Alpha DCX3000 Operator's Manual

DCX3000 Portable Generator

Operation Manual

3.0kW, 36/48V, DC Portable Generator

Effective: September 2006

Alpha Technologies

Alpha Technologies

Power

®

AlphaGen DCX3000

3.0kW, 36/48V DC Portable Generator
Operation Manual

041-028-B0-003, Rev. C

Effective Date: September 2006

Copyright© 2006

Alpha Technologies, Inc.

member of The Group

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 powering system, 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.

TM

Contacting Alpha Technologies: www.alpha.com

or

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

3

Table of Contents

Safety Notes ..........................................................................................................................6

1.0 Introduction .................................................................................................................8

2.0 Specifi cations.............................................................................................................. 9

3.0 Battery Cable Connections .......................................................................................10

3.1 Enclosures with Generator Access Door ....................................................... 10

3.2 Enclosures without Generator Access Door ...................................................11

3.3 Grounding ...................................................................................................... 16

4.0 Starting the Engine ................................................................................................... 18

5.0 Engine Shut-Down and Cable Removal ................................................................... 20

5.1 Long-term Storage ......................................................................................... 20

5.2 Scheduled Maintenance ................................................................................ 20

5.3 Transporting the Generator ............................................................................ 20

5.4 Fuse Replacement .........................................................................................21

6.0 Maintenance Record................................................................................................. 22

4

041-028-B0-003, Rev. C

List of Figures

Fig. 1-1, DCX3000 Overview ................................................................................................. 8

Fig. 1-2, Basic Block Diagram ............................................................................................... 8

Fig. 3-1, Generator Access Door and Battery Pack Adapter Cable ..................................... 10

Fig. 3-2, Enclosure without Generator Access Door.............................................................11

Fig. 3-3, Alligator Clamp-style Connection .......................................................................... 12

Fig. 3-4, Ring Lug-style Connection .................................................................................... 13

Fig. 3-5, Novus-style Connection ........................................................................................ 14

Fig. 3-6, Y-style Connection................................................................................................15

Fig. 3-7, Generator Grounding ............................................................................................ 16

Fig. 3-8, Overview of PWE Installation ................................................................................ 17

Fig. 4-1, Starting the Engine ................................................................................................18

Table 4-1, Battery Voltage and Output Indications .............................................................. 19

041-028-B0-003, Rev. C 5

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 this product, 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.

ATTENTION:

The use of ATTENTION indicates specifi c regulatory/code requirements that may affect the placement of
equipment and /or installation procedures.

NOTE:

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

CAUTION!

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

WARNING!

WARNING presents safety information to PREVENT INJURY OR DEATH to the technician
or user.

6

041-028-B0-003, Rev. C

General Safety Information

• The manufacturer cannot anticipate every circumstance that may involve a hazard, therefore, these
warnings are not all inclusive.

• Do not use the generator or any of its parts as a step.

• Generator must be properly grounded.

• Do not place or operate the generator in standing water, or expose to a forced spray of water.

• Do not make or break any connections while generator is running.

• Fuel spillage cleanup is the responsibility of the operator and should comply with local codes and
regulations.

• Do not refuel the generator while engine is running. Allow generator to cool before refueling.

• For fi re safety, the generator must be properly connected, maintained, and in compliance with applicable
codes and regulations.

• Engine exhaust contains carbon monoxide gas, which can be deadly in closed or poorly ventilated areas.

• Prior to each use, inspect the generator for leaks and damage. Immediately repair or replace any
damaged parts.

• Never operate the generator near combustible materials.

• Ensure cables do not cross hot surfaces or sharp edges. Inspect cables before and after each use.

• Drain oil and empty the fuel tank before transporting. Fuel can leak from the fi ller cap if the generator is
tilted.

• Never refuel the generator in the vicinity of open fl ames of heat sources. Do not smoke near the
generator.

• The generator should be operated on level ground. If necessary, it may be operated on a grade <15°.

• Use only vendor-authorized repair parts.

• Do not operate generator unattended.

