Alpha PN-6x-T 7.5kW 48VDC Technical Manual

Technical Manual

CE-3x2 5K-T 48Vdc Telecom Generator

PN-6x-T 7.5kW 48Vdc Telecom Generator

Effective: May 2008

Alpha Technologies

Alpha Technologies

Power

®

TM

CE-3x2 5K-T 48Vdc Telecom Generator

PN-6x-T 7.5kW 48Vdc Telecom Generator

Technical Manual

042-288-B0-001, Rev. A

Effective Date: May 2008

Copyright © 2008

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 .......................................................................................................................... 8

1.0 System Overview ...................................................................................................... 13

1.1 PN-6x-T System Diagram ..............................................................................14

1.2 CE3x2 5kW System Diagram ........................................................................15

1.3 Natural Gas System Block Diagram .............................................................. 16

1.4 Liquid Propane System Block Diagram ......................................................... 17

1.5 Specifi cations ................................................................................................. 18

2.0 Site Preparation ........................................................................................................ 21

2.1 Site Considerations ........................................................................................21

2.2 Acoustics ........................................................................................................21

2.3 Enclosure Impact Protection .......................................................................... 23

2.4 Natural Gas Meter Confi gurations ................................................................. 25

2.5 Liquid Propane Systems ................................................................................ 27

2.6 Grounding Requirements, CE-3x2 5K-T ........................................................ 28

2.7 Grounding Requirements, PN-6xT 7.5kW ..................................................... 29

3.0 Installation.................................................................................................................30

3.1 Installing the CE-3x2 5K-T or PN-6x-T 7.5kW Pad Template ........................ 30

3.2 Installation, CE-3x2 5K-T ............................................................................... 33

3.2.1 CE-3x2 5K-T Transportation and Lifting .............................................. 34

3.2.2 Enclosure Installation, CE-3x2 5K-T ................................................... 36

3.3 PN-6x-T 7.5kW Installation ........................................................................... 37

3.3.1 PN-6x-T 7.5kW Transportation and Lifting, ......................................... 38

3.3.2 Enclosure Installation Procedure, PN-6x-T 7.5kW ..............................40

3.4 Enclosure Grounding, CE-3x2 5K-T .............................................................. 41

3.5 Enclosure Grounding, PN-6x-T 7.5kW ........................................................... 42

3.6 Natural Gas Utility Fuel Hookup, CE-3x2 5K-T ..............................................43

3.7 Natural Gas Utility Fuel Hookup, PN-6x-T 7.5kW .......................................... 44

3.8 Liquid Propane Utility Fuel Hookup, CE-3x2 5K-T .........................................45

3.9 Liquid Propane Utility Fuel Hookup, PN-6x-T 7.5kW ..................................... 46

3.10 Making the DC Output Connection, CE-3x2 5K-T ......................................... 47

3.11 Making the DC Output Connection, PN-6x-T 7.5kW ...................................... 48

3.12 Connecting the Ignition Battery, CE-3x2 5K-T ...............................................49

3.13 Connecting the Ignition Battery, PN-6x-T 7.5kW ...........................................50

3.14 Terminal Block 2 (AC Line) Connections, CE-3x2 5K-T .................................51

3.15 Terminal Block 2 (AC Line) Connections, PN-6x-T 7.5kW ............................. 52

3.16 Final Inspection Checklist .............................................................................. 53

4.0 The Engine Control Module ..................................................................................... 54

4.1 Theory of Operation ....................................................................................... 56

4.1.1 Standby Operating Condition Less Than Three Minutes .................... 56

4.1.2 Standby Operating Condition More Than Three Minutes .................... 56

4.1.3 Normal APU Shutdown ....................................................................... 57

4.1.4 Abnormal APU Shutdown.................................................................... 57

4.2 ECM Operating Mode Summary ....................................................................57

4.3 LED Indicators ............................................................................................... 58

4

042-288-B0-001, Rev. A

4.4 Control Functions ...........................................................................................59

4.5 Alarm Classifi cations ...................................................................................... 60

4.6 ECM Alarm Overview ..................................................................................... 62

4.7 Connecting the Alarm and Control Connections ............................................63

4.8 ECM DIP Switch and Fuse Confi guration ......................................................64

4.9 ECM Interface Block Diagram and Connectors ............................................. 66

4.10 ECM Self-test ................................................................................................. 67

4.11 Maintenance Functions .................................................................................68

5.0 Turn-up and Test ....................................................................................................... 69

5.1 Appearance and Condition of Components ................................................... 69

5.2 System Preparation ....................................................................................... 69

5.3 Performing a Local APU Test ......................................................................... 70

5.4 Generator System Sensor Verifi cation ........................................................... 71

5.4.1 Enclosure Alarm Verifi cation ............................................................... 71

5.4.2 AC and DC Line Sense Verifi cation ....................................................72

6.0 Operation ..................................................................................................................73

6.1 Normal Operating Condition .......................................................................... 73

6.1.1 AC Line Fail ......................................................................................... 73

6.1.2 Low DC Bus Level............................................................................... 73

6.2 Alpha Ignition Battery Charger Overview .......................................................74

7.0 Maintenance ............................................................................................................. 75

7.1 Servicing the APU .......................................................................................... 76

7.2 Filter Cleaning, CE-3x2 5K-T ......................................................................... 77

7.3 Filter Cleaning, PN-6x-T 7.5kW ..................................................................... 78

7.4 Pad Shear Magnetic Switch Replacement..................................................... 79

7.5 Replacing Gas Hazard Sensor ...................................................................... 80

7.6 Replacing Ignition Battery Charger Module Assembly ................................... 81

7.7 Replacing Engine Control Module ................................................................ 82

7.8 Fuel Conversion, Natural Gas to LP .............................................................. 83

7.8.1 PN-6x-T Pre-regulator Removal with Low Pressure Switch Installation ...... 83

7.8.2 Switching the LP Port to the NG Port, PN-6x-T .................................. 84

7.8.3 Switching the NG Port to the LP Port, CE-3X2 ................................... 85

7.9 Maxitrol Pre-regulator Calibration .................................................................. 86

8.0 Interconnection ......................................................................................................... 89

