Alpha AlphaGen Curbside Owner's manual

Brand: Alpha

Model: AlphaGen Curbside

Category: Power generators

Type: Owner's manual

CE3G Enclosure

Fuel Quantity Alarm

Installation and Operation Manual

Effective: June, 2005

Alpha Technologies

Power

Alpha Technologies

3745-738-C0-001 Rev. A

Fuel Quantity Alarm Option

745-738-C0-001, Rev A

Effective Date: June, 2005

Alpha Technologies, Inc.

A member of The Alpha Group

Contacting Alpha Technologies: www.alpha.com

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

1-800-863-3930

For complete technical support, call

1-800-863-3364

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

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. If

there are questions regarding the safe operation of this product, please contact Alpha Technologies or your

nearest Alpha representative.

NOTE

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.

745-738-C0-001 Rev. A

Table of Contents

Safety Notes, Guidelines, and Precautions ........................................................................... 6

General Safety Precautions................................................................................................... 7

Battery Safety Notes.............................................................................................................. 8

Chemical Hazards ................................................................................................................. 8

Electrical Safety ..................................................................................................................... 9

Gas Safety ............................................................................................................................. 9

Battery Maintenance Guidelines.......................................................................................... 10

Recycling and Disposal ....................................................................................................... 10

Auxiliary Power Unit (APU) Notes ....................................................................................... 10

1.0 Introduction ................................................................................................................11

1.1 Pre-Installation ................................................................................................11

1.1.1 Parts, Tools, and Checklist ...................................................................11

1.2 Installation ...................................................................................................... 12

1.2.1 Installing Alarm Housing...................................................................... 12

1.2.2 Removing Low Fuel Pressure Switch Connector ................................ 13

1.2.3 Gas Box Modiﬁ cation .......................................................................... 14

1.2.4 Cable Connection and Routing ........................................................... 15

1.2.5 Sensor Module Installation .................................................................. 17

1.2.6 Reinstall Ignition Battery ..................................................................... 18

1.3 Alarm Operation ............................................................................................. 19

1.4 Return Unit to Service .................................................................................... 20

5745-738-C0-001 Rev. A

Figures and Tables

Fig. 1-1, Alarm Housing Fastener Location .......................................................12

Fig. 1-2, Alarm Housing Placement ...................................................................12

Fig. 1-3, Cable Connection and Routing............................................................12

Fig. 1-4 Low Fuel Pressure Switch (LFPS) Connector, Bulkhead Fitting .........13

Fig. 1-5 LFPS Connector Wiring .......................................................................13

Fig. 1-6 LFPS Assembly ...................................................................................14

Fig. 1-7 LFPS Wiring, Bulkhead Fitting.............................................................14

Fig. 1-8 Bottom View, Gas Utility Box ...............................................................14

Fig. 1-9 Sensors and Nut ..................................................................................15

Fig. 1-10 Water-tight Bulkhead Fitting ................................................................15

Fig. 1-11 Sensor Modules and Water-tight Bulkhead Fitting ..............................15

Fig. 1-12 Wiring Inside Gas Box .........................................................................16

Fig. 1-13 Reposition LFPS..................................................................................16

Fig. 1-14 Wire Arrangement, Generator Cabinet Side ........................................ 16

Fig. 1-15 Dust Cap Removal ..............................................................................17

Fig. 1-16 Sensor Module Installation ..................................................................17

Fig. 1-17 Completed Sensor Installation.............................................................17

Fig. 1-18 Completed Alarm Kit Installation..........................................................18

Fig. 1-19 Fuel Quantity Alarm Relay Wiring Harness .........................................19

Fig. 1-20 J2 Fuel Relay PCB Connections .........................................................20

745-738-C0-001 Rev. A

Safety Notes, Guidelines, and Precautions

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.

CAUTION!

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

equipment.

WARNING!

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

technician or user.

ATTENTION!

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

equipment and installation procedures.

NOTE

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

7745-738-C0-001 Rev. A

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 an unconnected battery cable can result in arcing, a ﬁ re, or possible explosion.

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

personnel 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 which is harmful to the skin and eyes. Emissions are electrolytic,

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

• Do not smoke or introduce sparks in the vicinity of a battery.

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

explosive. Proper venting of the enclosure is required.

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.

Enclosure, equipment or parts may be damaged or cause damage if used or installed improperly.

CAUTION!

745-738-C0-001 Rev. A

Battery Safety Notes

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 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.) whenever 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.

• 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 be performed only by authorized

personnel.

WARNING!

9745-738-C0-001 Rev. A

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 240 VAC. Ensure that utility power is disabled before beginning installation

or removal.

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

• 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.

• 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 that can result in arcing,

ﬁ re, or possible explosion.

Gas Safety

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

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

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

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

• Contact with liquid may cause skin and eye burns.

• 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.

745-738-C0-001 Rev. A

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 cable should be replaced immediately by Authorized Personnel

using replacement parts speciﬁ 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 speciﬁ 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

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.

Auxiliary Power Unit (APU) Notes

When the engine is stopping, a small amount of unburned fuel may be detected by the odor of gas fumes.

