal Block Diagram ...................................................... 17

Fig. 2-1, Generator Sound Levels at 100% Load ................................................................ 21

Fig. 2-2, Acoustical Measurements in Relation to Placement Near Residences ................. 22

Fig. 2-3, Vehicular Area Impact Protection for Collocated Natural Gas Meter ................... 23

Fig. 2-4, Vehicular Area Impact Protection for Remote Natural Gas Meter ........................ 24

Fig. 2-5, Collocated Natural Gas Meter Setup for CE-3x2 Generator ................................. 25

Fig. 2-6, Collocated Natural Gas Meter Setup for PN-6x-T 7.5kW System ......................... 25

Fig. 2-7, Collocated CE-3x2 5K-T Generator with Remote Natural Gas Meter ................... 26

Fig. 2-8, Remote Natural Gas Meter Setup for PN-6x-T 7.5kW Generator ......................... 26

Fig. 2-9, Liquid Propane Setup, CE-3x2 5K-T ..................................................................... 27

Fig. 2-10, Liquid Propane Setup, PN-6x-T 7.5kW ............................................................... 27

Fig. 2-11, Enclosure Grounding, CE-3x2 5K-T .................................................................... 28

Fig. 2-12, Enclosure Grounding, PN-6x-T 7.5kW ................................................................ 29

Fig. 3-1, Pad Frame Template for CE-3x2 5K-T .................................................................. 30

Fig. 3-2, Pad frame and mounting template CE-3x2 5.0 kW .............................................. 31

Fig. 3-3, Cross-section of Sweep Trench ............................................................................ 32

Fig. 3-4, Pad Bolt Location, CE-3x2 5K-T ........................................................................... 34

Fig. 3-5, Lifting Ear Attachment ........................................................................................... 35

Fig. 3-6, Enclosure with Lifting Ears Installed, CE-3x2 5K-T ............................................... 36

Fig. 3-7, Water Intrusion Alarm (1), Pad Shear Sensor (2), and Pad Shear Magnet (3) ..... 36

Fig. 3-8, PN-6x-T 7.5kW Sweep Dimensions (in inches) .................................................... 37

Fig. 3-9, Pallet Bolt Locations, PN-6x-T 7.5kW ................................................................... 38

Fig. 3-10, Enclosure with Lifting Ears Installed, PN-6x-T 7.5kW ......................................... 39

Fig. 3-11, Installation Location of Pad Shear/Magnet Assembly ......................................... 40

Fig. 3-12, Enclosure Grounding, CE-3x2 5K-T .................................................................... 41

Fig. 3-13, Enclosure Grounding, PN-6x-T 7.5kW ............................................................... 42

Fig. 3-14, Utility Gas Service Input, CE-3x2 5K-T ............................................................... 43

Fig. 3-15, Utility Gas Service Input, PN-6x-T 7.5kW ........................................................... 44

Fig. 3-16, Propane Fuel Hookup, CE-3x2 5K-T ................................................................... 45

Fig. 3-17, Propane Fuel Hookup, PN-6x-T 7.5kW ............................................................... 46

Fig, 3-18, DC Output, CE-3x2 5K-T ..................................................................................... 47

Fig. 3-19, DC Output Safety Shroud.................................................................................... 48

Fig. 3-20, DC Output Connections, PN-6x-T 7.5kW ............................................................ 48

Fig. 3-21, Battery Cable Stackup..........................................................................................49

Fig. 3-22, Battery Cable Stackup (Flag Terminal).................................................................50

042-288-B0-001, Rev. A3

7

Fig. 3-23, Terminal Block 2 (TB2) Position 1, 5kW .............................................................. 51

Fig. 3-24, Terminal Block 2 (TB2), PN-6x-T7.5kW .............................................................. 52

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 .................................................................................................... 63

Fig. 4-5, SW5 and Fuse Locations ...................................................................................... 64

Fig. 4-6, SW5 Settings......................................................................................................... 65

Fig. 4-7, ECM/APU Interconnection ................................................................................... 66

Fig. 5-1, Generator Set Master Switch and Run/Auto/Stop (RAS) Switch .......................... 70

Fig. 6-1, Ignition Battery Charger LED ................................................................................ 74

Fig. 6-2, Wiring for ECM, Ignition Battery Charger, and Ignition Battery ............................. 74