8.1 Gas Hazard Alarm Interface Connector .........................................................89

8.2 Low Fuel Pressure Interface Connector ........................................................ 89

8.3 Gas Solenoid Interface Connector ................................................................ 92

8.4 Charger Module Control Interface Connector ............................................... 90

8.5 ECM Enclosure Alarm Interface Connector ................................................... 91

8.6 Inverter Battery DC Sense Interface Connector ............................................ 91

8.7 Charger Control Interface Connector .............................................................92

8.8 ECM AC Line Sense 120/240V Interface ....................................................... 92

8.9 ECM APU Control Interface ........................................................................... 93

8.10 ECM Alarm Interface ...................................................................................... 93

042-288-B0-001, Rev. A

5

List of Figures

Fig. 1-1, PN-6x-T 7.5kW Telecom Generator ...................................................................... 13

Fig. 1-2, CE-3x2 5K-T Telecom Generator .......................................................................... 13

Fig. 1-3, PN-6x-T System Diagram ..................................................................................... 14

Fig. 1-4, CE3x2 System Diagram ........................................................................................ 15

Fig. 1-5, Arrangement of Metered, Nominal Pressure (1-2psi) Natural Gas System........... 16

Fig. 1-6, Excess Flow Valve ...............................................................................................16

Fig. 1-7, LP Propane Vapor Withdrawal Block Diagram ...................................................... 17

Fig. 2-1, Generator Sound Levels at 100% Load ................................................................ 21

Fig. 2-2, Acoustical Measurements in Relation to Placement Near Residences ................. 22

Fig. 2-3, Vehicular Area Impact Protection for Collocated Natural Gas Meter ................... 23

Fig. 2-4, Vehicular Area Impact Protection for Remote Natural Gas Meter ........................ 24

Fig. 2-5, Collocated Natural Gas Meter Setup for CE-3x2 Generator ................................. 25

Fig. 2-6, Collocated Natural Gas Meter Setup for PN-6x-T 7.5kW System .........................25

Fig. 2-7, Collocated CE-3x2 5K-T Generator with Remote Natural Gas Meter ................... 26

Fig. 2-8, Remote Natural Gas Meter Setup for PN-6x-T 7.5kW Generator ......................... 26

Fig. 2-9, Liquid Propane Setup, CE-3x2 5K-T ..................................................................... 27

Fig. 2-10, Liquid Propane Setup, PN-6x-T 7.5kW ............................................................... 27

Fig. 2-11, Enclosure Grounding, CE-3x2 5K-T .................................................................... 28

Fig. 2-12, Enclosure Grounding, PN-6x-T 7.5kW ................................................................ 29

Fig. 3-1, Pad Frame Template for CE-3x2 5K-T .................................................................. 30

Fig. 3-2, Pad frame and mounting template CE-3x2 5.0 kW .............................................. 31

Fig. 3-3, Cross-section of Sweep Trench ............................................................................ 32

Fig. 3-4, Pad Bolt Location, CE-3x2 5K-T ........................................................................... 34

Fig. 3-5, Lifting Ear Attachment ........................................................................................... 35

Fig. 3-6, Enclosure with Lifting Ears Installed, CE-3x2 5K-T ...............................................36

Fig. 3-7, Water Intrusion Alarm (1), Pad Shear Sensor (2), and Pad Shear Magnet (3) .....36

Fig. 3-8, PN-6x-T 7.5kW Sweep Dimensions (in inches) .................................................... 37

Fig. 3-9, Pallet Bolt Locations, PN-6x-T 7.5kW ................................................................... 38

Fig. 3-10, Enclosure with Lifting Ears Installed, PN-6x-T 7.5kW ......................................... 39

Fig. 3-11, Installation Location of Pad Shear/Magnet Assembly .........................................40

Fig. 3-12, Enclosure Grounding, CE-3x2 5K-T ....................................................................41

Fig. 3-13, Enclosure Grounding, PN-6x-T 7.5kW ............................................................... 42

Fig. 3-14, Utility Gas Service Input, CE-3x2 5K-T ............................................................... 43

Fig. 3-15, Utility Gas Service Input, PN-6x-T 7.5kW ........................................................... 44

Fig. 3-16, Propane Fuel Hookup, CE-3x2 5K-T ................................................................... 45

Fig. 3-17, Propane Fuel Hookup, PN-6x-T 7.5kW ...............................................................46

Fig, 3-18, DC Output, CE-3x2 5K-T ..................................................................................... 47

Fig. 3-19, DC Output Safety Shroud.................................................................................... 48

Fig. 3-20, DC Output Connections, PN-6x-T 7.5kW ............................................................48

Fig. 3-21, Terminal Block 2 (TB2) Position 1, 5kW .............................................................. 51

Fig. 3-22, Terminal Block 2 (TB2), PN-6x-T7.5kW ..............................................................52

6

042-288-B0-001, Rev. A

Fig. 4-1, Location of Engine Control Module (ECM) ...........................................................54

Fig. 4-2 (a), ECM LED Indicators, Switches, and Interface Connections ............................ 55

Fig. 4-2 (b), ECM Printed Circuit Boards ............................................................................ 55

Fig. 4-3, LED Indicators and Control Functions...................................................................59

Fig. 4-4, Terminal Block 1 .................................................................................................... 63

Fig. 4-5, SW5 and Fuse Locations ...................................................................................... 64

Fig. 4-6, SW5 Settings.........................................................................................................65

Fig. 4-7, ECM/APU Interconnection ................................................................................... 66

Fig. 5-1, Generator Set Master Switch and Run/Auto/Stop (RAS) Switch .......................... 70

