Alpha-technologies AlphaGen 5.0kW Auxiliary Power Unit Bedienungsanleitung

TM®®5.0kW Auxiliary Power UnitOperation and Maintenance ManualEffective: October, 2000Cable SeriesTM

Preface10031-132-B0-001 Rev. ATM©2000IMPORTANT INSTALLATION NOTESSave these instructions for future referenceNOTE:Alpha Technologies products are su

Preface11031-132-B0-001 Rev. ATM©2000Auxiliary Power Unit (APU) NotesNOTE:When the engine is stopping, a small amount of unburned fuelmay be detecte

Preface12031-132-B0-001 Rev. ATM©2000Battery Safety NotesChemical HazardsAny gelled or liquid emissions from a Valve-Regulated Lead-Acid (VRLA) batte

1. System Overview13031-132-B0-001 Rev. ATM©20001.1 System Enclosure OverviewThis manual is intended to provide a general functional overview for the

1. System Overview14031-132-B0-001 Rev. ATM©20001.1 System Enclosure Overview, continuedSystem components shown below allow for easy access during o

1. System Overview15031-132-B0-001 Rev. ATM©20001.2 SpecificationsNominal system specifications for 5kW Auxiliary Power Unit:DC Output voltage(VDC @

1. System Overview16031-132-B0-001 Rev. ATM©2000The DC output of the APU connects directly to the inverter batteries torecharge them when line power

1. System Overview17031-132-B0-001 Rev. ATM©20001.4 Engine Control Module OverviewThe primary purpose of Alphas Engine Control Module (ECM) is to c

1. System Overview18031-132-B0-001 Rev. ATM©20001.4 Engine Control Module Overview, continuedIgnition Battery ShelfEngine GeneratorSerial RS-485 Com

1. System Overview19031-132-B0-001 Rev. ATM©20001.5.1 Normal Operating ConditionUnder normal operating conditions (no alarms) the ECM's Run-Aut

2031-132-B0-001 Rev. ATM©2000

1. System Overview20031-132-B0-001 Rev. ATM©20001.5 Generator Modes of Operation, continued1.5.4. Normal APU ShutdownThe ECM will initiate a normal

1. System Overview21031-132-B0-001 Rev. ATM©20001.5.6.ECM Operating Mode SummaryThe ECM monitors the status of the AC line and DC bus to make adeter

1. System Overview22031-132-B0-001 Rev. ATM©20001.6 Operators Interface OverviewRefer to Figure 1-8 on the following page:The three positions of th

1. System Overview23031-132-B0-001 Rev. ATM©2000The service reset push-button is also used to obtain information aboutactive alarms. The Major and

1. System Overview24031-132-B0-001 Rev. ATM©20001.7 ECM Alarm OverviewAlarms are indicated in three ways: ECM LEDs, RS-485 communicationsand alarm c

1. System Overview25031-132-B0-001 Rev. ATM©20001.8 Ignition Battery Charger Overview,*1,7, 21%$77(5<  The Ignition Battery Charg

1. System Overview26031-132-B0-001 Rev. ATM©2000,QWDNHIURPUHDU'RRUYHQWVWRIURQW'RRUFORVHG&RROLQJDLURXWURRI'RRUFORVHG7KUH

1. System Overview27031-132-B0-001 Rev. ATM©20005HDU'RRU%ORFNHG)URQW'RRU9HQWV7DE'RRU7DE'RRU5HDU)URQW&(*(QFORVXUH5HDU

1. System Overview28031-132-B0-001 Rev. ATM©2000Prior to applying the power, note the condition of the outside of the unit.Open each door of the enc

2. Turn-Up and Test29 031-132-B0-001 Rev. ATM©20002.2.3 Starting a Local APU TestProcedure:1. Locate APU control board (mounted alongside the ECM).2

3031-132-B0-001 Rev. ATM©2000Overview: The purpose of the AlphaGen 5.0kW Auxiliary Power Unit Operationand Maintenance Manual is to detail system ope

2. Turn-Up and Test30031-132-B0-001 Rev. ATM©20002.2.3 Starting a Local APU Test, continued2. Place generator set master switch to the middle (ECM)

2. Turn-Up and Test31 031-132-B0-001 Rev. ATM©20002.2 Initial Operation, continued2.2.3 Starting a Local APU Test, continued11. Adjust pre-regulator

2. Turn-Up and Test32031-132-B0-001 Rev. ATM©20002.3 Generator System Sensor VerificationThe ECM has a built-in self-test feature. Each time the EC

2. Turn-Up and Test33 031-132-B0-001 Rev. ATM©2000 2.3 Generator System Sensor Verification, continued2.3.2 AC and DC line Sense VerificationThe ECM

3. Maintenance34031-132-B0-001 Rev. ATM©20003.1 Cleaning and LubricationThe Auxiliary Power Unit, being a gas-driven, air-cooled, combustion engine

3. Maintenance35031-132-B0-001 Rev. ATM©20003.2 Scheduled Maintenance3.2.1 Maintenance IntervalsThe engine/alternator requires maintenance at regu

