TM Cable Series ® 5.
031-132-B0-001 Rev.
TM 5.0kW Auxiliary Power Unit Overview: The purpose of the AlphaGen 5.0kW Auxiliary Power Unit Operation and Maintenance Manual is to detail system operation and maintenance procedures. Audience: This manual is intended for the system operators. About this Manual: Contents: This Operation and Maintenance Manual is comprised of four sections. Section 1 System Overview. This section describes the AlphaGen 5.0kW Auxiliary Power Unit (APU). Section 2 Turn-Up and Test.
Preface TM 5.0kW Auxiliary Power Unit Table of Contents Section 1, System Overview 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 System Enclosure Overview .................................................................. 13 Specifications ........................................................................... 15 APU Overview ........................................................................... 16 Engine Control Module Overview ............................................................
Preface TM 5.0kW Auxiliary Power Unit Table of Contents Section 3, Maintenence, continued 3.8 Replacing Engine Control Module ........................................................... 47 3.9 Replacing Flexible Gas Hose .................................................................. 48 3.10 Fuel Conversion - Natural Gas to Liquid Propane ...................................... 49 3.10.1 Pre-regulator/Low Fuel Pressure Switch Replacement ..................... 49 3.10.2 Dual-Fuel Load Block Conversion ..
Preface TM 5.0kW Auxiliary Power Unit List of Figures Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. 1-1 1-3 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3-6 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-17 4-18 4-19 4-21 4-20 4-22 4-23 4-24 System enclosure ..........................................
Preface IMPORTANT SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL CAUTION HAZARDOUS CONDITION To reduce the risk of electrical shock, injury or death caused by explosion of fuel or moving parts, and to ensure the safe operation of this unit, the following symbols have been placed throughout the manual. Where these symbols appear, servicing should be performed only by qualified personnel. DANGEROUS VOLTAGE This symbol indicates a dangerous voltage exists in this area of the product.
Preface SAFETY PRECAUTIONS NOTE: Failure to follow these precautions could result in injury or death caused by the explosion of fuel, moving parts hazards or electrocution. CAUTION: This set of procedures will require the operation of the generator and should only be performed by qualified, experienced personnel in a well-ventilated area. Technicians must have easy access to a fire extinguisher at all times. Propane/Natural Gases are highly explosive.
Preface SAFETY PRECAUTIONS The system must be serviced only by qualified personnel. Remove all rings, watches and other jewelry before servicing batteries or servicing the system. Verify the voltage requirements of the equipment to be protected (load), the AC input voltage to the power supply (line), and the output voltage of the system prior to installation. The utility service panel must be equipped with a properly rated circuit breaker for use with this power supply.
Preface IMPORTANT INSTALLATION NOTES The system must be installed ONLY by qualified service personnel. Consult local utility codes for additional cabinet grounding and utility requirements. ALPHA TECHNOLOGIES is not responsible for broken welds or other damage to the cabinet caused by improper installation. All dimensions are given in inches. For further information regarding this installation, contact ALPHA TECHNOLOGIES or your nearest ALPHA representative.
Preface Auxiliary Power Unit (APU) Notes NOTE: 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.
Preface Battery Safety Notes Chemical Hazards Any gelled or liquid emissions from a Valve-Regulated Lead-Acid (VRLA) battery is electrolyte which contains dilute sulfuric acid which is harmful to the skin and eyes; is electrically conductive; and is corrosive. If electrolyte contacts the skin, wash immediately and thoroughly with water. If electrolyte enters the eyes, wash thoroughly for 10 minutes with clean water or a special neutralizing eye wash solution and seek immediate medical attention.
1. System Overview 1.1 System Enclosure Overview This manual is intended to provide a general functional overview for the Auxiliary Power Unit (APU) used with the CEX2 Series Enclosures and also covers Basic APU Operation and Maintenance. For more detailed information pertaining to the installed APU, please consult the Generator Manufacturers Operators Manual. The APU is housed in a sound-attenuated, enclosed compartment which contains inlet and exhaust vents.
1. System Overview 1.1 System Enclosure Overview, continued System components shown below allow for easy access during operation and maintenance. The 12 Volt ignition battery for the APU is housed in an electronics compartment above the APU. All operations of the APU are controlled automatically by the Engine Control Module (ECM); operator intervention is not required to start or stop the APU.