ATTENTION:

• Alpha Technologies’ products are subject to change through continual improvement processes. Therefore,
specifi cations and design layouts may vary slightly from descriptions included in this manual. Updates to
the manual are issued when changes affect form, fi t or function.

• This product is manufactured to conform to the Federal Communications Commissions (FCC) Part 15,
Class A regulations. It is intended to be used for commercial, industrial or business environments.

• This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference
received, including interference that may cause undesired operation.

041-028-B0-003, Rev. C 7

1.0 Introduction

The Alphagen DCX3000 portable DC generator supplies DC power to a power node battery bus
during AC line interruptions. Upon loss of commercial AC power, the existing battery strings supply
the power supply inverters. After some interval of battery discharge, the operator deploys the portable
generator at the site to supply power to the DC bus. The generator delivers continuous, high-quality
power throughout the commercial AC interruption period. After restoration of commercial AC power,
the operator disconnects and removes the generator.

Status LEDs

1

Engine Switch

2

Choke

3

Fuel Valve

4

Voltmeter

5

Output Off Button

6

9

1

2

3

5

8

7

4

6

DC Out

7

Pull-start

8
9

Fuel Tank

Fig. 1-1, DCX3000 Overview

Engine Alternator Rectifier

Controller

DC Sense Feedback

Load

(batteries)

Fig. 1-2, Basic Block Diagram

8

041-028-B0-003, Rev. C

2.0 Specifi cations

Engine

Fuel/Fuel Tank Unleaded gasoline/3.5 gallon metal tank with level gauge
Rated Power 2800W continuous, 3000W maximum
Alternator Permanent magnet, brushless, bearingless
Output Voltage

Dual range selector
Output Regulation +/-1VDC
Control Features Automatic Voltage Regulation

Cable Interface Anderson type SBE-80 connector
Runtime @25% load (48V): 15.4 hours

Audible Noise Approximately 65dBA @ 7 meters under full load
Frame Fully enclosed
Dry Weight 117 lb
Dimensions 22" H X 17.6" W X 25.9" D (557mm x 447mm x 657mm)
Operating Temp 5°F to 104°F (-15°C to 40°C)
Required Accessories Output Interface Cable: Available in 10', 30', or 50' lengths

Agency Compliance CSA 22.2 No. 100-95

Optional Accessories Portable Generator Wheel Kit: P/N 745-793-20

Honda GX 200 6.5 hp, air-cooled, OHV, single cylinder, manual recoil starting, manual choke

36V: 39.5VDC, nominal at generator output connector
48V: 52.5VDC, nominal at generator output connector

Electronic Governor
Overcurrent Protection
Analog voltmeter with back light

@25% load (36V): 17.5 hours
@100% rated load: 6.5 hours

Battery Interface Cable: Choose Ring Lug, Heavy-duty Alligator Clamp, or Y-adapter (Connects the

power supply’s battery input directly to the generator. See Section 3.0 for more
information)

FCC part 15B Class A
CARB
UL 50, Section 30
NFPA 37, 70
EPA

Punch Tool Kit for Enclosures, 2.5" dia: P/N 745-131-20
Enclosure Upgrade Kit: P/N 745-131-21
Cable Bag and Cable Key Lanyard: P/N 745-764-21
Locking Handle: P/N 745-792-20

NOTE:

Please refer to www.alpha.com for available options and data sheets.

041-028-B0-003, Rev. C 9

3.0 Battery Cable Connections

3.1 Enclosures with Generator Access Door

Tools and Materials Needed:

• Portable Generator Battery Cable Kit

• DC Multimeter

Procedure:

1. Open the enclosure’s battery compartment and locate the battery pack connections for
the positive and negative battery cables leading to the power supply.

2. Observing polarity (red to positive, black to negative), connect the Battery Pack
Adapter Cable to the connections located in Step 1. Attach Ring Lug or Alligator Clamp
connections directly to the battery post. See Fig. 3-5 and Fig. 3-6 for Novus-style and Y-

style connections. Do not connect the extension cable to the DC OUT jack on the

front panel of the generator at this time.