Fig. 6-1, Ignition Battery Charger LED ................................................................................ 74

Fig. 6-2, Wiring for ECM, Ignition Battery Charger, and Ignition Battery ............................. 74

Fig. 7-1, Captive Fastener Location, CE-3x2 5K-T .............................................................. 77

Fig. 7-2, Air Filter Removal, CE-3x2 5K-T ........................................................................... 77

Fig. 7-3, Filter Replacement, PN-6x-T 7.5kW ...................................................................... 78

Fig. 7-4, Pad Shear Sensor ................................................................................................. 79

Fig. 7-5, Gas Hazard Sensor Location (Alpha P/N 744-891-20) ......................................... 80

Fig. 7-6, Ignition Battery Charger ........................................................................................ 81

Fig. 7-7, ECM ...................................................................................................................... 82

Fig. 7-8, PN-6x-T Pre-regulator Removal ............................................................................83

Fig. 7-9, PN-6x-T Switch Assembly Installed ....................................................................... 83

Fig. 7-10, Load Block, PN-6x-T 7.5kW ................................................................................ 84

Fig. 7-11, Changing Load Block Confi guration, PN-6x-T 7.5kW .........................................84

Fig. 7-12, Changing Load Block Confi guration, CE-3x2 5K-T ............................................. 85

Fig. 7-13, Primary Fuel Regulator ....................................................................................... 86

Fig. 7-14, Pre-regulator Calibration ..................................................................................... 87

Fig. 7-15, Secondary Demand Regulator ............................................................................ 87

Fig. 7-16, Manometer Connection ....................................................................................... 88

Fig. 8-1, Gas Hazard Detector Interface Connector ............................................................ 89

Fig. 8-2, Low Fuel Pressure Interface Connector ................................................................89

Fig. 8-3, Gas Solenoid Interface Connector ........................................................................ 90

Fig. 8-4, Charger Control Interface Connector .................................................................... 90

Fig. 8-5, ECM Enclosure Alarm Interface Connector...........................................................91

Fig. 8-6, Inverter Battery DC Sense Interface Connector ....................................................91

Fig. 8-7, Charger Control Interface Connector .................................................................... 92

Fig. 8-8, ECM AC Line Sense, 120/240V Interface ............................................................. 92

Fig. 8-9, APU Control Interface............................................................................................93

Fig. 8-10, ECM Connector Arrangement ............................................................................. 93

042-288-B0-001, Rev. A

7

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 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.

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.

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.

8

042-288-B0-001, 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 unconnected battery cable, can result in arcing, fi re, or possible explosion.

• A battery that shows signs of cracking, leaking or swelling must be replaced by authorized personnel
immediately 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 that is harmful to the skin and eyes. Emissions are electrolytic, and
are electrically conductive and are corrosive. Follow the Chemical Hazards notes if contact occurs.

• Do not smoke or introduce sparks in the vicinity of the batteries or natural gas/propane connections.

• Under certain overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas that is
explosive. Proper venting of the enclosure is required.

• Follow the battery manufacturer’s approved transportation and storage instructions.

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.

• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may
have developed in your body.

042-288-B0-001, Rev. A

9

Battery Safety Notes

WARNING!

Lead-acid batteries contain dangerous voltages, currents, and corrosive material. Battery
installation, maintenance, service, and replacement must only be performed by authorized
personnel.

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

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

• 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.) when 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.

• 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.

• 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 and can result in arcing,
fi re, or possible explosion.

• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by Authorized
Personnel using a battery of identical type and rating.

10

042-288-B0-001, 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 cables 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 Instructions

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.

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

or removal.

• 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.

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.

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

• Contact with liquid may cause skin and eye burns.

042-288-B0-001, Rev. A

11

Auxiliary Power Unit (APU) Notes

• While the engine is stopping, a small amount of unburned fuel may be present. Fans are used to expel
these fumes from the enclosure, but fumes 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% to 20% of the Lower Explosive Limit (LEL). 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. The reset button may be used to disable the alarm for 10 minutes at any time.

• If gas fumes are detected before running the engine, or more than 10 minutes after running the engine,
check the system for leaks and correct as necessary.

12

042-288-B0-001, Rev. A

1.0 System Overview

AlphaGen Telecom curb-side generator systems power outside plant communication networks. Every
AlphaGen system incorporates industry leading power technology, including natural gas or propane
fueling, exclusive audible noise baffl ing, remote status monitoring features, and a durable, weather
resistant enclosure construction.

This document describes the installation, operation, and maintenance of the CE-3x2 5K-T and PN-6x-T

7.5kW Telecom generators.

Features:

• Cost effective extended runtime solution for outdoor powering applications

• Quiet operation, small size, and low profi le provides for easier installation in populated areas

• Eliminates large quantities of batteries otherwise required for extended runtime

• Telecom-grade 48Vdc output

• Built-in safeguards to protect the system, operator, and public

• Safe unattended operation designed to UL2200, NFPA 37, 54, 58 & 70 standards

Fig. 1-1, PN-6x-T 7.5kW Telecom Generator

042-288-B0-001, Rev. A

Fig. 1-2, CE-3x2 5K-T Telecom Generator

13

1.0 System Overview, continued

1.1 PN-6x-T System Diagram

SR

STARTER RELAY

0

1

7

N

7

0

-1

2

LP
UE

ROUND P2-2

F

G

CRANK P2-1

.
MP

PRESS.