1. System Overview 1.2 Specifications Nominal system specifications for 5kW Auxiliary Power Unit: DC Output voltage (VDC @ full load) Output current Engine (air cooled) RPM System size: CE3X2 (CE9X2) Acoustic 36V/48V 39/52 39V, 128A max.52V, 96A max. 400cc, 14Hp Rated Single OHV 3900 RPM max. (variable speed) Height 44” (52”) Width 26” Depth 24” Weight CE3X2, 383lbs. (CE9X2, 413lbs.) 69.7dBa @ 10 feet, (8 point average @85% load) 36V/48V APU Fuel Consumption Propane - 2520 BTU/ft3 1.00gal/hr.
1. System Overview 1.3 APU Overview Alphas Auxiliary Power Unit (APU) provides a second source of power from which the power supply systems can draw, in the event that the utility power supplied to the system is lost or unacceptable (i.e., low or high voltage, noisy, unstable, etc.). It consists of a gas driven (natural or propane vapor) engine/ alternator (DC).
1. System Overview 1.4 Engine Control Module Overview The primary purpose of Alphas Engine Control Module (ECM) is to control and monitor the CE-3X2 Series AlphaGen Auxiliary Power Unit (APU) The ECM is used in conjunction with a Generator Remote Interface (GRI) PCBA, often referred to as the Power Board. The ECM/Power Board Assembly is mounted to the top of the Engine-Generator housing, to the left of the ignition battery. The Power Board is attached to the ECM via three ribbon cables.
1. System Overview 1.4 Engine Control Module Overview, continued Engine Control Module Ignition Battery Shelf Engine Generator Fig. 1-6 Location of Engine Control Module within the Engine-Generator Cabinet. Serial RS-485 Comm. port Enclosure Alarm Interface STOP E C M Alarm LEDs START SYS Run/Auto/Stop (RAS) switch APU Interface Alarm/Service pushbutton DC Sense Battery Charger Control Interface Parallel transponder interface Utility Line Sense Fig.
1. System Overview 1.5 Generator Modes of Operation 1.5.1 Normal Operating Condition Under normal operating conditions (no alarms) the ECM's Run-Auto-Stop (RAS) three-position rocker switch will be in the "center" or AUTO position . The ECM has complete control over the APU while in the AUTO mode. Also, each time the RAS switch is moved from the STOP position, to the center or AUTO position, the ECM will run the APU for one minute after a short delay.
1. System Overview 1.5 Generator Modes of Operation, continued &UDQN &\FOH &UDQN VHF VHF VHF VHF VHF VHF VHF VHF VHF VHF VHF VHF VHF VHF VHF VHF VHF 2YHUFUDQN $WWHPSW &UDQNLQJ (QJLQH 3DXVH QR FUDQN (QJLQH $ODUP Table 1-1 Normal Mode Crank Cycle 1.5.4.
1. System Overview 1.5 Generator Modes of Operation, continued 1.5.6.ECM Operating Mode Summary The ECM monitors the status of the AC line and DC bus to make a determination when to start and stop the generator. The ECM also monitors APU status while the engine is running and will immediately shut down the unit if certain alarm conditions are detected. The ECM reports status information via a parallel data interface and/or an Alpha-Bus serial data (RS-485) interface.
1. System Overview 1.6 Operators Interface Overview Refer to Figure 1-8 on the following page: The three positions of the rocker switch are RUN - AUTO - STOP (RAS). The RAS switch is normally left in the center, AUTO, position so that the ECM has control of the generator set. A minor alarm is indicated when the RAS switch is not in the AUTO position. The STOP ("down") position is used to stop or prevent APU operation during maintenance.
1. System Overview 1.6 Operators Interface Overview, continued The service reset push-button is also used to obtain information about active alarms. The Major and Minor alarm LEDs are very general and a technician will need more detailed information upon arrival to the site of an alarming ECM. To retrieve details about an active alarm, the user presses and releases the service-reset switch. An active alarm (Major or Minor) will be indicated by the LEDs as indicated in Table 1-2.
1. System Overview 1.7 ECM Alarm Overview Alarms are indicated in three ways: ECM LEDs, RS-485 communications and alarm contact closures on ECM transponder interface. Alarm indication on the ECM LEDs is obtained by pressing the service reset button momentarily and noting the combination of illuminated LEDs. 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.