3. Route the extension cable (10’, 30’, or 50’) into the enclosure’s battery compartment.
Protect cable from chafi ng against sharp edges.

4. Connect the Battery Pack Adapter Cable to the extension cable. Extension cables are
equipped with in-line fuses. Replace only with 100 Amp 300VAC fuse (Alpha P/N 460­191-10).

CAUTION!
Inspect cable sets before each use for damage and wear. Use only cable sets that are designed for

this generator.

10

Fig. 3-1, Generator Access Door and Battery Pack Adapter Cable

041-028-B0-003, Rev. C

3.0 Battery Cable Connections, continued

3.2 Enclosures without Generator Access Door

Tools and Materials Needed:

• 2.5" Punch Tool Kit for Enclosures (Alpha P/N 745-131-20)

• 2.5" Enclosure Upgrade Kit (Alpha P/N 745-131-21)

• Electric drill

• #7 Drill bit (.2010”) or #9 drill bit (.1960”)

• #2 Phillips screwdriver

WARNING!

Disconnect all sources of service power to the enclosure before drilling holes. Ensure the
area is clear of wires and electrical boxes. Do not locate the hole above electrical boxes to
prevent damage from water intrusion while the plug is removed.

Procedure:

1. If not previously installed, punch or cut a 2.5” hole in the enclosure (shown below) to

route the generator’s battery cable. Ensure area is clear of electrical wires and boxes.

2. Install the grommet into the hole, and install the weatherproof plug into the grommet.

3. Using the #7 or #9 drill bit, drill a hole approximately 2” below and to one side of the

grommet, attach the lanyard on the inside of the enclosure with the #10 bolt and nut
provided.

Suggested location of battery

cable hole for PWE enclosures

Hole for lanyard bolt

Fig. 3-2, Enclosure without Generator Access Door

041-028-B0-003, Rev. C 11

3.0 Battery Cable Connections, continued

Extension Cable Set,
50’ P/N 875-324-21
30’ P/N 875-324-20
10’ P/N 875-324-22

Alligator Clamp-style

Battery Pack Adapter Cable,

P/N 874-946-20

3

Red

2

Fuse

1

Black

Ensure clamps lay fl at against

batteries, facing inward

12

Fig. 3-3, Alligator Clamp-style Connection

041-028-B0-003, Rev. C

3.0 Battery Cable Connections, continued

Extension Cable Set,
50’ P/N 875-324-21
30’ P/N 875-324-20
10’ P/N 875-324-22

Ring Lug-style

Battery Pack Adapter Cable,

P/N 874-946-21

3

Red

2

Fuse

1

Black

Cable rings connect directly

to the battery terminals

Fig. 3-4, Ring Lug-style Connection

041-028-B0-003, Rev. C 13

3.0 Battery Cable Connections, continued

Circuit Breaker

mustbe CLOSED

GENERATOR

BREAKER

60A

EXTGENERATOR

REDBLACK

BYPAS

FROMXT1

UPS

S

CONVENI ENCE

HEATING PADS

Novus Power

Panel

Novus-style

Battery Pack Adapter Cable

P/N 875-324-23

OUTPUTS

Plus

LA-P

Extension Cable Set,
50’ P/N 875-324-21
30’ P/N 875-324-20
10’ P/N 875-324-22

Fig. 3-5, Novus-style Connection

14

041-028-B0-003, Rev. C

3.0 Battery Cable Connections, continued

Extension Cable Set,
50’ P/N 875-324-21
30’ P/N 875-324-20
10’ P/N 875-324-22

Y-style

Battery Pack Adapter Cable

P/N 874-946-22

3

2

Fuse

1

Fig. 3-6, Y-style Connection

041-028-B0-003, Rev. C 15

3.0 Battery Cable Connections, continued

3.3 Grounding

Tools and Materials Needed:

#8AWG copper ground wire and clamps

Procedure:

1. Read and thoroughly understand the Engine Owner’s Manual before operating this
equipment.

2. Before starting the generator, follow all instructions outlined in the BEFORE OPERATION
section of the Engine Owner’s Manual.