Fans are used to expel these fumes from the enclosure and 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% - 20% of the Lower Explosive Limit (LEL). The alarm must remain active for at least three

seconds before it will be recognized by the Engine Control Module (ECM).

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 ﬂ 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. Also, the reset button may be used to disable the alarm for 10 minutes at any time.

If gas fumes are detected before the engine is run, or in excess of approximately 10 minutes after running

the engine, you must check the system for leaks as described in the INSTALLATION manual and correct as

necessary.

11745-738-C0-001 Rev. A

1.0 Introduction

Alpha Technologies’ Remote Fuel Quantity Alarm system utilizes non-invasive Hall-effect sensing

modules to monitor fuel levels in Liquid Propane Gas (LPG) tanks equipped with “Remote Ready”

fuel gauge dials. The sensing modules transmit a ratiometric voltage output proportional to the liquid

volume in the cylinder. This voltage is detected and summed by the Fuel Alarm Quantity Relay circuit.

When necessary, the “Total Fuel Half Full” relay (Normally Closed or Normally Open “Form C” dry

contact) activates a Fuel Level alarm at the customer’s monitoring facility.

This document provides instructions for the following:

• Alarm Module Installation

• Gas Box Modiﬁ cation and Wiring

• Sensor Installation and Connection

1.1.1 Parts, Tools, and Checklist

Qty Description Part Number

1 Field Retroﬁ t Kit, Fuel Quantity Alarm,CE-3X2 Alpha P/N 745-738-20-003

1 UNIBIT # 4 or equivalent

1 Ruler or Tape Measure

1 File (round) or deburring tool

1 Adjustable crescent wrench 10"

1 Multimeter and leads

1 7/16" wrench

1 Gas pipe leak detector

1 AMP contact extraction tool AMP P/N 189727-1

1 AMP contact insertion tool AMP P/N 91002-1

Inside CE-G cabinet:

1. Turn Gas tanks OFF.

2. If tanks are NOT equipped with Remote-Ready dials, remove braided gas hoses from tank valves.

3. Remove tanks, set aside.

NOTE

DO NOT perform this procedure on a system providing backup power.

NOTE

Refer to the Battery Safety Notes page in the front of this document for information regarding safe

maintenance practices when working with battery equipment.

1.1 Pre-Installation

745-738-C0-001 Rev. A

1.2 Installation

1.2.1 Installing Alarm Housing

1. Disconnect and remove Ignition Battery.

2. Install the Fuel Quantity Alarm Relay PCB and mounting bracket by removing

fastener backing and pressing module into place on a clean surface on the the

side of the ECM housing.

Remove backing

Fig. 1-1, Alarm Housing Fastener Strips

Attach to side of ECM housing

Connect P1 here

Fig. 1-2, Alarm Housing Placement

Fig. 1-3, Cable Routing

3. Connect P1 of wire harness (Alpha P/N 875-419-20-XXX) to J1 of the Fuel

Quantity Alarm Relay PCB as shown below

4. Route cable along front of battery tray and secure with cable tie.

13745-738-C0-001 Rev. A

1.2 Installation, continued

1.2.2 Removing Low Fuel Pressure Switch Connector

1. Use AMP contact extraction tool (P/N189727-1) and remove the Low Fuel

Pressure Switch (LFPS) connector. Retain connector for reassembly

2. Remove bulkhead ﬁ tting.

LFPS connector

Bulkhead ﬁ tting

Pin 1

Black Wire

Pin 2

White Wire

Fig. 1-4, LFPS Connector, Bulkhead Fitting

Fig. 1-5, LFPS Connector Wiring

745-738-C0-001 Rev. A

1.2 Installation, continued

1.2.3 Gas Box Modiﬁ cation

1. To make room for drilling, loosen ﬂ are ﬁ tting and rotate LFPS to the right.

Pivot assembly

Loosen ﬁ tting

2. Pull the black and white LFPS wires through to the gas utility box enclosure. Take

care not to damage the connector contacts.

3. Loosen the existing bulkhead ﬁ tting and remove.

4. Use #4 UNIBIT to enlarge and deburr the LFPS wire hole to 7/8".

Fig. 1-6, LFPS Assembly

Fig. 1-7, LFPS Wiring, Bulkhead Fitting

Fig. 1-8, Outside Bottom View, Gas Utility Box

3/4"

3.00"

Existing opening

for braided hose

7/8" dia. opening

for Strain Relief

Connector

5. Drill and deburr 7/8" dia. opening in bottom of gas box as indicated in Fig. 1-8.

6. Clean metal shavings from gas box and install strain relief connector.

Enlarge to 7/8" dia.

15745-738-C0-001 Rev. A

1.2 Installation, continued

1.2.4 Cable Connection and Routing

1. Individually route sensors through ﬁ tting nut at this time.

Enclosure side Gas Box side

Fig. 1-10, Watertight Bulkhead Fitting

2. Install the NPT 1/2" water tight bulkhead ﬁ tting.

3. Individually route each sensor through the bulkhead ﬁ tting. Do not attach nut at

this time.

4. Pull 54" of cable through the ﬁ tting and route through the strain relief connector at

the bottom of the gas box.