1. System Overview 1.8 Ignition Battery Charger Overview The Ignition Battery Charger keeps the Ignition Battery sufficiently charged to start the Auxiliary Power Unit (APU) in the event of an extended power outage. The ECM monitors Ignition Battery Voltage via the generator control board. The ECM regulates the amount of charging and switches the battery charger OFF to prevent overcharging the ignition battery.
1. System Overview 1.9 Propane Enclosure Overview The CE-X series engine generator enclosures have the capability of either vapor fuel configurations, Natural or Propane vapor withdrawal. As shown below, several safety features were added to ensure the cabinets comply with applicable sections of NFPA 54 (National Fuel Gas Code), NFPA 58 (Storage and Use of Propane), and NFPA 37 (Engine generators) regarding proper spacing between intake vents to combustible openings and venting devices on propane systems.
1. System Overview 1.9 Propane Enclosure Overview, continued &( ; (QFORVXUH 5HDU )URQW ,QWDNH IURP 5HDU ([KDXVW &RROLQJ DLU WRZDUGV IURQW 5HDU 'RRU 9HQWV 7DE 'RRU 7DE 'RRU Fig.1-11 Airflow patterns, CE-X Enclosure &( * (QFORVXUH 5HDU )URQW 5HDU 'RRU %ORFNHG )URQW 'RRU 9HQWV 7DE 'RRU 7DE 'RRU Fig. 1-12 Airflow patterns, CE-G Enclosure ©2000 TM 27 031-132-B0-001 Rev.
1. System Overview 2.1 Appearance and condition of components Prior to applying the power, note the condition of the outside of the unit. Open each door of the enclosure. Observe and note the condition of the following: For each (front and rear) door assembly: 1. Doors and locking mechanisms. 2. Seals. 3. Door Intrusion switches. 2.2 Initial Operation The following procedure involves starting and stopping the engine using the Engine Control Module (ECM).
2. Turn-Up and Test 2.2 Initial Operation, continued 2.2.2 Engine Lubrication Check Engine lubrication Level Procedure: Check the engine crankcase oil level. If necessary, add oil to fill it to the FULL mark. DO NOT OVERFILL. Refer to the engine manufacturers operators manual for proper fill capacities and oil types. Ensure that the same brand of oil is used for topping the oil level, as some oil manufacturers additives are not compatible with each other.
2. Turn-Up and Test 2.2 Initial Operation, continued 2.2.3 Starting a Local APU Test, continued 2. Place generator set master switch to the middle (ECM) position. CAUTION: The Generator Control Board master switch will override the Run/Auto/Stop (RAS) switch on the ECM. This switch is normally left in the center, or "ECM" position. (On older 5kW generators, the center position may be marked 'Auto' or be blank.) STOP E C M STOP START E C M START Fig. 2-3 Location of ECM Run/Auto/Stop switch Fig.
2. Turn-Up and Test 2.2 Initial Operation, continued 2.2.3 Starting a Local APU Test, continued 11. 12. 13. 14. 15. 16. ©2000 Adjust pre-regulator, or dual regulator (located on gas bottle assembly for Propane) if necessary by removing regulator cap and adjusting for 11 ±1 of water column pressure. Set RAS to STOP. Remove brass manometer fitting and re-install plug to demand regulator input monitoring port using approved pipe sealant. Check demand regulator input monitoring port for leaks.
2. Turn-Up and Test 2.3 Generator System Sensor Verification The ECM has a built-in self-test feature. Each time the ECMs Run-Auto-Stop switch is placed in the Auto Position, a one-minute self-test is performed and any failures will be 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 3 seconds and then back to the Auto position. 2.3.1 Enclosure Alarm Verification 1.
2. Turn-Up and Test 2.3 Generator System Sensor Verification, continued 2.3.2 AC and DC line Sense Verification The ECM monitors 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 will verify these functions. 1. Verify the ECM is in the Auto position, the APU is not running, and there are no major or minor alarms reported other than Tamper.
3. Maintenance 3.1 Cleaning and Lubrication The Auxiliary Power Unit, being a gas-driven, air-cooled, combustion engine, requires periodic maintenance. Maintenance items may include: changing the engine oil at recommended intervals; cleaning and/or replacing the engine air filter; checking the intake and exhaust vents and fans for proper operation; and cleaning and/or replacing the enclosure filters. NOTE: A corrosion-inhibiting coating (such as LPS3 by LPS Corp.