3. Maintenance36031-132-B0-001 Rev. ATM©20003.2 Scheduled Maintenance, continued3.2.2 ECM Service Required NotificationThe ECM monitors time betwe

3. Maintenance37031-132-B0-001 Rev. ATM©20003.2 Scheduled Maintenance, continued3.2.3 ECM Self-Test FeaturesGenerator testing can be initiated in f

3. Maintenance38031-132-B0-001 Rev. ATM©20003.2 Scheduled Maintenance, continued3.2.3 ECM Self-Test Features, continuedIf AC line should fail dur

3. Maintenance39031-132-B0-001 Rev. ATM©20003.2 Scheduled Maintenance, continued3.2.3 ECM Self-Test Features, continuedAuto-Test DurationThe leng

Preface4031-132-B0-001 Rev. ATM©20005.0kWAuxiliary Power UnitTMTable of ContentsSection 1, System Overview1.1 System Enclosure Overview ...

3. Maintenance40031-132-B0-001 Rev. ATM©20003.3 Servicing the APUSome tools and equipment may be required such as: Phillips screwdriver 10 mm soc

3. Maintenance41031-132-B0-001 Rev. ATM©2000The air intake filter is located on the rear door.WARNING:Failure to keep the filters clean or using imp

3. Maintenance42031-132-B0-001 Rev. ATM©20003.5 PAD SHEAR Magnetic Switch and Water Intrusion FloatAllow 15 minutes for completion of procedureTool

3. Maintenance43031-132-B0-001 Rev. ATM©20003.5 PAD SHEAR Magnetic Switch and Water Intrusion Float, contd.Cut wires to tamper switch sensor.Use Ph

3. Maintenance44031-132-B0-001 Rev. ATM©20003.6 Replacing GAS HAZARD SensorAllow 5 minutes for completion of procedureTools required:Hook and loop f

3. Maintenance45031-132-B0-001 Rev. ATM©2000Disconnect the sensor from the wireharness and replace with the newsensor. Add the opposite piece of the

3. Maintenance46031-132-B0-001 Rev. ATM©20003.7 Replacing Ignition Battery Charger Module AssemblyEnd of ProcedureAllow 15 minutes for completion of

3. Maintenance47031-132-B0-001 Rev. ATM©20003.8 Replacing Engine Control ModuleAllow 5 minutes for completion of procedureTools required: NoneRemova

3. Maintenance48031-132-B0-001 Rev. ATM©2000Allow 5 minutes for completion of procedureTools required: 15/16 open-end wrenchRemoval and replacement

3. Maintenance49031-132-B0-001 Rev. ATM©20003.10 Fuel Conversion - Natural Gas to Liquid Propane3.10.1 Pre-regulator/Low Fuel Pressure Switch Replac

Preface5031-132-B0-001 Rev. ATM©20005.0kWAuxiliary Power UnitTMTable of ContentsSection 3, Maintenence, continued3.8 Replacing Engine Control Module

3. Maintenance50031-132-B0-001 Rev. ATM©20003.10 Fuel Conversion - Natural Gas to LP, continued3.10.2 Dual-Fuel Load Block ConversionAllow 15 minute

3. Maintenance51031-132-B0-001 Rev. ATM©2000Coat the fitting with thread sealant.Use only NFPA-approved pipe sealant ,i.e., Megaloc Multipurpose thr

3. Maintenance52031-132-B0-001 Rev. ATM©20003.11 Fan Replacement ProcedureAllow 5 minutes (per fan) for completion of procedure.Tools required: Slot

3. Maintenance53031-132-B0-001 Rev. ATM©20003.12 Muffler Replacement ProcedureAllow 15 minutes for completion of procedure.Tools required: #2 Philli

3. Maintenance54031-132-B0-001 Rev. ATM©20003.12 Muffler Replacement Procedure, continuedEnd of Procedure4. Install the new muffler in thehousing.5.

3. Maintenance55031-132-B0-001 Rev. ATM©20003.13 Muffler Exhaust Flange Gasket Replacement ProcedureCAUTION:Gasket must be installed properly, or lo

3. Maintenance56031-132-B0-001 Rev. ATM©20003.14 Gas Solenoid Replacement Procedure1. Shut off or disconnect gas service.2. Remove Natural Gas pre-r

3. Maintenance57031-132-B0-001 Rev. ATM©20003.15 Replacing Cabinet Exhaust Duct Upper Seal1. Remove old seal and clean ductedge with rubbing alcohol

3. Maintenance58031-132-B0-001 Rev. ATM©20003.16 Removal and Replacement of Generator SetAllow 45 minutes for completion of procedureTools required:

3. Maintenance59031-132-B0-001 Rev. ATM©20005. Use wrenches to loosen mufflerflange bolts (2 places).3.16 Removal and Replacement of Generator Set,

Preface6031-132-B0-001 Rev. ATM©20005.0kWAuxiliary Power UnitTMList of FiguresFig. 1-1 System enclosure ...