E

L

T

RY +
TTE

3-5 BA
P

P

I

R

OW O

OVE

L

1

1

-

7

P1

P1-10 E NGINE RUNNING

P1-2 GROUND

P1-

P1 -4 OV ER CRAN K

P1-1 GROUND

P1-3 BATTERY+

P1-6 START

P1-9 STOP

TT

N

VC

N

P

S

STP

LOP

OVT

O

RUN

BCA

Battery Charging

Regulator

HR

SM

SS

SS

SR

P

P

IGNITION MODULE

QCON1

IGN

3

NP2-1
O

NITI
IG

D
EE

P

1-12 O VERS
P

OVS

IGNITION MODULE

HR

70

GAUGES P2-6

CONTROL

PCB

SPEED SENSING

P3- 4

P3-3

AC1

AC2

STM

YEL

RED

P7- 2

M4

P2-16

7

-1

2
P

37

THROTTLE

INHIBIT FOR

P7-4

P7-1

M2

0

-2

2
P

L
NTRO

O
C

SECONDS AFTER
30

SECOND SHUTDOWN

START, THEN 5

2-18
P

13

WHT

M1

P2-19

NT

E
TM

R

ENGINE

COMP A

SW
P

HIGH OILTEM

R

D

ATO

EA

ST

3L

EATER
H

BLOCK

T
HO

LOP

LOW OIL PRESSURE SWITCH

OR
T
E
R

ARBU
C

R
E

HEAT

P7-3

M3

N

-12

-3

2

2

P

-) P

(
BAT

T
TPU

SING
N

SE

DCOU

P3-2

P3-1

DCP

DCN

C
A
+

D

B

-

+

IGNITION

BATTERY

-

C

NC

163

2

9

J4

M
EC

3

2

4

1

J9

K
C

RED

BLA

2

1

J1

34

J2

Y

2
1

ER

RGER

A

TT
BA

CH

BLACK

RED

J9

N

ER

SIO

T

A

TRU

W

N

I

N

487

5

YELLOW

1

R
EA

12

11

10

PADSHEAR

0

1

J

2

1 WATERINTRUSION

3

ORANGE

E
T

WHI

WHITE

RED

PADSH

L

SURESW

S

LOW FU E

PRE

1

2

5

678

3

4

3

1

B1
T

R
WE

O

ESS.

P

R
LP

E

AZARD
H
S

A

GASHAZARD

LOW F U

G

0

5

462

9

8

7

1

TE
WHI

BLACK

BLACK

K

GE
N

GREEN

RA

BLAC

O

1

2

Y

L

PG MOD EL

ON

L

9

12

1011

N
E
P

(See Fig. 3-12 for details)

O

OUND
R

NC

DOOR

12 V

G

4

1

11

13

12

-7

2

2-8
B

TB

T

R
O

S

123

S

A
G

HAZARD

SEN

AC SENSE

2

1

-2

2
B2-1

T

TB

TB2- 11

-13

2
B

T

TB2- 20

E

RECT

00 AM P CB

2

NEG

Y

A
EL

AC FAIL

R

B
C

W

UT
P

OUT

AUX S W

DOOR S

DOOR S W

S

S

Y

A

RM

A
AL

BYPA

6
8

REL

7

1

Fig. 1-3, PN-6x-T System Diagram

AC
V

120

1

2
345

6
7

8
9
0

1
11
12

13

4
1

15
6

1
17
18

19

20
21
2223

TB 2

C

L

A

C

N

A

G

AC

IL

AC/

FA

COM

O

AIL

AC/

F

N

/

IL
A

NC

AC

F

LPG

(12V)

G
P

(-)

L

r

OM

Doo

C

O

oor

N

D

M
R

NO

COM

MINOR

ALA
M

R

NC

MINOR

ALA

NO

MINOR

ALARM

NC

ENG

RUN

N

NO

ENG

RU

ENG

RUN

COM

BY

NC

ALM

M

BY

NO

AL

M
O

BY

ALM

C

NC

COM

MINOR

ALARM

R

M
O
C

ALARM
RM

NO

ALA

M
R
A

NC

L

MAJORMAJORMAJO

A

POS

L

COM

NC

NO

N

COM

NC

NO

2
4
3

0

9

­TB1

ECM

4
1-

CM

B
T

E

5

M

1-

C

B
T

E

-6

ECM

TB1

14

042-288-B0-001, Rev. A

1.0 System Overview, continued

1.2 CE3x2 5kW System Diagram

FUEL

SOLENOID

P8

+

IGNITION

BATTERY

-

RED

BLACK

2
1

P5

SM

BLACK
BLK
RED

CR

RED

P4-5

BATTERY HEATER MAT (OPTIONAL)

N

P4-2

P4-1

N

N

70

P3-4

P3-9

FUEL

GROUND P3-2

CONTROL

P1-1GROUND

P3-5 BATTERY +

P1-2GROUND

P1-3BATTERY +

P

N

P

N

OVC

1

2

6

J4

ECM

N

N

HR

CR

71

CRANK P3-1

P1-11OVER TEMP.

P1-9STOP

P1-6START

P1-10ENGINE RUNNING

P1-7LOW OIL PRESS.

P1-4OVER CRANK

STT

STP

LOP

OVT

RUN

4

9

5

3

7

10

CHARGER CONTROL

1

J9

2

BLK

MODULE

IGNITION

WHT

B

70

IGNC

C

P4-6

70

RUN P3-6

SPEED SENSING

PCB

CONTROL

P1-12OVER SPEED

P2-4

P2-3

OVS

AC2

AC1

TB2-7

NC

NC

12345

8

11

12

TB 1

PAD SHEAR

DOOR OPEN

WATER INTRUSION COM

PAD SHEAR COM

LOW FUEL PRESS. COM

GAS HAZARD PWR/ALRM COM

LOW FUEL PRESS.