3. Maintenance 3.2 Scheduled Maintenance 3.2.1 Maintenance Intervals 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 manufacturers operators manual.
3. Maintenance 3.2 Scheduled Maintenance, continued 3.2.2 ECM Service Required Notification The ECM monitors time between periodic maintenance of the enginegenerator. The Service Interval internal ECM variable represents the number of hours of engine-run-time between periodic services. When the engine runs for a number of hours equal to Service Interval, the ECM sets the Service Required Alarm and turns on the amber notification LED.
3. Maintenance 3.2 Scheduled Maintenance, continued 3.2.3 ECM Self-Test Features Generator testing can be initiated in four ways: 1. The ECM can be programmed to periodically run an automatic test (Default OFF). Refer to Section 3.2.3 for additional information. 2. A Self-Test can be commanded via status communications. 3. Momentary activation of the Engine Run command will cause the ECM to effectively run a test.
3. Maintenance 3.2 Scheduled Maintenance, continued 3.2.3 ECM Self-Test Features, continued If AC line should fail during a test, the test will terminate normally but the engine will continue to run until line returns. If the test fails because the DC Bus alarm activates, the test will terminate, the self-test fail alarm will activate but the generator will continue to run until the DC Bus alarm clears.
3. Maintenance 3.2 Scheduled Maintenance, continued 3.2.3 ECM Self-Test Features, continued Auto-Test Duration The length of each Auto-test is measured in minutes. The default test duration is 10 minutes. The test duration may be set between 10 and 120 minutes. Manually enabling the Autotest feature Switch SW5-8 is used to enable the autotest feature with a 14-day test interval.
3. Maintenance 3.3 Servicing the APU Some tools and equipment may be required such as: Phillips screwdriver 10 mm socket wrench 3/8 inch open socket wrench DVM capable of displaying true RMS AC voltage and frequency (i.e., Fluke 87) Battery operated frequency counter (needed only if a frequency reading DVM is not available).
3. Maintenance 3.4 Filter Cleaning The air intake filter is located on the rear door. WARNING: Failure to keep the filters clean or using improperly installed filters, may cause internal system failures due to lack of cooling air or dirt buildup. Equipment failures caused from filter blockage or dirt ingress due to clogged or improperly installed filters is not covered under warranty. Filter Removal, Replacement, and Cleaning 1. 2. 3. 4. 5. 6. Unlock and remove the rear door.
3. Maintenance 3.5 PAD SHEAR Magnetic Switch and Water Intrusion Float Allow 15 minutes for completion of procedure Tools required: 3/8-1/4-5/16 wrenches Wire cutters Phillips screwdriver Removal and replacement procedure: 1. 2. Remove the APU housing access panel. Locate and remove the switch and float mounting bracket as shown below. The pad shear switch and water intrusion float bracket is located on the outside of the APU housing.
3. Maintenance 3.5 PAD SHEAR Magnetic Switch and Water Intrusion Float, contd. Removal and replacement procedure (continued): Cut wires to tamper switch sensor. Use Phillips screwdriver to remove old switch. Remove the mounting nuts which hold the water intrusion float to the bracket. Replace float and verify the magnet can slide freely up the mounting post, and that it rests against the retaining clip at the bottom of the mounting post. Replace magnetic tamper switch with Phillips screwdriver.
3. Maintenance 3.6 Replacing GAS HAZARD Sensor Allow 5 minutes for completion of procedure Tools required: Hook and loop fastener Removal and replacement procedure: 1. Locate and remove the gas hazard sensor as shown below. The gas hazard is located on the outside of the APU housing, above the pad shear/water intrusion sensor mounting bracket. It is attached to the APU housing by means of a hook and loop fastener. Pull the sensor free. 031-132-B0-001 Rev.
3. Maintenance 3.6 Replacing GAS HAZARD Sensor, continued Removal and replacement procedure, continued: Disconnect the sensor from the wire harness and replace with the new sensor. Add the opposite piece of the hook and loop fastener, and reinstall the sensor. NOTE: Verify the replacement gas sensor is calibrated to detect the appropriate gas (i.e., Propane or Natural Gas). End of Procedure ©2000 TM 45 031-132-B0-001 Rev.
3. Maintenance 3.7 Replacing Ignition Battery Charger Module Assembly Allow 15 minutes for completion of procedure Tools required: #2 Phillips screwdriver Removal and replacement procedure: 1. Locate and remove the charger module as shown below. The charger module is located on the outside of the APU housing, above the generator run/stop switch mounting bracket. Disconnect the connectors from the front of the module.