Fig. 7-1, Captive Fastener Location, CE-3x2 5K-T .............................................................. 77

Fig. 7-2, Air Filter Removal, CE-3x2 5K-T ........................................................................... 77

Fig. 7-3, Filter Replacement, PN-6x-T 7.5kW ...................................................................... 78

Fig. 7-4, Pad Shear Sensor ................................................................................................. 79

Fig. 7-5, Gas Hazard Sensor Location (Alpha P/N 744-891-20) ......................................... 80

Fig. 7-6, Ignition Battery Charger ........................................................................................ 81

Fig. 7-7, ECM ...................................................................................................................... 82

Fig. 7-8, PN-6x-T Pre-regulator Removal ............................................................................ 83

Fig. 7-9, PN-6x-T Switch Assembly Installed ....................................................................... 83

Fig. 7-10, Load Block, PN-6x-T 7.5kW ................................................................................ 84

Fig. 7-11, Changing Load Block Conguration, PN-6x-T 7.5kW ......................................... 84

Fig. 7-12, Changing Load Block Conguration, CE-3x2 5K-T ............................................. 85

Fig. 7-13, Primary Fuel Regulator ....................................................................................... 86

Fig. 7-14, Pre-regulator Calibration ..................................................................................... 87

Fig. 7-15, Secondary Demand Regulator ............................................................................ 87

Fig. 7-16, Manometer Connection ....................................................................................... 88

Fig. 8-1, Gas Hazard Detector Interface Connector ............................................................ 89

Fig. 8-2, Low Fuel Pressure Interface Connector ................................................................ 89

Fig. 8-3, Gas Solenoid Interface Connector ........................................................................ 90

Fig. 8-4, Charger Control Interface Connector .................................................................... 90

Fig. 8-5, ECM Enclosure Alarm Interface Connector........................................................... 91

Fig. 8-6, Inverter Battery DC Sense Interface Connector .................................................... 91

Fig. 8-7, Charger Control Interface Connector .................................................................... 92

Fig. 8-8, ECM AC Line Sense, 120/240V Interface ............................................................. 92

Fig. 8-9, APU Control Interface............................................................................................ 93

Fig. 8-10, ECM Connector Arrangement ............................................................................. 93

8

042-288-B0-001, Rev. A3

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.

A NOTE provides additional information to help complete a specic task or procedure.

NOTE:

The use of ATTENTION indicates specic regulatory/code requirements that may affect the placement of

equipment and installation procedures.

ATTENTION:

The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or

equipment.

CAUTION!

A WARNING presents safety information to PREVENT INJURY OR DEATH to the

technician or user.

WARNING!

042-288-B0-001, Rev. A3

9

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.

• Use proper lifting techniques whenever handling enclosure, equipment, parts, or batteries.

• Batteries contain dangerous voltages, currents and corrosive material. Battery installation, maintenance,

service and replacement must be performed by authorized personnel only.

• Never use uninsulated tools or other conductive materials when installing, maintaining, servicing or

replacing batteries.

• Use special caution when connecting or adjusting battery cabling. An improperly connected battery cable,

or unconnected battery cable, can result in arcing, re, or possible explosion.

• A battery that shows signs of cracking, leaking or swelling must be replaced by authorized personnel

immediately using a battery of identical type and rating.

• Avoid any contact with gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery.

Emissions contain dilute sulfuric acid that is harmful to the skin and eyes. Emissions are electrolytic, and

are electrically conductive and are corrosive. Follow the Chemical Hazards notes if contact occurs.

• Do not smoke or introduce sparks in the vicinity of the batteries or natural gas/propane connections.

• Under certain overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas that is

explosive. Proper venting of the enclosure is required.

• Follow the battery manufacturer’s approved transportation and storage instructions.

To avoid damage:

• Prior to installation, verify that the AC input voltage to the enclosure and its equipment match with respect

to voltage and frequency.

• Prior to installation, verify that the output voltage from the enclosure or its equipment match the voltage

requirements of the connected equipment (load).

• Prior to installation, verify that the enclosure’s utility service panel is equipped with a properly rated circuit

breaker for use with the equipment inside. Refer to manufacturer’s recommendations.

• Review and upgrade utility service panel circuit breaker requirements whenever the equipment within the

enclosure is changed.