3. Attach #8AWG copper grounding wire between the generator grounding lug and the
service entrance grounding bar, or directly to the utility grounding rod.

WARNING!

To prevent injury, the generator must share a common ground with the enclosure service
entrance.

Fig. 3-7, Generator Grounding

Generator Grounding Lug

16

041-028-B0-003, Rev. C

3.0 Battery Cable Connections, continued

To prevent injury, the generator MUST share a common ground with the enclosure service
entrance.

Power Meter

Ground Stake

Ground Wire

Ground Wire

Fig. 3-8, Overview of PWE Installation

041-028-B0-003, Rev. C 17

4.0 Starting the Engine

Prior to starting the generator, review the Safety Information on page 6 of this manual.
Set the generator on a fl at, level surface, free of standing or running water, or combustible materials.

Operating the generator at an angle of more than 15 degrees may result in the oil level dropping
below a safe level. This may cause the low oil sensor to trip, or failure of the generator to shut down.

This generator runs very quietly. It is not always possible in ambient-noise situations to determine
whether it is running simply by sound. Verify that the generator is OFF before proceeding with the
following procedure.

Tools and Materials Needed:

#2 Flat-tip screwdriver (to open side panel)

Procedure:

1. Verify fuel is in the fuel tank.

2. Open the maintenance cover on the left side panel of the generator.
Set the Voltage Select switch to match the battery pack voltage (36V or
48V). Close cover before starting engine.

3. Verify polarity and battery voltage continuity on extension cables.
Connect the extension cable coupler to the DC OUT jack on the
generator. Verify the voltmeter indicates the voltage of the battery pack.

Voltage Select Switch

NOTE:

Set correct voltage on Voltage Select Switch. Generator will not engage with incorrect voltage
setting.

4. Insert key and turn the ENGINE SW to the ON position.

5. If the engine is cold, pull the CHOKE knob out.

6. Turn the FUEL VALVE to the ON position.

7. Pull the starter handle (right side panel) until the engine starts. Verify the OUTPUT INDICATOR
LED is a steady green (not blinking). If the OUTPUT INDICATOR LED is fl ashing red, a voltage
mis-match has occurred, or the battery pack is excessively discharged. Refer to the voltage table
on page 19 for more information.

8. As the engine warms, push the CHOKE knob in.

OUTPUT INDICATOR LED

(Step 7)

ENGINE SW

(Step 4)

FUEL VALVE
(Step 6)

CHOKE

(Steps 5, 8)

DC OUT
(Step 3)

18

Fig. 4-1, Starting the Engine

041-028-B0-003, Rev. C

4.0 Starting the Engine, continued

Battery Voltage

0V to 2V

2V to 27V

27V to 42V

42V to 55V

>56V

1 All battery voltage measurements are ± 1V
2 To enable forced output when the Overload Alarm LED is fl ashing, press the output button for at least 5

seconds. The Overload Alarm LED stops fl ashing. Release the output button, and then press it again for
at least fi ve seconds. The Output Indicator LED turns on steady, and power output begins. The operator
may then release the output button.

3 Engine shuts down after 1 second.

Voltage Select

Switch Position

36V
48V
36V
48V
36V
48V
36V
48V
36V
48V

Output Indicator

(Green LED)

OFF
OFF
OFF
OFF

ON

OFF
OFF

ON

OFF
OFF

Overload Alarm

(Red LED)

OFF
OFF

FLASHING
FLASHING

OFF

FLASHING
FLASHING

OFF

FLASHING
FLASHING

Forced Output

Not Available
Not Available

ENABLED
ENABLED

Not Available

ENABLED

Not Available
Not Available
Not Available
Not Available

21

3
3

Table 4-1, Battery Voltage and Output Indications

NOTE:

To manually disconnect the Output Voltage, press the OUTPUT SW momentarily to remove voltage from the
battery pack. See Step 1 of Section 5.0, Engine Shutdown and Cable Removal.

To re-establish output voltage after manual or automatic disconnection, turn the ENGINE SW counter­clockwise to OFF. After the engine stops, turn the ENGINE SW to ON and follow the procedures in Section

4.0, Starting the Engine.