GAS HAZARD ALARM

WATER INTRUSION

GAS HAZARD PWR (+12vFUSED)

9

5

8

6

7

4

3

1

2

10

J10

COIL

TRIGGER

STM

LK

YEL

B

P7-3

P7-2

M4

M3

P3-12

P3-16

DC OUTPUT

SENSING

P2-2

P2-1

P3-17

37

DCP

DCN

874-869-20

RELAY

POS#1

ALARM

BYPASS

TB2-20

TB2-13

TB2-11

678910

NO CONNECTION

DOOR OPEN COM

GROUND

12 VDC APU FAN

14

12

11

13

RED

WHT

P7-4

P7-1

M2

M1

P3-19

P3-20

CONTROL

THROTTLE

P3-18

13

(CATV)

(TELCOM)

11

12

J8

DC SENSE

GROUND

TB2 PWR (+12 VDC )

AC SENSE

J5

J6

5

6

1

3 LEAD

STATOR

APU COMPARTMENT

low oil pressure

high engine temp

HET

LOP

P4-7

P4-8

P4-9

P4-10

1

2

150 AMP

Fuse

(GREY)

SMH

(GREY)

123

3
1

2

BLOCK HEATER

RECTIFIER

1

2

J1

4
3
2

J2

1

CHARGER

BATTERY

BLACK

RED

ORANGE

YELLOW

INTRUSION

WATER

PAD SHEAR

LOW FUEL

1

2

PRESSURE

GREEN

123

GAS

BLACK

ORANGE

HAZARD

DETECT

Fig. 1-4, CE3x2 System Diagram

NOT USED

123

+

TB2-7

TB2-8

APU

ENCLOSURE FAN

(GREY)

SMH 175

CUSTOMER OUPUT CABLE CONNECTION

L

COM

NO
NC

RELAY

AC FAIL

DOOR SW

DOOR SW

ALARM

BYPASS

RELAY

ECM

TB1-2

1

AC

L

2

AC

N

3

AC

G

AC/

FAIL

COM

ECM

ECM

ECM

ECM

ECM

TB1-9

TB1-9

TB1-4

TB1-5

TB1-6

4
5
6
7

8

9

10
11

12

13
14

15
16

17

18

19

20
21
22
23

AC/

FAIL

AC/

FAIL

MON.

LPG

(12VDC)

MON.

LPG

(12VDC)

Door

COM

Door

NO

MINOR

ALARMNOCOM

MINOR

ALARM

NC

MINOR

ALARM

NO

ENG

RUN

ENG

RUN

RUN

ENG

ALMBYNC

ALMBYNO

ALMBYCOM

MINOR

ALARM

NC

MAJOR

ALARM

COM

MAJOR

ALARM

NO

MAJOR

ALARM

NC

NO

NC

(POS)

(NEG)

NC

NO

COM

COM

N

ECM

J5-5

ECM

J5-6

ECM

TB1-7

ECM

TB1-8

6

2

8

4

7

3

1

0

042-288-B0-001, Rev. A

15

1.0 System Overview, continued

1.3 Natural Gas System Block Diagram

CAUTION!
Do not include the generator system as part of a local gas piping system test. Damage to the

generator pre-regulator may result. The generator system is pressure tested in accordance with
NFPA standards prior to shipment.

ENGINE

Demand

Low-pressure

Regulator

CONTROLS

APU

Enclosure

Flare Coupling

(Quick-Disconnect)

Low pressure excess
flow valve (optional)

NOTE: 1 psi = 28" WC

0.5 psi (min.)

1 psi (nominal)

10 psi (max)

14" WC

(max.)

Solenoid

S

Engine must have
7" to 11" WC and 156 cubic
feet/Hr. to operate

Pre-Regulator

Maxitrol 325-3

10 psi max input

Meter

WC = Water Column H

CONTROL

Manual

Shutoff

O

2

High pressure

(optional)

excess flow valve

Fig. 1-5, Arrangement of Metered, Nominal Pressure (1-2psi) Natural Gas System

NOTE:

For added safety, a low pressure and high pressure excess fl ow valve may be installed.

ATTENTION:

Federal DOT Regulation 49 CFR Part 192.383, Excess Flow Valve Customer Notifi cation, requires gas
utilities to either voluntarily install Excess Flow Valves (EFVs) on all new home service lines or to notify
builders about EFVs’ benefi ts and availability. EFVs are installed on gas service lines during pre-construction
site work, and automatically activate when a gas line is ruptured. Excess fl ow valves should never be used as
in-line regulators. They cannot perform this function and may damage equipment.

16

Fig. 1-6, Excess Flow Valve

(above ground ¾" x 4" NPT nipple)

Alpha P/N 042-146-10

042-288-B0-001, Rev. A

1.0 System Overview, continued

1.4 Liquid Propane System Block Diagram

LP PROPANE - VAPOR WITHDRAWAL

DEMAND

LOW PRESSURE

REGULATOR

APU

ENCLOSURE

SENSOR

8oz

MAX

11"WC

BLOCK DIAGRAM

ENGINE

SOLENOI

S

LOW FUEL ALM

LOW FUEL
PRESSURE
SWITCH

CONTROLS

D

CONTROL

11"W

OUTLE

C

T

PROPANE

POST-REG

PROPANE

ENCLOSURE

LPG TANK

Fig. 1-7, LP Propane Vapor Withdrawal Block Diagram

042-288-B0-001, Rev. A

17

1.0 System Overview, continued

1.5 Specifi cations

Model CE-3x2 5.0kW

DC Output Voltage: -51.5 to -52V @ no load -51.5 to -52V @ no load
DC Output Load Regulation: 0.5V 0.5V
Output Current: 52V @96A max. 52V @ 144A max.

PN-6x-T 7.5kW

Noise

Voiceband: <54dBrnc <54dBrnc
Wideband: <100mVrms in any 3kHz bandwidth from 10k to 20mHz <100mVrms in any 3kHz bandwidth from 10k to 20mHz
Broadband: <250mVp-p from 20 to 100mHz <250mVp-p from 20 to 100mHz
Engine: 398cc, air-cooled, single OHV

RPM (Variable Speed): 2800 to 3600RPM 2100 to 3450RPM

10.5hp (using natural gas fuel)

624cc, air-cooled, twin OHV

13.1hp (using natural gas fuel)

Acoustic Noise

dBA 10' @ 100% rated load: 68.5 avg. 70.3 avg.
dBA 20' @ 100% rated load: 62.5 avg. 64.3 avg.
dBA 10' @ 70% rated load: 66.9 avg. 66.4 avg.
dBA 20' @ 70% rated load: 60.9 avg. 60.4 avg.