• Prior to installation, contact local utilities, local building maintenance departments, and cable/piping

locator services to ensure that installation does not interfere with existing utility or building cables/piping.

• Do not exceed the output rating of equipment. Verify load requirements prior and during connection

process.

• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may

have developed in your body.

10

042-288-B0-001, Rev. A3

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.

To avoid injury:

• Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel

knowledgeable of batteries and the required safety precautions.

• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove

all metallic objects from hands and neck.

• Batteries produce explosive gases. Keep all open ames and sparks away from batteries.

• Use tools with insulated handles. Do not rest any tools on top of batteries.

• Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects,

or other reproductive harm. Battery post terminals and related accessories contain lead and lead

compounds. Wash hands after handling (California Proposition 65).

• Wear protective clothing (insulated gloves, eye protection, etc.) when installing, maintaining, servicing, or

replacing batteries.

• If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your

company’s approved chemical exposure procedures.

• Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with

a solution of one pound Bicarbonate of soda to one gallon of water. Report chemical spill using your

company’s spill reporting structure and seek medical attention if necessary.

• Always replace batteries with those of an identical type and rating. Never install old or untested batteries.

• Do not charge batteries in a sealed container. Each individual battery should have at least 0.5 inches of

space between it and all surrounding surfaces to allow for convection cooling.

• All battery compartments must have adequate ventilation to prevent an accumulation of potentially

dangerous gas.

• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have

developed on your body.

• Never use uninsulated tools or other conductive materials when installing, maintaining, servicing, or

replacing batteries.

• Use special caution when connecting or adjusting battery cabling. An improperly connected battery cable

or an unconnected battery cable can make contact with an unintended surface and can result in arcing,

re, or possible explosion.

• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by Authorized

Personnel using a battery of identical type and rating.

Lead-acid batteries contain dangerous voltages, currents, and corrosive material. Battery

installation, maintenance, service, and replacement must only be performed by authorized

personnel.

Battery Safety Notes

WARNING!

042-288-B0-001, Rev. A3

11

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. Battery cables should be replaced immediately by authorized personnel

using replacement parts specied by vendor.

Loose battery connection hardware. Refer to battery manufacturer’s documentation for the correct

torque and connection hardware for the application.

• Apply battery manufacturer’s specied antioxidant compound on all exposed connections.

• Verify battery terminals and/or exposed connection hardware is not within 2 inches of a conductive

surface. Reposition batteries as necessary to maintain adequate clearance.

• Clean up any electrolyte (battery emission) in accordance with all federal, state, and local regulations or

codes.

• Proper venting of the enclosure is recommended. Follow the Battery Manufacturer’s approved

transportation and storage instructions.

• Always replace batteries with those of an identical type and rating. Never install old or untested batteries.

• Do not charge batteries in a sealed container. Each individual battery should have at least 0.5

inches of space between it and all surrounding surfaces to allow for convection cooling.

• All battery compartments must have adequate ventilation to prevent an accumulation of potentially

dangerous gas.

Recycling and Disposal Instructions

Spent or damaged batteries are considered environmentally unsafe. Always recycle used batteries or dispose

of the batteries in accordance with all federal, state and local regulations.

Electrical Safety

• Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical

connection or conductor is not energized. Check the circuit with a volt meter with respect to the grounded

portion of the enclosure (both AC and DC) prior to any installation or removal procedure.

• Always use the buddy system when working under hazardous conditions.

• A licensed electrician is required to install permanently wired equipment.

• Input voltages can range up to 240Vac. Ensure that utility power is disabled before beginning installation

or removal.

• Ensure no liquids or wet clothes contact internal components.

• Hazardous electrically live parts inside this unit are energized from batteries even when the AC input

power is disconnected.

Gas Safety

• Do not smoke or use any source of ame around gas lines. Propane and natural gas are extremely

ammable, and explosive at high concentrations. Large releases can create a ammable vapor cloud.

• In high concentrations gas is an asphyxiant that displaces oxygen from the breathing atmosphere.

• Contact with liquid may cause skin and eye burns.