3. Maintenance 3.8 Replacing Engine Control Module Allow 5 minutes for completion of procedure Tools required: None Removal and replacement procedure: 1. 2. Verify APU is OFF. Locate and remove the ECM as shown below. STOP E C M STOP E C M START START Remove connectors ECM in place with connectors attached STOP E C M START Release ECM captive latch and slide PCBA from housing. Perform steps in reverse order to replace ECM. ©2000 TM 47 031-132-B0-001 Rev.
3. Maintenance 3.9 Replacing Flexible Gas Hose CAUTION: It is important to install the hose properly to prevent gas leakage which could lead to explosion. This procedure must only be perfomed by a certified or qualified technician. Allow 5 minutes for completion of procedure Tools required: 15/16 open-end wrench Removal and replacement procedure: 1. 2. 3. 4. 5. Verify fuel supply shut off. Loosen upper (1) and lower (2) hose fittings. Remove flexible fuel hose.
3. Maintenance 3.10 Fuel Conversion - Natural Gas to Liquid Propane 3.10.1 Pre-regulator/Low Fuel Pressure Switch Replacement Allow 10 minutes for completion of procedure. Tools required: 7/8 open-end wrench Amp Contact Extraction tool, Part No. 455822-2 Repair and/or replacement procedure: 1. Verify fuel supply is shut off. 2. Unplug connector, Use pin extraction tool to remove pins from connector. Pull wires through fitting. 3. With 7/8 wrench, loosen pre-regulator fitting. Remove pre-regulator. 4.
3. Maintenance 3.10 Fuel Conversion - Natural Gas to LP, continued 3.10.2 Dual-Fuel Load Block Conversion Allow 15 minutes for completion of procedure Tools required: 7/8 open-end wrench NFPA-approved pipe sealant - Megaloc Multipurpose thread sealant (stock #15-808) - or equivalent Repair and/or replacement procedure: In this procedure, the gas inlet hose will be switched from the Natural Gas (NG) port to the Liquid Propane (LP) port to facilitate the switching from one fuel type to another.
3. Maintenance 3.10 Fuel Conversion - Natural Gas to LP, continued 3.10.2 Dual-Fuel Load Block Conversion, continued Repair and/or replacement procedure, continued: Coat the fitting with thread sealant. Use only NFPA-approved pipe sealant , i.e., Megaloc Multipurpose thread sealant (stock #15-808) - or equivalent. Install the fitting in the new fuel port. Install the sealing plug into the nowopen port.
3. Maintenance 3.11 Fan Replacement Procedure Allow 5 minutes (per fan) for completion of procedure. Tools required: Slotted screwdriver Repair and/or replacement procedure: NOTE: Perform this procedure after verifying the presence of correct fan supply voltage (12VDC). Once the voltage has been verified, remove power from the fan circuit(s) and perform the replacement procedure as outlined below. 1. Open the rear door of the enclosure 2. Disconnect fan wire harness. 3.
3. Maintenance 3.12 Muffler Replacement Procedure Allow 15 minutes for completion of procedure. Tools required: #2 Phillips screwdriver or hand drill 1/2 deep-well socket wrench 6 extension 3/8 drive Removal and replacement procedure: NOTE: Allow the unit to cool thoroughly before beginning procedure. 1. Remove fastening hardware on muffler access panel. 2. Use the 1/2 deep-well socket to remove the upper flange U-bolt assembly. 3. Use the 5/16 wrench to remove the Cable-5 Flexi-mounts.
3. Maintenance 3.12 Muffler Replacement Procedure, continued 4. Install the new muffler in the housing. 5. Fasten the muffler in place with the Flexi-mount hardware. Tighten until clamp and muffler are securely in place. %2/7 :$6+(5 6. Detail of Flexi-mount. Add anti-seize compound (i.e., Permatex® Antiseize p/n 80209) to bolt threads. 08))/(5 02817,1* )/$1*( :$6+(5 )/(;, 02817 7. Muffler in place - ready to receive upper exhaust pipe; install exhaust pipe and muffler access panel.
