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

PowerAlpha Technologies ®

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 GroupTM

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.

Contacting Alpha Technologies: www.alpha.com

or

For general product information and customer service (7 AM to 5 PM, Pacific Time), call

1-800-863-3930,

For complete technical support, call

1-800-863-3364

7 AM to 5 PM, Pacific 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 .................................................................................................	Speci fi 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 Con fi 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 Classifications......................................................................................	60
	4.6	ECM Alarm Overview.....................................................................................	62
	4.7	Connecting the Alarm and Control Connections............................................	63
	4.8	ECM DIP Switch and Fuse Configuration ......................................................	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 Verification...........................................................	71
		5.4.1 Enclosure Alarm Verification ...............................................................	71
		5.4.2 AC and DC Line Sense Verification ....................................................	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 Configuration, PN-6x-T 7.5kW .........................................	84
Fig. 7-12, Changing Load Block Configuration, 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 specific regulatory/code requirements that may affect the placement of equipment and installation procedures.

NOTE:

A NOTE provides additional information to help complete a specific 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, fire, 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 flames 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, fire, 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 specified 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 specified 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 flame around gas lines. Propane and natural gas are extremely flammable, and explosive at high concentrations. Large releases can create a flammable 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 flash. 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 baffling, 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 profile 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

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

042-288-B0-001, Rev. A

13

14

A .Rev 001,-B0-288-042

BATTERY				1
CHARGER				J1
				2
	J2
1	2	3	4

BLACK

RED

WATER

PAD SHEAR

INTRUSION

YELLOW

ORANGE

Fig

LOW FUEL

WHITE

PRESSURE SW

RED

WHITE

.

LPG MODEL

BLACK

1

ONLY

1

BLACK

-

WHITE

3,

2

GREEN

-PN

BLACK

ORANGE

6x

1 23

TB2-8

TB2-7

T-

DOOR SW

DiagramSystem

GAS

HAZARD

SENSOR

TB2-1

TB2-2

ALARM

BYPASS

RELAY

DOOR SW

OUTPUT CB

AC FAIL

AUX SW

1

6 8 7

RELAY

NO

COM

NC

0

2 4 3

NO

NC

COM

N

L

ECM

ECM

ECM

ECM

TB1-6 TB1-5

TB1-4 TB1-9

23 22 21 20 19 18 17 16 15 14 13 12 11 10

9

8

7

6

5

4

3

2

1

MAJOR MAJOR MAJOR MINOR

ALM

ALM

ALM

ENG

ENG

ENG

MINOR

MINOR

MINOR

Door

Door

LPG

LPG

AC/

AC/

AC/

AC

AC

AC

ALARM ALARM ALARM ALARM BY

BY

BY

RUN

RUN

RUN

ALARM

ALARM

ALARM

NO

COM

( - )

(12V )

FAIL

FAIL

FAIL

G

N

L

NC

NO

COM

NC

COM

NO

NC

COM

NO

NC

NO

NC

NO

NC

NO

COM

COM

COM

RED

BLACK

- +

IGNITION

BATTERY

	4	ECM
	J9
	3		J4
	2		2
	1		6
			1
	J9		9
			5
	1
			3
	2		7
	J10		10
			4
	1	WATER INTRUSION	8
			11	NC
	2
			12	NC
	3	PADSHEAR
	4
	5	LOW FUELPRESS.	1
	6		3
	7	GAS HAZARD	TB 1
	8
	9	GAS HAZARDP OWER	1
	10	DOOR OPEN
			2
	11
		NC	3
	12		4
	13	12 V
			5
	14	GROUND
			6
			7
		(See Fig. 3-12 for details)
			8
			9
			10