041-028-B0-003, Rev. C 19

5.0 Engine Shut-Down and Cable Removal

WARNING!

Engine block and muffl er become extremely hot during normal operation.

Procedure:

1. Press the OUTPUT SW to remove voltage from the battery pack.

2. Turn the ENGINE SW OFF.

3. Turn the FUEL VALVE OFF.

4 Disconnect the battery pack adaptor from the extension cable.

5. Remove the extension cable from the front panel of the generator.

6. Remove the battery pack adaptor from the battery pack.

7. Remove #8AWG copper ground wire.

5.1 Long-term Storage

If the generator is not going to be operated for an extended period of time, follow the storage
instructions in the TRANSPORTING/STORAGE section of the Engine Owner’s Manual.

CAUTION!
Drain fuel system before extended storage. Inspect fuel system and cable sets prior to restarting

generator after extended storage.

5.2 Scheduled Maintenance

Refer to the Honda Engine Owner’s Manual and follow all instructions in the MAINTENANCE
section.

5.3 Transporting the Generator

Refer to the Engine Owner’s Manual and follow all instructions in the TRANSPORTING/
STORAGE section.

20

041-028-B0-003, Rev. C

5.0 Engine Shut-Down and Cable Removal, continued

5.4 Fuse Replacement

Tools and Materials Needed:

• 10mm and 8mm socket

• Ratchet handle

• Torque wrench

• Replacement fuse: Alpha P/N 460-273-10, Hinode Electric Co. P/N 350GH-80

Procedure:

1. Set the ENGINE SW to OFF. Disconnect the extension
cable from the DC Out jack.

2. Remove the four 10mm nuts from the front plastic housing,
and remove the housing.

3. Locate the fuse cover below the OUTPUT SW.

4. Remove the two 8mm bolts on the bottom of the fuse cover.
Remove the cover.

5. Remove the two 10mm nuts holding the fuse onto the fuse
holder. When reassembling, carefully tighten nuts to the
following torque specifi cations:

3.2 to 6.4 N m

2.4 to 4.7 ft-lbs.
28 to 56 in-lbs.

6. Replace fuse, and reassemble the generator in reverse
order.

041-028-B0-003, Rev. C 21

6.0 Maintenance Record

Use the following form to log maintenance and repair of your DCX3000.

Maintenance Record

Model Number Serial Number

Date

Hour

Mete

r

Action Initials

(Refer to engine owners manual for service requirements and intervals)

22

041-028-B0-003, Rev. C

Alpha Technologies

Power

Copyright © 2006 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies. 041-028-B0-003, Rev. C.

Due to continuing product improvements, Alpha reserves the right to change specifi cations without notice.

®

Alpha Technologies
3767 Alpha Way
Bellingham, WA 98226

USA

Tel: [phone]
Fax: [phone]
Web: www.alpha.com

Alpha Technologies Ltd.
4084 McConnell Court
Burnaby, BC, V5A 3N7

CANADA

Tel: [phone]
Fax: [phone]

Alpha Technologies
Europe Ltd.
Twyford House
Thorley
Bishop's Stortford
Hertfordshire
CM22 7PA

UNITED KINGDOM

Tel: [phone]
Fax: [phone]

Alpha Technologies GmbH
Hansastrasse 8
D 91126 Schwabach

GERMANY

Tel: [phone]
Fax: [phone]

Alphatec, Ltd
P.O. Box 56468
Limassol, Cyprus

CYPRUS

Tel: [phone]
Fax: [phone]

AlphaTEK ooo
Khokhlovskiy Pereulok 16
Stroenie 1
109028 Moscow

RUSSIA

Tel: [phone]
Fax: [phone]

Alphatec Baltics
S. Konarskio G. 49
Vilnius 2009

LITHUANIA

Tel: [phone]
Fax: [phone]

Alpha Technologies
5 Avenue Victor Hugo
F 92140 Clamart France

FRANCE

Tel: [phone]
Fax: [phone]