3. Maintenance 3.13 Muffler Exhaust Flange Gasket Replacement Procedure CAUTION: Gasket must be installed properly, or loud improper exhaust operation may exist. NOTE: Allow the unit to cool thoroughly before beginning procedure. Allow 15 minutes for completion of procedure. Tools required: #2 Phillips screwdriver or hand drill 1/2 deep-well socket wrench 6 extension 3/8 drive Removal and replacement procedure: 1. Remove rear door of enclosure; locate and remove generator access panel. 2.
3. Maintenance 3.14 Gas Solenoid Replacement Procedure Allow 45 minutes for completion of procedure. Assistance will be required to perform this procedure. Tools required: Special Gas Package tool, Alpha p/n 086-134-10, (must be purchased separately) 3/4 wrench Crescent wrench Pipe thread compound Removal and replacement procedure: 1. 2. 3. 4. Shut off or disconnect gas service. Remove Natural Gas pre-regulator or low fuel pressure switch from gas utility box. Use 15/16 wrench to disconnect flex hose.
3. Maintenance 3.15 Replacing Cabinet Exhaust Duct Upper Seal NOTE: The enclosure must be removed to gain access to the exhaust duct upper seal. Contact Alpha Technologies Technical Support at 1-800-863-3364 for information regarding this procedure. Allow 15 minutes for completion of procedure Tools required: Rubbing Alcohol or similar non-acid-based cleaner Scissors Removal and replacement procedure: 1.
3. Maintenance 3.16 Removal and Replacement of Generator Set Allow 45 minutes for completion of procedure Tools required: #2 Phillips screwdriver Crescent wrench 1/4 drive 3/8 drive 7/16 socket Removal and replacement procedure: 2. Disconnect all APU connectors and remove APU housing door. 1. Switch ECM to STOP 4. Remove APU slide locking bolt. 3. Verify Gas OFF and use Crescent wrench to remove upper end of flexible fuel hose. 031-132-B0-001 Rev.
3. Maintenance 3.16 Removal and Replacement of Generator Set, continued Removal and replacement procedure (continued): 5. Use wrenches to loosen muffler flange bolts (2 places). 6. Pull hose away from interior of APU housing. 8. Use 3/8 drive, with 6 extension and 7/16 socket to remove APU mounting bolts (4 places). 7. Slide APU from housing to its fully extended position, watching for pinch hazards on hoses or electrical wiring. ©2000 TM 59 031-132-B0-001 Rev.
3. Maintenance 3.16 Removal and Replacement of Generator Set, continued Removal and replacement procedure (continued): To replace the APU, reverse the steps above, except for special instructions as follows: To reconnect gas hose, do not use any sealing compounds or gas pipe dope because flare fittings are designed with compression seals that eliminate the need for these sealants.
3. Maintenance 3.17 Maxitrol Pre-Regulator Calibration Required tools: Screwdriver, DWYER # 1212 water column (0-16") gas pressure test kit Allen head ratchet wrench, approved pipe dope, approved leak detector compound. The Maxitrol regulator has a maximum inlet pressure of 5 PSI. Alpha Technologies recommends all installations range between 0.5-2 PSI for consistency of gas flow.
3. Maintenance 3.17 Maxitrol Pre-Regulator Calibration, continued SECONDARY OR DEMAND REGULATOR Fig. 3-5 Regulator Calibration Component Arrangement "Secondary" or "Demand" Regulator Calibration Tap Fig. 3-6 Secondary Regulator Component Location 031-132-B0-001 Rev.
3. Maintenance 3.17 Maxitrol Pre-Regulator Calibration, continued NO MATCHES OR OPEN FLAMES: Use caution whenever working in the area to prevent possible combustion fuel vapors. LEAK HAZARD: Use caution whenever working in the area to prevent and correct any leaks detected. Calibration Procedure: 1. On the ECM, perform the following: Set the ECM Run/Auto/Stop (RAS) switch to the STOP position. Remove the Allen-head screw located on the "Secondary" or "Demand" Regulator.
3. Maintenance 3.17 Maxitrol Pre-Regulator Calibration, continued Calibration Procedure, continued 7. Verify the DWYER # 1212 manometer reads 5-1/2" above the 0 mark, and 5-1/2" below the 0 mark. This equals 11" water column of pressure. Adjust the Maxitrol regulator in a clockwise direction to increase pressure, and in a counterclockwise direction to decrease pressure. CAUTION: DO NOT BOTTOM OUT THE REGULATOR ADJUST SCREW. RETEST THE INLET PRESSURE TO THE MAXITROL GAS PACKAGE. 8. 9. 10. 11.