12

042-288-B0-001, Rev. A3

Auxiliary Power Unit (APU) Notes

• 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. It may be possible to detect this gas additive odor even

though the gas hazard sensor does not issue an alarm. The gas sensor will issue an alarm when the

detected levels of gas reaches 10% to 20% of the Lower Explosive Limit (LEL). The gas hazard sensor

has a 10 minute delay for periods of purging and power up. During the purge phase, the Green alarm light

will ash. When the purge phase is completed, the light will glow steadily. In the event the detector has

been disconnected from power for more than 24 hours, it may require a period of more than 10 minutes

to complete its purge phase. In that event, push the reset button to disable the alarm for repeated purge

cycles. The reset button may be used to disable the alarm for 10 minutes at any time.

• If gas fumes are detected before running the engine, or more than 10 minutes after running the engine,

check the system for leaks and correct as necessary.

042-288-B0-001, Rev. A3

13

Fig. 1-1, PN-6x-T 7.5kW Telecom Generator

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 bafing, 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.

Features:

• Cost effective extended runtime solution for outdoor powering applications

• Quiet operation, small size, and low prole provides for easier installation in populated areas

• Eliminates large quantities of batteries otherwise required for extended runtime

• Telecom-grade 48Vdc output

• Built-in safeguards to protect the system, operator, and public

• Safe unattended operation designed to UL2200, NFPA 37, 54, 58 & 70 standards

Fig. 1-2, CE-3x2 5K-T Telecom Generator

14

042-288-B0-001, Rev. A3

Fig. 1-3, PN-6x-T System Diagram

1.0 System Overview, continued

1.1 PN-6x-T System Diagram

SS

HR

SM

SR

STARTER RELAY

STM

71

IGNITION MODULE

70

N

M4

IGN

P7-2

70

HR

M3

N

P7-3

-

SR

P

SS

P

+

STP

N

STT

OVC

N

P

LOP

RUN

OVT

OVS

37

AC1

AC2

DCP

DCN

P7-4

P7-1

M1

M2

HIGH OIL

TEMP SW

13

LO P

RECT

120VAC

BLACK

RED

ECM

TB 1

NC

12V

GROUND

GAS HAZARD

PAD SHEAR

LOW FUEL PRESS.

TB2-8

ORAN GE

YELLOW

TB2-7

WHITE

2

BLACK

RED

GREEN

ORANGE

1

1 23

AC SENSE

200 AMP CB

TB2-1

TB2-2

L

TB

2

N

6

345

2

1

7

DOOR SW

7

6

8

1

NC (W20)

12

11

9

810

15

2

4

3

0

14

13

20

19

17

18

MAJOR ALARM NC

212223

IGNITION

BATTERY

QCON1

HOT

WHITE

WATER INTRUSION

YEL

RED

WHT

POS

NEG

BLACK

RED

16

AC FAIL RELAY

120VAC (RELAY 1)

COM (W18)

ENGINE

COMPARTMENT

CONTROL PCB

NC

TB2-20

BCA

A

C

D

B

E

+

-

1A

NC

NO

COM

L2

L1

AC FAIL RELAY

240VAC (RELAY 3)

ALARM

BYPASS

RELAY

(RELAY 2)

OUTPUT CB

AUXILIARY SW

(W33) ECM TB1-6

(W30)

(W29)

(W24)

(W25)

(W27)

(W26)

(W28)

(W17)

(W15)

(W13)

(W11)

(W12)

(W10)

(W9)

(W4)

(W1)

(W7)

(W6)

(W3)

(W5)

(W2)

Current view shows 240VAC input utility sense configuration.

*(W9) is moved from RELAY 3 COM to RELAY 1 COM for 120VAC input utility sense configuration.

BATTERY

CHARGER

J1

1

2

J2

1 2 3 4

BATTERY

CHARGING

REGULATOR

J4

2

6

1

9

5

3

7

10

4

8

11

12

1

3

J10

1

2

3

4

5

6

7

8

9

10

11

12

13

14

J9

1

2

J9

4

3

2

1

GAS HAZARD POWER

DOOR OPEN

1

2

3

4

5

6

7

8

9

10

11

12

MAJOR ALARM COM

MAJOR ALARM NO

MINOR ALARM NC COM

ALM BYPASS COM

ALM BYPASS NO

ALM BYPASS NC

ENGINE RUN COM

ENGINE RUN NO

ENGINE RUN NC

MINOR ALARM NO

MINOR ALARM NC

MINOR ALARM NO COM

DOOR NO

DOOR COM

LPG ( - )

LPG (12V)

