DC Generator
APS-500-DCH-28
DCGS Operation Guide
DCGS Generator Operation Guide
Summary
The APS-500-DCH-28 is an on board 28V DC generator system (DCGS) designed
to provide 14 kW of DC power in a lightweight high-power diesel engine package.
The DCGS houses the engine, generator pack and radiator with remote panel
interface. The system is monitored and controlled by the remote panel.
The DCGS is composed of
Diesel Engine
32.5 hp, 1.5 liter normally aspirated (no turbo) diesel engine derated to run at a low
speed of 2200 rpm for low vibration and wear. It is also capable of providing full
required power for 14kW DC at 12,000 feet altitude with an up idle to 3000 rpm.
The engine produces no visible smoke and is EPA rated tier 3. This engine is
manufactured in the USA and has 4,000 distribution outlets worldwide for spares
commonality and ease of repair.
Generator
Self contained 14kW at 27.6 VDC generator, mounted to engine bellhousing. The
generator pack uses 72 pole stators and high speed/frequency rotor which
eliminates ripple current and voltage. The unit self regulates and can handle up
to 120% continuous overload with no degradation in voltage.
Remote Control and Monitoring Panel
Multi-pin connector cable provides transmission of highly reliable engine
transducer data to remote panel. Remote panel has keyed start and preheat
indicator for easy starting. Remote Monitor includes tachometer and also has
indicator lights for low oil pressure, high water temp and air filter clog. Any
lighted alarm will cause engine stop.
Specifications:
GENERATOR SPECIFICATIONS
Power: 14 kW @ 28VDC
Voltage: 27.6 VDC, Floating Positive, Chassis Ground
Frequency: NA
Current: 500 Amps
Current Distortion: less than 1000 milli-amp ripple current typical
Voltage Distortion: negligible
Induction type: 3-72 pole stationary stators, redundant
Load Regulation: +/- 1.0% No Load to Full Load.
Efficiency: 85% typical.
Output Connection: 2 - 5/16” stud post in barriered compartment.
Over-Current Capability: 120% Overload continuous .
Overload Protection: 200 amp fuse.
Thermal Protection: Internal temperature sensor prevents heat damage.
ENGINE SPECIFICATIONS
Cylinders: 3 inline
Displacement: 1.5 liter
Aspiration: Normal, non-turbo
Fuel: Fuel injection
Cooling: Closed circulation with shock proof radiator
Coolant Capacity: 6 liters
Lubricant Capacity: 6 liters
Starter/Alt Electrical: 12 volt
Rating to 5,000 ft: 27.0HP (20kW) at 2000 rpm.
Rating at 8,000 - 12,000 ft: 23.4HP (17.4kW) at 3000 rpm via switch
Torque: 128Nm @ 1800 rpm for rapid load response
Operating speed: 2200 rpm up to 8,000 ft, 3000 rpm 8,001 -12,000 ft.
Filters: Spin on oil and fuel filters
EPA Rating: Tier 3
Operating Temperature: -20° C to 55° C
Storage Temperature: -20° C to 70° C
Humidity: 0-100% RH non-condensing.
SYSTEM SPECIFICATIONS
Weight 410 lbs.
Dimensions 34.90 x 18.99 x 31.15 LWH
Remote Panel 8.00 x 2.00 x 8.00 LWH
Air cleaner Donaldson with spin prefilter
Sound level: 91 dB @ 1 meter with Super Trap
Service interval: 500 hour oil and filters change
Smoke: full load - invisible to naked eye
Operation:
The unit is a self contained, self regulating system requiring no setup or
adjustments. DCGS does not have an integral fuel tank so fuel must be provided
from an outside source such as the vehicle fuel system with a fuel pump.
When DC load is applied to the DCGS, it will self regulate and adjust current
output and engine rpm automatically. There is no need to monitor engine rpm or
maintain throttle position. The DCGS is designed to run with loads connected.
Operating the DCGS without loads is not recommended. An interlock is provided
to prevent operation of the DCGS unless 28VDC is present on the DC buss. See
“to start DCGS” below.
The DCGS is activated by a key interlock on the remote panel.
There are four indictor lights for status on the Remote Panel and a tachometer.
To start the DCGS
1) Insure load is connected to DCGS output panel on rear of DCGS. Insure cover
is installed with four screws. Do not operate DCGS without load connected.
Unit will auto sense if 28VDC present.
2) Insert key into key slot on remote panel. Turn key clockwise to “on” click
position. Preheat indicator lamp will light. Wait a few moments. After
Preheat lamp goes out turn key clockwise, springloaded, to “start” and hold
key in start position until engine starts. Release key. Key is spring loaded
and will return to on position when released.
3) Check tachometer and verify that unit is operating at 2200 rpm.
4) If operating above 9,000 feet altitude be sure up idle is engaged on main engine
package. Up idle is on engine, not remote panel. Up idle is a pull
handle/throttle cable, black in color.
5) Check oil pressure lamp, ensure it is not on.
6) Check water temp lamp, ensure it is not on.
7) Check air filter lamp, ensure it is not on.
8) Any indicator lamps that are on will cause DCGS to cease operating. See
troubleshooting guide for reference.
9) Repair any condition that may be causing indicator lights to be on.
10) System is now operating.
11) Fuses will blow if overload condition exists. Replace fuses and check loads
for shorts or excessive power draw.
12) To turn DCGS off turn key, on remote panel, counter clockwise.
13) DCGS will power down. DC voltage will still be present in the Remote Panel
module but DCGS will be off.
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