3. Maintenance60031-132-B0-001 Rev. ATM©2000To replace the APU, reverse the steps above, except for special instructions asfollows: To reconnect gas

3. Maintenance61031-132-B0-001 Rev. ATM©2000AdjustmentpointAccess capPrimary FuelRegulatorRemove the adjustment cover on theMaxitrol regulator and

3. Maintenance62031-132-B0-001 Rev. ATM©2000Calibration Tap"Secondary" or "Demand"Regulator3.17 Maxitrol Pre-Regulator Calibrati

3. Maintenance63031-132-B0-001 Rev. ATM©2000NO MATCHES OR OPEN FLAMES:Use caution whenever working in the area to prevent possible combustionfuel va

643. Maintenance031-132-B0-001 Rev. ATM©2000Calibration Procedure, continued7. Verify the DWYER # 1212 manometer reads 5-1/2" above the 0 mar

4. Interconnection65031-132-B0-001 Rev. ATM©2000The signals from the sensors to the ECM should follow the state table asshown. The signals sent to th

4. Interconnection66031-132-B0-001 Rev. ATM©20004.2 ECM Interface Topology and ConnectorsThe ECM PWR- GRI PCBA provides the interface between cabin

4. Interconnection67031-132-B0-001 Rev. ATM©2000The Gas Hazard Detector Interface Connector is connected between the wireharness and detector unit a

4. Interconnection68031-132-B0-001 Rev. ATM©20004.3 Connectors, continued4.3.2 Low Fuel Pressure Interface ConnectorThe interface control is a 2 pin

4. Interconnection69031-132-B0-001 Rev. ATM©20004.3.3 Solenoid (See Fig. 4-1 for location)Pin # Description Function1 Gas Solenoid +12V +12VDC suppl

Preface7031-132-B0-001 Rev. ATM©2000MECHANICAL OR MOVING PARTS HAZARDThese symbols indicate the presence of a mechanical or moving partshazard in t

4. Interconnection70031-132-B0-001 Rev. ATM©20004.3.4 Charger Module  Control Interface ConnectorThe Charger Module  Control Interface Connector i

4. Interconnection71031-132-B0-001 Rev. ATM©20004.3.5 Charger Module - Output Interface ConnectorThe Charger Output Interface Connector (J1) is conn

4. Interconnection72031-132-B0-001 Rev. ATM©20004.3.6 APU Ignition Battery Interface ConnectorThe interface control is a 2-pole Anderson connector:P

4. Interconnection73031-132-B0-001 Rev. ATM©2000Pin Description Function1 +12V Ignition Battery Ignition battery Fused 12V from APU.2 Neg Ignition B

4. Interconnection74031-132-B0-001 Rev. ATM©20003579J 3J 3Engine Control Module (ECM) PCBG R I (Power Board)Engine Control Module LED Indicators and

4. Interconnection75031-132-B0-001 Rev. ATM©20004.3.9 ECM-PWR GRI Enclosure Sensor Interface Ribbon CableThe connector is a 14 pin 0.100 spaced, 15

4. Interconnection76031-132-B0-001 Rev. ATM©20004.3 Connectors, continuedPin Description Function1 Gas Hazard*2 Pad Shear*3 Water Intrusion*4 Low Ga

4. Interconnection77031-132-B0-001 Rev. ATM©20004.3 Connectors, continued4.3.11 Analog and Logic Power Interface Ribbon CablePin Description Functio

4. Interconnection78031-132-B0-001 Rev. ATM©20004.3 Connectors, continuedThe Alarm Interface Connector (J10) connected to the Power PCBA. Theinterf

4. Interconnection79031-132-B0-001 Rev. ATM©20004.3.13 Inverter Battery DC Sense Interface ConnectorECM - Inverter Battery DC Sense Interface Connec

Preface8031-132-B0-001 Rev. ATM©2000NOTE:Failure to follow these precautions could result ininjury or death caused by the explosion of fuel,moving pa

4. Interconnection80031-132-B0-001 Rev. ATM©20004.3.14 Battery Charger Control Interface ConnectorThe Battery Charger Control Interface Connector is

4. Interconnection81031-132-B0-001 Rev. ATM©20004.3 Connectors, continuedPin Description Function1 +12V Ignition Battery Ignition battery Fused 12V

4. Interconnection82031-132-B0-001 Rev. ATM©20004.3 Connectors, continued5($59,(:5($59,(::,5(6,'(-The interface control (J6) is a 2-pin (1x2

4. Interconnection83031-132-B0-001 Rev. ATM©20004.3 Connectors, continued4.3.17 ECM - Alarm Interface & CommunicationsThe Alarm output interface

4. Interconnection84031-132-B0-001 Rev. ATM©20001234567891011124.3 Connectors, continued4.3.17 ECM - Alarm Interface & Communications, continued

4. Interconnection85031-132-B0-001 Rev. ATM©20004.3 Connectors, continued4.3.17 ECM - Alarm Interface & Communications, continued8QXVHG8QXVHG

UNITED STATESASIA PACIFICLATIN AMERICAAlpha Technologies3767 Alpha WayBellingham, WA 98226Tel: (360) 647-2360Fax: (360) 671-4936Web: www.alpha.comCAN

Preface9031-132-B0-001 Rev. ATM©2000 The system must be serviced only by qualified personnel. Remove all rings, watches and other jewelry before se