Enclosure side

Gas box side

Fig. 1-11, Sensor Modules and Bulkhead Fitting

Fig. 1-9, Sensors and Nut

NOTE

The sensors will be attached to the "remote ready" dials upon completion of the modiﬁ cations to the gas box.

745-738-C0-001 Rev. A

1.2 Installation, continued

1.2.4 Cable connection and Routing, continued

5. Tighten strain relief for sensor module cables.

Pivot LFPS

assembly

Tighten ﬁ tting

7. Use AMP contact insertion tool (P/N 91002-1) to reattach LFPS connector.

Tighten the sealing nut on the watertight ﬁ tting at this time.

6. Route the LFPS wires through the bulkhead ﬁ tting and nut. Pivot LFPS assembly

to original position and retighten (ﬁ nger tight plus ¼-turn) the ﬂ are ﬁ tting.

Fig. 1-13, Reposition LFPS

Tighten strain relief

Fig. 1-12, Wiring Inside Gas Box

LFPS Wires

Fig. 1-14, Wire Arrangement, Generator Cabinet Side

Tighten nut

LFPS Connector

NOTE

Before returning the system to service, all gas ﬁ ttings must be leak tested and leak tight.

17745-738-C0-001 Rev. A

Install the LP1 and LP2 Module (part of the

wire harness) onto the respective cylinders

using the following instructions:

1. Remove the dust cap by sliding it from

the dial, and clean the cavity under dust

cap

2. Slide module into slot on dial from edge

of dial. Do not attempt to install module

vertically.

3. Apply thumb pressure in area provided

and push module toward center of

dial until it snaps in place. Repeat

procedure for second tank. Connect

other end of wire harness to J1 of Fuel

Relay PCB.

To remove the module, apply slight upward

pressure on the wire side of the module,

apply thumb pressure and slide module to

the outer edge of the dial.

1.2 Installation, continued

1.2.5 Sensor Module Installation

Fig. 1-15, Dust Cap Removal

Fig. 1-16, Sensor Module Installation

Fig. 1-17, Completed Sensor Installation

NOTE

Debris in the cavity prevents the module from properly

seating and accurately sensing the fuel level.

745-738-C0-001 Rev. A

1.2 Installation, continued

1.2.6 Reinstall Ignition Battery

1. Place Ignition Battery on battery tray.

2. Connect “Ignition Battery Positive” and “Ignition Battery Negative” leads from the

Alarm Relay wiring harness with the respective positive and negative Ignition

Battery cables. At this time, the Green LED (lower LED) on the Alarm Relay

housing will blink. This indicates the Alarm Relay is receiving power.

Fig. 1-18, Completed Alarm Kit Installation

19745-738-C0-001 Rev. A

After completion of the installation instructions the Fuel Quantity Alarm will be operational. Verify

green LED is on and blinking. This is the PCB “heartbeat” indicating the PCB is operating.

The RED LED is an alarm LED. The red LED will be lit when the Fuel quantity is less than ½ of total

fuel in any combination (i.e., if LP1 is full and LP2 is empty, or if both tanks are half empty).

1.3 Alarm Operation

Fig. 1-19, Fuel Quantity Alarm Wiring Harness

PIN 8 IGN BATT NEGATIVE

PIN 7 IGN BATT POSITIVE

PIN 6 LP2 SENSOR GROUND

PIN 5 LP2 SENSOR 5V SUPPLY

PIN 4 LP2 SENSOR OUTPUT

PIN 3 LP1 SENSOR GROUND

PIN 2 LP1 SENSOR 5V SUPPLY

PIN 1 LP1 SENSOR OUTPUT

LP2 SENSOR

LP1 SENSOR

CE3G COMPARTMENT

To J1,

Fuel Relay

PCB

The ﬁ gure below shows the wiring between J1 of the Fuel Quantity Alarm PCB, the ignition battery

and the fuel gauge dials on the LPG tanks in the CE-G compartment.

NOTE

If both modules are not installed on the cylinders there will be no alarm. If one MODULE is disconnected and

one is still connected there will be an alarm.

745-738-C0-001 Rev. A

Fig. 1-20, J2, Fuel Relay PCB Connector

1.3 Alarm Operation, continued

The ﬁ gure below shows the wiring of J2, of the Fuel Quantity Alarm PCB connector.

HALF TOTAL FUEL (NC)

BLANK

HALF TOTAL FUEL LEVEL (NO)

HALF TOTAL FUEL LEVEL RETURN

1.4 Return unit to Service

1. Restore gas pressure by opening both cylinders valves.

2. Use approved leak detection solution and test all gas ﬁ ttings for leaks.

3. Verify all tools removed from cabinets.

4. Replace cabinet doors.

5. Restart Generator in accordance with start-up procedures in appropriate generator

document.

6. Verify normal system operation at headend.

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Alpha AlphaGen Curbside Owner's manual

Brand: Alpha

Model: AlphaGen Curbside

Category: Power generators

Type: Owner's manual

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Alpha AlphaGen Curbside Owner's manual

Alpha AlphaGen Curbside Owner's manual

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