4. Interconnection 4.1 Alarm Sensor States The signals from the sensors to the ECM should follow the state table as shown. The signals sent to the status monitoring system are described in the ECM Operators and Maintenance Manual (Alpha p/n 744-862-C0).
4. Interconnection 4.2 ECM Interface Topology and Connectors The ECM PWR- GRI PCBA provides the interface between cabinet sensors, APU control, and power conditioning to the ECM. The interface also supplies all the necessary signals, alarms, logic power, and analog voltages required for telemetry to the cable head end, central office, or network manager, and allows the Alpha Systems control module to start and stop the Engine alternator as part of network controlled periodic tests and exercises.
4. Interconnection 4.3 Connectors 4.3.1 Gas Hazard Alarm Interface 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. See Fig. 4-1 for location.
4. Interconnection 4.3 Connectors, continued 4.3.2 Low Fuel Pressure Interface Connector The interface control is a 2 pin Mini Mate N Lok connector (Near gas solenoid). See Fig. 4-1 for location. Pin 1 = +12VDC activates (opens) solenoid ONLY when APU is running. Controlled by APU engine ON command. Pin 2 = Pin Solenoid common (negative) connection.
4. Interconnection 4.3 Connectors, continued 4.3.3 Solenoid (See Fig. 4-1 for location) Pin # Description Function 1 Gas Solenoid +12V 2 Gas Solenoid Common +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. Return path for Gas Solenoid 9DSRU )XHO 6ROHQRLG /)3 5($5 9,(: 5($5 9,(: )520 $38 Fig. 4-4 Gas Solenoid Interface Connector ©2000 TM 69 031-132-B0-001 Rev.
4. Interconnection 4.3 Connectors, continued 4.3.4 Charger Module Control Interface Connector The Charger Module Control Interface Connector is connected between the charger module and ECM with Sense/Power leads connected to the APU Output DC Bus. The interface control is a 4-pin (2x2 row) Universal Mini MateN-Lok style male connector. See Fig. 4-1 for location. Pin Description Function 1 Ignition Battery (+) Sense (YELLOW) wire.
4. Interconnection 4.3 Connectors, continued 4.3.5 Charger Module - Output Interface Connector The Charger Output Interface Connector (J1) is connected between the charger module and the Ignition Battery as shown. The interface control is a 2pole Anderson connector. See Fig. 4-1 for location. Pole Description Function RED Charger Output POSITIVE BLK Charger Output NEGATIVE To Ignition battery Positive post To Ignition battery Negative post 5($5 9,(: Fig.
4. Interconnection 4.3 Connectors, continued 4.3.6 APU Ignition Battery Interface Connector The interface control is a 2-pole Anderson connector: Pin 1 = +12VDC activates (opens) solenoid ONLY when APU is running. Controlled by APU engine ON command) Pin 2 = Solenoid common (negative) connection. See Fig. 4-1 for location.
4. Interconnection 4.3 Connectors, continued 4.3.7 Alarm Control Interface to APU Interface Connector (APU-I/O) The interface control is a 12 pin (3x4 row) Mini Mate-NLok style connector. See Fig. 4-1 for location. Pin Description Function 1 2 3 4 5 +12V Ignition Battery Neg Ignition Battery Low Oil Pressure Over-Temp Start Command 6 7 8 9 Common (Start /Stop) Stop Command Over-Speed Over-Crank 10 11 12 Engine Run Not Used Not Used Ignition battery Fused 12V from APU.
4. Interconnection 4.3 Connectors, continued 4.3.8 ECM PWR-GRI Interface G R I (Power Board) Engine Control Module (ECM) PCB SW5 J2 10 1 J2 2 F2 11 J1 J1 12 4 6 5 7 F1 8 J3 J3 13 3 14 15 9 16 F3 Fig.4-9 ECM Printed Circuit Boards Engine Control Module LED Indicators and switches: 1. 2. 3. 4. 5. 6. 7. 8. 9. Communications Input (J4) Note: Pin #1 at bottom of connector.
4. Interconnection 4.3 Connectors, continued 4.3.9 ECM-PWR GRI Enclosure Sensor Interface Ribbon Cable The connector is a 14 pin 0.100 spaced, 150V rated ribbon cable with polarized cable connectors that prevent incorrect connections in the field. Designations for the connector mounted on the PCBA shall be identified by silk screen J1 and marked with the #1 pin of the PCB receptacle for polarization. See Fig. 4-9 for location.