System Size: CE-3x PN-6x

Height (in/cm): 44/111.8 36/99.1
Width (in/cm): 26/66 39.25/99.7
Depth (in/cm): 24/61 24/61
Weight (lb/kg): 395/179.2 338/153.3

Fuel Consumption

Natural Gas: 1000BTU/ft
Propane Gas: 2520 BTU/ft

Gas Inlet Pressure: 0.5 to 2 PSI Inlet pressure

Ignition Charger Voltage: 13.5Vdc 13.5Vdc
Ignition Charger Current: 6A max. 6A max
Remote Interface Length: 50ft. max

Agency Compliance: UL2200, NFPA 37/54/58 and 70, CSA 22.2, FCC Class A UL2200, NFPA 37/54/58 and 70, CSA 22.2, FCC Class A

3

3

80ft3/hr 156ft3/hr

1.1gal/hr 1.48gal/hr

3

/hr 54ft3/hr

40ft

4.62lb/hr 6.24lb/hr

(Please contact Alpha Technologies for low pressure)

Distance depends upon proper installation, de-rating,
and wire gauge. Please contact Alpha Technologies for

remote interface length usage.

0.5 to 2 PSI Inlet pressure

(Please contact Alpha Technologies for low pressure)

25ft. max
Distance depends upon proper installation, de-rating, and
wire gauge. Please contact Alpha Technologies for remote

interface length usage.

Common to All Models

Fuel System, Controls & Monitoring: The controls and fuel system meet applicable sections of NFPA 37, 54, and 58 for automatic unattended operation of

Sensors: Gas hazard, pad shear, water intrusion & tamper
Safety shutdowns: Low oil pressure

remotely located generators. Full system control and status monitoring included

Water intrusion
Pad shear
Gas hazard (propane or Natural Gas)

Over speed
Over crank
Over temp
Low fuel pressure shutdown (Propane only

Optional Features

Optional Integrated Propane
Storage: (5kW APU only)

For locations where gas is not available, Alpha offers the CE-G propane enclosure for use with the 5kW APU system.
Contact local propane supplier for proper tank sizing. Fully CSA & NFPA compliant, and designed for curbside
applications.

18

)

042-288-B0-001, Rev. A

1.0 System Overview, continued

1.5 Specifi cations, continued

Engine Specifi cations, PN-6x-T 7.5kW

Manufacturer: Kohler
Make/model: CH20
Cycle: 4
Compression Ratio: 8:5:1
Displacement, cu. in. (cc): 38 (624)
Rated Horsepower:

(using natural gas fuel)
Engine Speed (rpm): 2100-3450
Bore, in. (mm): 3.08 (77)
Stroke, in. (mm): 2.64 (67)
Valve Train: Overhead valve
Valve Material:

Intake
Exhaust

Number of Cylinders: 2
Cylinder Block Material: Aluminum with cast iron liners
Cylinder Head Material: Aluminum
Cylinder Head Tightening Torque,

ft. lb (Nm):
Piston Rings: 2 compression, 1 oil
Crankshaft Material: Heat treated, ductile iron casting
Bearings:

Number
Type

Governor: Electronic
Starter Motor: Electric, 12Vdc, solenoid shift
Lubrication System: Full pressure
Oil Capacity:

(with fi lter and cooler), qt. (L) 2 (1.9 )
Oil Filter Tightening Torque 1/2 turn
Oil Pressure, psi (kPa): 25-35 (172-241)
Low Oil Pressure, psi (kPa): 3.5±1.5 (24.1±13.8)
Fuel Type: Natural gas or propane
Fuel Pressure, kPA (in. water): 7-11 (1.7-2.7)
Battery Voltage: 12Vdc
Battery Ground: Negative
Battery Recommendation (min.): 585 CCA @ 0ºF ( -18ºC)
Spark Plug Type:

(Kohler P/N 24 132 02-S)
Spark Plug Gap, in. (mm): 0.030 (0.75)
Spark Plug Tightening Torque, ft.

lb (Nm):
Ignition System: Capacitive discharge
Cooling System: Air cooled
High Engine Temperature, ºF (ºC): 305 (152)
Exhaust System: USFS approved spark arrestor

13.1

Steel

®

Stellite

face

30 (41)

2
Replaceable sleeve

(Champion RC12YC)

18-22 (24.4-29.8)

48Vdc Generator Set Specifi cation

Manufacturer: Kohler
Dimensions (in/mm): 21.5"L x 20"W x 21.8"H

Weight (lb/kg): 190/86
Rated* kW: 7.5
Rated Voltage:

(after rectifi er)
Rated Amps: 144 @ 52Vdc
Stator Resistance:

(ohms)
Stator Type: 3-phase, 3-lead,

Excitation Method: Permanent magnet,

Coupling Type: Direct-to-Engine
Insulation (stator): Class 180,

Winding Material: Copper
* Derate approximately 4% per 1000 ft (300m)

over 500 ft (153m) above sea level. Derate 1%
for each 10ºF (5.5ºC) increase in temperature
above 77ºF (25ºC).