AC/FAIL NC

AC/FAIL NO

AC/FAIL COM

AC G

AC L2

AC L1

AC N

(W32) ECM TB1-5

(W31) ECM TB1-4

(W23) ECM TB1-9

DOOR SW

(W21) ECM TB1-8

NO (W22)

(W19) ECM TB1-7

(W16) ECM J10-14

(W14) ECM J10-13

NC

NO

COM

LOW OIL

PRESS. SW

WATER

INTRUSION

PAD SHEAR

LOW FUEL

PRESS. SW

LPG MODEL

ONLY

GAS

HAZARD

POWER

CARBURETOR

HEATER

BLOCK HEATER

P3-5 BATTERY+

P1-1 GROUND

P1-2 GROUND

P1-3 BATTERY+

P1-4 OVER CRANK

P1-6 START

P1-7 LOW OIL PRESS.

P1-9 STOP

P1-10 ENGINE RUNNING

P1-11 OVER TEMP.

P1-12 OVER SPEED

GROUND P2-2

FUEL P2-10

CRANK P2-1

IGNITION P2-13

P3-4

P3-3

P3-1

P3-2

SPEED SENSING

DC OUTPUT

SENSING

P2-17

P2-18

INHIBIT FOR 30

SECONDS AFTER

START, THEN 5

SECOND SHUTDOWN

GAUGES P2-6

BAT ( - ) P2-3

P2-12

P2-16

P2-20

P2-19

THROTTLE

CONTROL

3 LEAD

STATOR

*

BLACK

TB2-13

TB2-11

1

2

042-288-B0-001, Rev. A3

15

1.0 System Overview, continued

1.2 CE3x2 5kW System Diagram

Fig. 1-4, CE3x2 System Diagram

6

345

2

1

7

12

11

9

810

15

14

13

20

19

17

18

MAJOR ALARM NC

212223

16

1A

MAJOR ALARM COM

MAJOR ALARM NO

MINOR ALARM NC COM

ALM BYPASS COM

ALM BYPASS NO

ALM BYPASS NC

ENGINE RUN COM

ENGINE RUN NO

ENGINE RUN NC

MINOR ALARM NO

MINOR ALARM NC

MINOR ALARM NO COM

DOOR NO

DOOR COM

LPG ( - )

LPG (12V)

AC/FAIL NC

AC/FAIL NO

AC/FAIL COM

AC G

AC L2

AC L1

AC N

DOOR SW

1

7

4

2

8

6

0

ALARM

BYPASS

RELAY

(RELAY 2)

3

(W32) ECM TB1-6

(W31) ECM TB1-5

(W30) ECM TB1-4

(W22) ECM TB1-9

(W29)

(W23) ECM TB1-2

(W19)

(W28)

(W27)

(W26)

(W25)

(W24)

NC

COM

OUTPUT CB OPTION

AUXILIARY SW

(W21) ECM TB1-8

NO

(W20) ECM TB1-7

(W17)

(W16)

(W18) ECM P5-6

(W15) ECM TB1-1

(W14) ECM P5-5

NC

NO

COM

L

N

AC FAIL RELAY

120VAC (RELAY 1)

NC

NO

COM

L2

L1

AC FAIL RELAY

240VAC (RELAY 3)

(W3)

(W2)

BL K

P5

2

1

P8

BLAC K

CR

SM

RED

N

P4-2

P4-5

RED

CR

IGNITION

P4-6

P4-1

HR

70

P7-3

TRIGGER

COIL

IGNC

WHT

BL

K

ST M

P7-4

P7-1

P7-2

M2

M4

M3

B

LK

RED

YEL

P

N

ST P

LOP

P

N

RUN

OVC

ST T

OVT

OVS

P2-4

P2-3

SPEED SENSING

AC2

AC1

DCP

DCN

P2-2

P2-1

DC OUTPUT

SENSIN G

P3-12

13

P3-1 7

P3-1 8

P3-2 0

P3-16

CONTROL

THROTTLE

IGNITION

BATTERY

+

37

2

1

ALARM

BYPASS

RELAY

POS#1

TB2-7

TB2-2 0

TB2-13

TB2-11

BLACK

RED

J9

11

5

12

9

8

TB2 PWR (+12 VDC )

J5

1

2

3

4

5

6

7

8

9

10

11

12

TB 1

(TELCOM)

APU COMPARTMENT

GROUND

P4 - 9

P4-8

P4- 10

P4 - 7

1

2

150 AMP

Fuse

(GREY

)