4. Interconnection 4.3 Connectors, continued 4.3.10 ECM and PWR-GRI Interface Ribbon Cable This connector is a 10 pin 0.100 spaced, 150V rated ribbon cable with polarized cable connectors that prevent incorrect connections in the field. Designations for the connector mounted on the PCBA shall be identified by silk screen J2 and marked with the #1 pin of the PCB receptacle for polarization. See Fig. 4-9 for location.
4. Interconnection 4.3 Connectors, continued 4.3.11 Analog and Logic Power Interface Ribbon Cable This connector is a 16 pin 0.100 spaced, 150V rated ribbon cable with polarized cable connectors that prevent incorrect connections in the field. Designations for the connector mounted on the PCBA shall be identified by silk screen J3 and marked with the #1 pin of the PCB receptacle for polarization. See Fig. 4-9 for location.
4. Interconnection 4.3 Connectors, continued 4.3.12 ECM - Enclosure Alarm Interface The Alarm Interface Connector (J10) connected to the Power PCBA. The interface control is a 14-pin (2x7 row) Universal Mini Mate-N-Lok style male connector. See Fig. 4-9, item 10 for location.
4. Interconnection 4.3 Connectors, continued 4.3.13 Inverter Battery DC Sense Interface Connector ECM - Inverter Battery DC Sense Interface Connector J8. See Fig. 4-9, item 13 for location. The interface control is a 3-pin (1x3 row) Mini Mate-N-Lok style connector. Pin Description Function 1 DC Bus Sense (POS.) 2 No Connection 3 DC Bus Sense ( NEG.
4. Interconnection 4.3 Connectors, continued 4.3.14 Battery 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 2position plug-in connector. See Fig. 4-9, item 14 for location. Pin Description Function 1 Control POSITIVE 2 Control Negative This control connects pin 1 & 2 together, thereby turning the Charger ON, I.E.
4. Interconnection 4.3 Connectors, continued 4.3.15 ECM - APU Control Interface The interface control is a 12-pin (2x6 row) Mini Mate-N-Lok style connector. See Fig. 4-9, item 12 for location. 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.
4. Interconnection 4.3 Connectors, continued 4.3.16 ECM - AC Sense 120/240V Interface The interface control (J6) is a 2-pin (1x2 row) Mini Mate-N-Lok style connector. See Fig. 4-9, item 16 for location. Pin Description Function 1 Line 1, 120VAC AC Sense The Line side that powers the ECM and Power PCB, and provide AC line sense to start the APU 2 Line 2, Neutral The Neutral side the incoming line power. - 5($5 9,(: 5($5 9,(: :,5( 6,'( Fig.
4. Interconnection 4.3 Connectors, continued 4.3.17 ECM - Alarm Interface & Communications The Alarm output interface and communications connectors are referenced and described in Section 3.4, Transponder Interconnection, of the ECM Operators manual (Alpha p/n 744-862-C0). See Fig. 4-9 items 1 and 9 for location. 3LQ Fig.4-18 RS-485 Communications Input Connector See Fig. 4-9, item 1 for location. 3LQ Fig.4-19 Transponder Interface Connector See Fig. 4-9, item 9 for location.
4. Interconnection 4.3 Connectors, continued 4.3.
4. Interconnection 4.3 Connectors, continued 4.3.17 ECM - Alarm Interface & Communications, continued Top view Plug-side view Terminal 1 Terminal 1 Wire-insertion-side view Terminal 1 Fig. 4-22 ECM, SCM connector arrangement 8QXVHG 6&0 &200 3,1 %/$&. :LUH 3,1 5(' :LUH 8QXVHG Fig. 4-23 SCM-to-ECM interconnect cable Plug-side view Top view Terminal 1 Terminal 1 Wire-insertion-side view Terminal 1 Fig. 4-24 RS-485-to-ECM interconnect cable ©2000 TM 85 031-132-B0-001 Rev.
Investigate the of Alpha @ www.alpha.com ® UNITED STATES ASIA PACIFIC LATIN AMERICA Alpha Technologies 3767 Alpha Way Bellingham, WA 98226 Tel: (360) 647-2360 Fax: (360) 671-4936 Web: www.alpha.com CANADA Alpha Technologies 4084 McConnell Ct. Burnaby, B.C.