546 x 508 x 554

52 ± 0.5Vdc @ no load

0.024

ungrounded

brushless

epoxy varnish,
vacuum-impregnated

042-288-B0-001, Rev. A

19

1.0 System Overview, continued

1.5 Specifi cations, continued

Engine Specifi cations, CE-3x2 5K-T

Manufacturer: Kohler
Make/model: CV14
Cycle: 4
Compression Ratio: 8:5:1
Displacement, cu. in. (cc): 24.3 (398)
Rated Horsepower:

(using natural gas fuel)
Engine Speed (rpm): 2800-3600
Bore, in. (mm): 3.43 (87)
Stroke, in. (mm): 2.64 (67)
Valve Train: Overhead valve
Valve Material:

Intake
Exhaust

Number of Cylinders: 1
Cylinder Block Material: Aluminum with cast iron liners
Cylinder Head Material: Aluminum
Piston Rings: number/type: 2 compression, 1 oil
Crankshaft Material: Heat treated, ductile iron casting
Bearings:

Number
Type

Governor: Electronic
Starter Motor: Electric, solenoid shift
Lubrication System: Full pressure
Oil Capacity:

(with fi lter and cooler), qt. (L) 2.1 (2.0)
Oil Type: summer/winter: Synthetic 5W-30
Oil Pressure, psi (kPa): 25-35 (172-241)
Low Oil Pressure, psi (kPa): 2-5 (13.8-34.5)
Fuel Type: Natural gas or propane
Fuel Pressure, kPA (in. water): 7-11 (1.7-2.7)
Battery Voltage: 12Vdc
Battery Ground: Negative
Battery Recommendation (min.): 425 CCA @ 0ºF ( -18ºC)
Spark Plug Type: Kohler P/N 24 132 03
Spark Plug Gap, in. (mm): 0.75 (0.030)
Spark Plug Tightening Torque, ft.

lb (Nm):
Ignition System: Battery/Coil
Cooling System: Integrated air cooled
High Engine Temperature, ºF (ºC): 305 (152)

10.5

Steel

®

Stellite

face

2
Replaceable sleeve

18-22 (24.4-29.8)

48Vdc Generator Set Specifi cation

Manufacturer: Kohler
Dimensions (in/mm): 24"L x 26"W x 44"H

Weight (lb/kg): 395/179
Rated* kW: 5kW
Rated Voltage:

(after rectifi er)
Rated Amps: 96 @ 52Vdc
Stator Resistance:

(ohms):
Stator Type: 3-phase, 3-lead,

Excitation Method: Permanent magnet,

Coupling Type: Direct-to-Engine
Insulation (stator): Class 155,

Winding Material: Copper
* Derate approximately 4% per 1000 ft (300m)

over 500 ft (153m) above sea level. Derate 1%
for each 10ºF (5.5ºC) increase in temperature
above 77ºF (25ºC).

546 x 508 x 554

52 ± 0.5Vdc @ no load

0.024

ungrounded

brushless

epoxy varnish,
vacuum-impregnated

20

042-288-B0-001, Rev. A

2.0 Site Preparation

2.1 Site Considerations

• Where possible, select a site away from houses, and above the 100-year fl ood plain.

• Place in a shaded location to minimize the effects of solar loading.

• Avoid locating the enclosure where it obstructs or inhibits visibility.

• Locate the enclosure away from sprinkler systems, or other sources of forced water.

• Locate the enclosure out of the prevailing wind to minimize the buildup of snow or wind­borne dust.

• Determine if soil conditions are suitable for the appropriate grounding system.

• Verify utility power cabling is terminated at the site.

• Ensure maintenance access and exhaust clearance.

• Locate the enclosure to allow for 36" of clearance around all enclosure door and exhaust
openings.

2.2 Acoustics

Nuisance noise is of concern to nearby residents. Nuisance noise is a directional noise
which can cause discomfort during engine-generator operation to nearby residential
occupants (audible levels may vary due to absorption and refl ection caused by the immediate
surroundings).

Audible impact on neighborhoods is mitigated by recent advances in muffl ers, fl ame resistant
sound materials, intake air sound attenuators, along with improved cabinet airfl ow dynamics.
The fi gures below show the measured audible levels from CE-3x2 5KW and PN-6x-T 7.5kW
generators at full load. Note the symmetry of these emissions. Deployment decisions must
include noise consideration to minimize nuisance noise.

North West

72.8dBA

West

71.9dBA

10'

South West

70.1BA

042-288-B0-001, Rev. A

North

73.0dBA
North East

Exhaus

Intake

71.4dB

t

A

East

70.0dBA

5'

South East

70.5dBA

South

72.4dBA

CE-3x2 PN-6x-T

Fig. 2-1, Generator Sound Levels at 100% Load

dB a

56. 3

64. 3

70. 3

20'

10'

50'

Feet

21

2.0 Site Preparation, continued

2.2 Acoustics, continued

20 Feet, (64 dBa)

50 Feet (56 dBa)

Fig. 2-2, Acoustical Measurements in Relation to Placement Near Residences

(generator sound levels at full load)

22

042-288-B0-001, Rev. A

2.0 Site Preparation, continued

2.3 Enclosure Impact Protection

The National Fire Protection Agency (NFPA) requires that equipment using natural gas
or liquid propane be protected, based on good engineering practices, in areas where
vehicle traffi c is normally expected at that location. The required protection is based on the
anticipated speed of the vehicles operated in that area. The NFPA does not provide specifi c
guidelines for when protection is needed or the nature of the protection. However, the intent is
to provide suffi cient protection for the equipment should contact occur by a vehicle operating
in the area at a reasonably expected speed.

Alpha Technologies, Inc. cannot anticipate all the ways a vehicle may potentially threaten an
installed generator system, or the specifi c type of protection that is appropriate for a particular
location. The determination of the threat to the equipment and the means of protection are
the responsibility of the end user of the equipment and the authority having local jurisdiction.
The following installation drawings are general recommendations and are not intended to
be specifi c guidelines for protecting the equipment. The numbers of bollard posts (or other
protection devices) depend upon equipment locations, site surveys, and traffi c patterns as
shown below in a typical installation.

Generator Protection, Vehicular Areas

Several variations of installation are possible. The diagrams provide information on the
different confi gurations and site installations. The collocated natural gas meter shown below
may require two to four bollard posts depending on location, site surveys, and traffi c patterns.
Typical bollard post construction may change based on local codes regarding pipe material,
concrete, or stanchion design.