1

RECTIFIER

DC SENS E

J8

J6

AC SENSE

3

RED

BLACK

CHARGER

BATTERY

4

3

J2

2

1

ORANGE

TB2-8

WATER

INTRUSION

YELLOW

123

+

ORANGE

BLACK

GREEN

LOW FUEL

PRESSURE

FUEL

SOLENOID

B

C

MODULE

874-869-20

CONTROL

PCB

N

70

N

-

71

70

STATOR

3 LEAD

N C

J4

2

3

6

1

4

10

7

SMH

(GREY)

1

2

PAD SHEAR

ECM

HET

LOP

GAS

HAZARD

DETECT

HIGH ENGINE TEMP

LOW OIL PRESSURE

M1

(CATV )

P3-19

WHT

APU

ENCLOSURE FAN

1

J1

2

123

TB2-7

123

CUSTOMER OUPUT

CABLE CONNECTION

NOT USED

CHARGER CONTROL

BATTERY HEATER MAT (OPTIONAL)

5

6

BLOCK HEATER

1

2

SMH 175

(GREY)

P3-5 BATTERY+

P1-1 GROUND

P1-2 GROUND

P1-3 BATTERY+

P1-4 OVER CRANK

P1-6 START

P1-7 LOW OIL PRESS.

P1-9 STOP

P1-10 ENGINE RUNNING

P1-11 OVER TEMP.

P1-12 OVER SPEED

FUEL P3-9

CONTROL P3-4

GROUND P3-2

CRANK P3-1

RUN P3-6

NC

12V

GROUND

GAS HAZARD

PAD SHEAR

LOW FUEL PRESS.

WATER INTRUSION

J10

1

2

3

4

5

6

7

8

9

10

11

12

13

14

GAS HAZARD POWER

DOOR OPEN

(W13)

(W11)

(W12)

(W10)

(W9)

(W7)

(W6)

(W4)

(W5)

(W1)

**

*

Current view shoes 240VAC input utility sense configuration.

*(W2) is moved from TB2-1A to TB2-2 for 120VAC ECM Sense configuration.

**(W9) is moved from RELAY 3 COM to RELAY 1 COM for 120VAC input

utility sense configuration.

16

042-288-B0-001, Rev. A3

Federal DOT Regulation 49 CFR Part 192.383, Excess Flow Valve Customer Notication, requires gas

utilities to either voluntarily install Excess Flow Valves (EFVs) on all new home service lines or to notify

builders about EFVs’ benets and availability. EFVs are installed on gas service lines during pre-construction

site work, and automatically activate when a gas line is ruptured. Excess ow valves should never be used as

in-line regulators. They cannot perform this function and may damage equipment.

Fig. 1-6, Excess Flow Valve

(above ground ¾" x 4" NPT nipple)

Alpha P/N 042-146-10

1.0 System Overview, continued

1.3 Natural Gas System Block Diagram

For added safety, a low pressure and high pressure excess ow valve may be installed.

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.

Fig. 1-5, Arrangement of Metered, Nominal Pressure (1-2psi) Natural Gas System

NOTE:

ATTENTION:

CAUTION!

S

CONTROL

CONTROLS

ENGINE

Demand

Low-pressure

Regulator

14" WC

(max.)

WC = Water Column H

2

O

Pre-Regulator

Maxitrol 325-3

10 psi max input

Flare Coupling

(Quick-Disconnect)

NOTE: 1 psi = 28" WC

0.5 psi (min.)

1 psi (nominal)

10 psi (max)

Engine must have

7" to 11" WC and 156 cubic

feet/Hr. to operate

Solenoid

APU

Enclosure

Meter

Manual

Shutoff

Low pressure excess

flow valve (optional)

High pressure

excess flow valve

(optional)

042-288-B0-001, Rev. A3

17

Fig. 1-7, LP Propane Vapor Withdrawal Block Diagram

1.0 System Overview, continued

1.4 Liquid Propane System Block Diagram

DEMAND

REGULATOR

LOW PRESSURE

SOLENOID

8oz

ENGINE

LP PROPANE - VAPOR WITHDRAWAL

LOW FUEL

PRESSURE

S

CONTROL

CONTROLS

11"WC

PROPANE

POST-REG

OUTLET

SENSOR

ENCLOSURE

APU

BLOCK DIAGRAM

SWITCH

PROPANE

ENCLOSURE

11"WC

MAX

LOW FUEL ALM

LPG TANK

18

042-288-B0-001, Rev. A3

1.0 System Overview, continued

1.5 Specications

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.