11

12

1

2 AC SENSE

TB2-20

TB2-13

TB2-11

- B	+	A
E	D	C

RECT

200 AMP CB

NEG

POS

120VAC

TB 2

Battery Charging			BCA
Regulator
P		SS
		SR
P		SM
		SS
								HR
P	P3-5	BATTERY +	GROUND P2-2		N
N	P1-1	GROUND	FUEL	P2-10	70
N	P1-2	GROUND
P	P1-3	BATTERY +
OVC	P1-4	OVER CRANK
STT	P1-6	START	CRANK	P2-1	71			SR
LOP	P1-7	LOW OILPRESS.						STARTER RELAY
STP
	P1-9	STOP
RUN
	P1-10 ENGINE RUNNING
OVT	P1-11 OVER TEMP.
OVS	P1-12 OVERSPEED					QCON1
					IGN
			IGNITION	P2-13				IGNITION MODULE
		CONTROL						IGNITION MODULE
		PCB
AC1	P3-4	SPEED SENSING	GAUGES	P2-6	70
AC2						HR
	P3-3
DCN	P3-1		BAT ( -)	P2-3	N
		DCOUTPUT				P7-3
DCP	P3-2
		SENSING		P2-12	M3
				P2-16	M4	P7-2	YEL	STM
37
	P2-17
	INHIBIT FOR		THROTTLE
	30SECONDS AFTER		CONTROL			P7-4
	START, THEN 5			P2-20	M2		RED
	SECOND SHUTDOWN
13
	P2-18					P7-1
				P2-19	M1		WHT
	ENGINE
HIGH OIL TEMPSW	COMPARTMENT
HOT
LOP
					3LEAD
					STATOR
LOW OIL PRESSURE SWITCH

BLOCK HEATER

CARBURETOR

HEATER

Diagram System T-6x-PN 1.1

continued Overview, System 0.1

B0-288-042

0.1

-

A .Rev 001,

BATTERY

J1

RED

Diagram System 5kW CE3x2 2.1

continued Overview, System

1

Diagram System CE3x2 4,-1 .Fig

CHARGER

2

BLACK

J2

+

1

2 3 4

-

FUEL

IGNITION

SOLENOID

BATTERY

RED

BLK

P8

BATTERY HEATER MAT (OPTIONAL)

RED

BLACK

P5

BLACK

RED

P4-5

SM

CR

ECM

J4

P

P3-5 BATTERY +

FUEL P3-9

70

WATER

CONTROL P3-4

N

P4-2

2

N

P1-1GROUND

GROUND P3-2

N

N

6

N

P1-2GROUND

INTRUSION

1

P

P1-3BATTERY +

P4-1

J9

9

OVC

P1-4OVER CRANK

CRANK P3-1

71

CR

N

PAD SHEAR

YELLOW

STT

5

P1-6START

N

ORANGE

1

CHARGER CONTROL

3

LOP

P1-7LOW OIL PRESS.

2

7

STP

P1-9STOP

HR

J10

10

RUN

P1-10ENGINE RUNNING

LOW FUEL

4

OVT

P1-11OVER TEMP.

1

WATER INTRUSION

8

OVS

P1-12OVER SPEED

P4-6

70

PRESSURE

2

WATER INTRUSION COM

11

NC

RUN P3-6

70

3

PAD SHEAR

12

NC

CONTROL

B

IGNITION

1

4

PAD SHEAR COM

C

MODULE

GAS

5

LOW FUEL PRESS.

GREEN

2

6

LOW FUEL PRESS. COM

PCB

HAZARD

7

GAS HAZARD ALARM

BLK

BLACK

AC1

IGNC

WHT

ORANGE

8

GAS HAZARD PWR/ALRM COM

TB 1

P2-4

DETECT

9

TB2-7

AC2

GAS HAZARD PWR (+12vFUSED)

1

P2-3 SPEED SENSING

NOT USED

10

DOOR OPEN

2

ALARM

DCN

P2-1

11

DOOR OPEN COM

3

DC OUTPUT

TRIGGER

12

NO CONNECTION

4

BYPASS

DCP

P2-2

P3-12

M3

P7-3 BLK

+

FAN

5

RELAY

SENSING

COIL

13

12 VDC APU

6

POS#1

14

GROUND

7

TB2-11

P3-16

M4

P7-2

YEL

STM

8

TB2-13

37

123

123

9

TB2-20

P3-17

1 2

10

THROTTLE

J5

11

(CATV)

12

CONTROL

5

TB2 PWR (+12 VDC )

20869874--

P3-20

M2

P7-4

RED

TB2-7

6

GROUND

APU

TB2-8

(TELCOM)