042-288-B0-001, Rev. A

Generator

Fig. 2-3, Vehicular Area Impact Protection for Collocated Natural Gas Meter

23

2.0 Site Preparation, continued

2.3 Enclosure Impact Protection, continued

Generator Protection, Vehicular Areas, continued

The remote located natural gas meter shown below may require two to four bollard posts
depending on location, site survey, and traffi c pattern. This is a typical installation design with
gas meters supported by dual risers and located near the cabinet.

ATTENTION:

Install enclosure protection in compliance with local codes.

Generator

Fig. 2-4, Vehicular Area Impact Protection for Remote Natural Gas Meter

24

042-288-B0-001, Rev. A

2.0 Site Preparation, continued

2.4 Natural Gas Meter Confi gurations

The gas utility company should have the meter installed prior to generator arrival. Meter
confi gurations must comply with local codes. The illustrations provided are for illustrative
purposes only.

Gas Utility Box

Natural Gas Meter

Street Regulator

Manual Shutoff

Excess Flow Valve
(optional)

Street Pressure

Fig. 2-5, Collocated Natural Gas Meter Setup for CE-3x2 Generator

Natural Gas Meter

Street Regulator

Manual Shutoff

Excess Flow Valve

(optional)

Street Pressure

042-288-B0-001, Rev. A

Fig. 2-6, Collocated Natural Gas Meter Setup for PN-6x-T 7.5kW System

25

2.0 Site Preparation, continued

2.4 Natural Gas Meter Confi gurations, continued

The gas utility company should have the meter installed prior to generator arrival. Meter
confi gurations must comply with local codes. Examplesz provided are for illustrative purposes
only.

Street Regulator

Manual Shutoff

Gas Utility Box

Natural Gas Meter

Street Pressure

Fig. 2-7, Collocated CE-3x2 5K-T Generator with Remote Natural Gas Meter

Street Regulator

Manual Shutoff

Manual
shutoff required if
meter cannot be
seen

Natural Gas Meter

Excess Flow Valve
(optional)

26

Excess Flow Valve

Street Pressure

(optional)

Fig. 2-8, Remote Natural Gas Meter Setup for PN-6x-T 7.5kW Generator

042-288-B0-001, Rev. A

2.0 Site Preparation, continued

2.5 Liquid Propane Systems

For systems using liquid propane, the end user must provide a suitable LP tank. For
collocated propane enclosures, see the CE-G Series Enclosure Installation Manual, Alpha
P/N 031-093-C0-001, located at www.alpha.com.

Manual
Shutoff

Fig. 2-9, Liquid Propane Setup, CE-3x2 5K-T

Manual
Shutoff

Location

User-provided LP Tank

User-provided LP Tank

042-288-B0-001, Rev. A

(Most Common)

Fig. 2-10, Liquid Propane Setup, PN-6x-T 7.5kW

27

2.0 Site Preparation, continued

2.6 Grounding Requirements, CE-3x2 5K-T

The ground rod system is typically used in remote applications where the generator is located
away from the power supply enclosure and exposed to lightning strikes, or coincidental
surges. The wiring interface between the DC Genset and system carries a system ground to
ensure common ground between both cabinets and communication devices. The remote APU
cabinet ground rod serves only as an alternate discharge path.

NOTE:

Alpha Technologies recommends using the grounding method illustrated below. The grounding method for a particular site will be
dependant upon soil type, available space, local codes, NEC (National Electric Code), and other site- specifi c characteristics.

Alpha Technologies recommends 5 ohms minimum ground resistance between enclosure and ground rods, in accordance with IEEE
1100-1999 Powering and Grounding Electronic Equipment. NEC minimum grounding standard is 25 ohms.

Alpha Technologies assumes no responsibility or liability for failure of the installer to comply with the requirements of all applicable local
and national codes. Where allowed, exothermic welding may be used as an alternative to Burndy clamps and connectors.

6

7

5

8

4

3

1

2

Fig. 2-11, Enclosure Grounding, CE-3x2 5K-T

Service grounding (required). #6AWG Copper wire from

1

service entrance ground bar.

2

Two ground rods, 6' apart

10

(for reference only)

Burndy YGHP58C2W-3 or equivalent compression ground

6

tap connector
Terminate at ground bar

7

9

28

Lightning protection (optional). 1/2" x 8' Copper ground

3

rods, 4 places.

4

Burndy YGHP58C2W-3 or equivalent compression ground
tap connector

5

#6 bare copper wire from loop to enclosure ground bar

Terminate at ground bar

8

#6 bare copper loop terminated at each ground rod, 30” below

9

grade (min). Corrosion-proof (25 yr. life-span) connections
suitable for direct burial MUST be used

10

#2 AWG wire

042-288-B0-001, Rev. A

2.0 Site Preparation, continued

2.7 Grounding Requirements, PN-6xT 7.5kW

The ground rod system is typically used in remote applications where the generator is located
away from the power supply enclosure and exposed to lightning strikes, or coincidental
surges. The wiring interface between the DC Genset and system carries a system ground to
ensure common ground between both cabinets and communication devices. The remote APU
cabinet ground rod serves only as an alternate discharge path.

A

B

Conduit

AC In

DC Out

Ground

A

B

042-288-B0-001, Rev. A

• 8 feet long, 1/2 inch diameter copper electrode.

• To aid in serviceability, place the ground electrode outside the concrete pad’s perimeter. Consult
local utility codes for additional cabinet grounding and utility requirements.

• #6AWG bare copper wire exposed 5 feet above grade (min.) for output ground bus bar.

• Clamp #6AWG bare copper wire exposed 5 feet above grade (min.) for output ground bus bar.

Front of Enclosure

Fig. 2-12, Enclosure Grounding, PN-6x-T 7.5kW

29