Noise

Voiceband: <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

10.5hp (using natural gas fuel)

624cc, air-cooled, twin OHV

13.1hp (using natural gas fuel)

RPM (Variable Speed): 2800 to 3600RPM 2100 to 3450RPM

Acoustic Noise

dBA 10' @ 100% rated load: 68.5 avg. 70.3 avg.

dBA 20' @ 100% rated load: 62.5 avg. 64.3 avg.

dBA 10' @ 70% rated load: 66.9 avg. 66.4 avg.

dBA 20' @ 70% rated load: 60.9 avg. 60.4 avg.

System Size: CE-3x PN-6x

Height (in/cm): 44/111.8 36/99.1

Width (in/cm): 26/66 39.25/99.7

Depth (in/cm): 24/61 24/61

Weight (lb/kg): 395/179.2 338/153.3

Fuel Consumption

Natural Gas: 1000BTU/ft

3

80ft

3

/hr 156ft

3

/hr

Propane Gas: 2520 BTU/ft

3

1.1gal/hr 1.48gal/hr

40ft

3

/hr 54ft

3

/hr

4.62lb/hr 6.24lb/hr

Gas Inlet Pressure: 0.5 to 2 PSI Inlet pressure

(Please contact Alpha Technologies for low pressure)

0.5 to 2 PSI Inlet pressure

(Please contact Alpha Technologies for low pressure)

Ignition Charger Voltage: 13.5Vdc 13.5Vdc

Ignition Charger Current: 6A max. 6A max

Remote Interface Length: 50ft. max

Distance depends upon proper installation, de-rating,

and wire gauge. Please contact Alpha Technologies for

remote interface length usage.

25ft. max

Distance depends upon proper installation, de-rating, and

wire gauge. Please contact Alpha Technologies for remote

interface length usage.

Agency Compliance: UL2200, NFPA 37/54/58 and 70, CSA 22.2, FCC Class A UL2200, NFPA 37/54/58 and 70, CSA 22.2, FCC Class A

Common to All Models

Fuel System, Controls & Monitoring: The controls and fuel system meet applicable sections of NFPA 37, 54, and 58 for automatic unattended operation of

remotely located generators. Full system control and status monitoring included

Sensors: Gas hazard, pad shear, water intrusion & tamper

Safety shutdowns: Low oil pressure

Water intrusion

Pad shear

Gas hazard (propane or Natural Gas)

Over speed

Over crank

Over temp

Low fuel pressure shutdown (Propane only

)

Optional Features

Optional Integrated Propane

Storage: (5kW APU only)

For locations where gas is not available, Alpha offers the CE-G propane enclosure for use with the 5kW APU system.

Contact local propane supplier for proper tank sizing. Fully CSA & NFPA compliant, and designed for curbside

applications.

042-288-B0-001, Rev. A3

19

1.0 System Overview, continued

1.5 Specications,continued

48Vdc Generator Set Specication

Manufacturer: Kohler

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 rectier)

52 ± 0.5Vdc @ no load

Rated Amps: 144 @ 52Vdc

Stator Resistance:

(ohms)

0.024

Stator Type: 3-phase, 3-lead,

ungrounded

Excitation Method: Permanent magnet,

brushless

Coupling Type: Direct-to-Engine

Insulation (stator): Class 180,

epoxy varnish,

vacuum-impregnated

Winding Material: Copper

* Derate approximately 4% per 1000 ft (300m)

over 500 ft (153m) above sea level. Derate 1%

for each 10ºF (5.5ºC) increase in temperature

above 77ºF (25ºC).

Engine Specications, PN-6x-T 7.5kW

Manufacturer: Kohler

Make/model: CH20

Cycle: 4

Compression Ratio: 8:5:1

Displacement, cu. in. (cc): 38 (624)

Rated Horsepower:

(using natural gas fuel)

13.1

Engine Speed (rpm): 2100-3450

Bore, in. (mm): 3.08 (77)

Stroke, in. (mm): 2.64 (67)

Valve Train: Overhead valve

Valve Material:

Intake

Exhaust

Steel

Stellite

®

face

Number of Cylinders: 2

Cylinder Block Material: Aluminum with cast iron liners

Cylinder Head Material: Aluminum

Cylinder Head Tightening Torque,

ft. lb (Nm):

30 (41)

Piston Rings: 2 compression, 1 oil

Crankshaft Material: Heat treated, ductile iron casting

Bearings:

Number

Type

2

Replaceable sleeve

Governor: Electronic

Starter Motor: Electric, 12Vdc, solenoid shift

Lubrication System: Full pressure

Oil Capacity:

(with lter and cooler), qt. (L) 2 (1.9 )

Oil Filter Tightening Torque 1/2 turn

Oil Pressure, psi (kPa): 25-35 (172-241)

Low Oil Pressure, psi (kPa): 3.5±1.5 (24.1±13.8)

Fuel Type: Natural gas or propane

Fuel Pressure, kPA (in. water): 7-11 (1.7-2.7)

Battery Voltage: 12Vdc

Battery Ground: Negative

Battery Recommendation (min.): 585 CCA @ 0ºF ( -18ºC)

Spark Plug Type:

(Kohler P/N 24 132 02-S)

(Champion RC12YC)

Spark Plug Gap, in. (mm): 0.030 (0.75)

Spark Plug Tightening Torque, ft.

lb (Nm):

18-22 (24.4-29.8)

Ignition System: Capacitive discharge

Cooling System: Air cooled

High Engine Temperature, ºF (ºC): 305 (152)

Exhaust System: USFS approved spark arrestor

20

042-288-B0-001, Rev. A3

Engine Specications, CE-3x2 5K-T

Manufacturer: Kohler

Make/model: CV14

Cycle: 4

Compression Ratio: 8:5:1

Displacement, cu. in. (cc): 24.3 (398)

Rated Horsepower:

(using natural gas fuel)

10.5

Engine Speed (rpm): 2800-3600

Bore, in. (mm): 3.43 (87)

Stroke, in. (mm): 2.64 (67)

Valve Train: Overhead valve

Valve Material:

Intake

Exhaust

Steel

Stellite

®

face

Number of Cylinders: 1

Cylinder Block Material: Aluminum with cast iron liners

Cylinder Head Material: Aluminum

Piston Rings: number/type: 2 compression, 1 oil

Crankshaft Material: Heat treated, ductile iron casting

Bearings:

Number

Type

2

Replaceable sleeve

Governor: Electronic

Starter Motor: Electric, solenoid shift

Lubrication System: Full pressure

Oil Capacity:

(with lter and cooler), qt. (L) 2.1 (2.0)

Oil Type: summer/winter: Synthetic 5W-30

Oil Pressure, psi (kPa): 25-35 (172-241)

Low Oil Pressure, psi (kPa): 2-5 (13.8-34.5)

Fuel Type: Natural gas or propane

Fuel Pressure, kPA (in. water): 7-11 (1.7-2.7)

Battery Voltage: 12Vdc

Battery Ground: Negative

Battery Recommendation (min.): 425 CCA @ 0ºF ( -18ºC)

Spark Plug Type: Kohler P/N 24 132 03

Spark Plug Gap, in. (mm): 0.75 (0.030)

Spark Plug Tightening Torque, ft.

lb (Nm):

18-22 (24.4-29.8)

Ignition System: Battery/Coil

Cooling System: Integrated air cooled

High Engine Temperature, ºF (ºC): 305 (152)

1.0 System Overview, continued

1.5 Specications,continued

48Vdc Generator Set Specication

Manufacturer: Kohler

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 rectier)

52 ± 0.5Vdc @ no load

Rated Amps: 96 @ 52Vdc

Stator Resistance:

(ohms):

0.024

Stator Type: 3-phase, 3-lead,

ungrounded

Excitation Method: Permanent magnet,

brushless

Coupling Type: Direct-to-Engine

Insulation (stator): Class 155,

epoxy varnish,

vacuum-impregnated

Winding Material: Copper

* Derate approximately 4% per 1000 ft (300m)

over 500 ft (153m) above sea level. Derate 1%

for each 10ºF (5.5ºC) increase in temperature

above 77ºF (25ºC).

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Alpha AlphaGen Curbside Technical Manual

Alpha AlphaGen Curbside Technical Manual

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