13

P3-18

M1

P7-1

WHT

J6

P3-19

ENCLOSURE FAN

J8

1 AC SENSE

DC SENSE

123

P4-10

P4-8

7

2

1 3

P4-9

-

P4

APU COMPARTMENT

2 1

150 AMP

HET

high

engine

temp

CUSTOMER OUPUT CABLE CONNECTION

Fuse

DOOR SW

SMH

LOP

ALARM

low oil pressure

3 LEAD

STATOR

BYPASS

RELAY

DOOR SW

AC FAIL

RECTIFIER

RELAY

BLOCK HEATER

NC NO

COM

L

ECM

TB1-2

6 8 7

N

1

0

2 4 3

ECM

ECM

TB1-8

TB1-7

ECM

ECM

J5-6

J5-5

ECM ECM

ECM ECM

ECM

TB1-6 TB1-5

TB1-4 TB1-9

TB1-9

23222120 1918 171615141312 1110 9

8

7

6

5 4

3

2

1

MAJOR	MAJOR MAJOR	MINOR	ALM	ALM	ALM	ENG	ENG
ALARM	ALARM ALARM	ALARM	BY	BY	BY	RUN	RUN
NC	NO COM	NC	COM	NO	NC
		COM				COM	NO

ENG	MINOR MINOR MINOR			Door	Door LPG		LPG	AC/	AC/	AC/
RUN	ALARM ALARM ALARM			NO	COM	MON.	MON.	FAIL FAIL		FAIL
NC	NO	NC	NO			(12VDC) (12VDC)			NO	COM
			COM			(NEG)	(POS)	NC

AC AC AC G N L

15

1.0System Overview, continued

1.3Natural 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	CONTROLS
Regulator

	14" WC	CONTROL
	(max.)
	APU	Solenoid
		S
	Enclosure

Flare Coupling (Quick-Disconnect)

Engine must have

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

Pre-Regulator

Maxitrol 325-3

10 psi max input

Low pressure excess	Meter	Manual
flow valve (optional)
NOTE: 1 psi = 28" WC
0.5 psi (min.)		Shutoff
1 psi (nominal)
10 psi (max)			High pressure excess flow valve
	WC = Water Column H2O		(optional)

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

NOTE:

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

ATTENTION:

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

Fig. 1-6, Excess Flow Valve

(above ground ¾" x 4" NPT nipple)

Alpha P/N 042-146-10

16	042-288-B0-001, Rev. A

1.0System Overview, continued

1.4 Liquid Propane System Block Diagram

LP PROPANE - VAPOR WITHDRAWAL

		BLOCK DIAGRAM
		ENGINE
DEMAND
LOW PRESSURE		CONTROLS
REGULATOR
	8oz
	MAX	SOLENOID
		S	CONTROL
APU	11"WC	LOW FUEL ALM
ENCLOSURE
		LOW FUEL
SENSOR		PRESSURE
		SWITCH

11"WC

OUTLET PROPANE POST-REG

PROPANE

ENCLOSURE

LPG TANK

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

042-288-B0-001, Rev. A

17

1.0System Overview, continued

1.5 Specifications

Model	CE-3x2 5.0kW	PN-6x-T 7.5kW
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.
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	624cc, air-cooled, twin OHV
	10.5hp (using natural gas fuel)	13.1hp (using natural gas fuel)
RPM (Variable Speed):	2800 to 3600RPM	2100 to 3450RPM
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/ft3	80ft3/hr	156ft3/hr
Propane Gas: 2520 BTU/ft3	1.1gal/hr	1.48gal/hr
	40ft3/hr	54ft3/hr
	4.62lb/hr	6.24lb/hr
Gas Inlet Pressure:	0.5 to 2 PSI Inlet pressure	0.5 to 2 PSI Inlet pressure
	(Please contact Alpha Technologies for low pressure)	(Please contact Alpha Technologies for low pressure)
Ignition Charger Voltage:	13.5Vdc	13.5Vdc
Ignition Charger Current:	6A max.	6A max
Remote Interface Length:	50ft. max	25ft. max
	Distance depends upon proper installation, de-rating,	Distance depends upon proper installation, de-rating, and
	and wire gauge. Please contact Alpha Technologies for	wire gauge. Please contact Alpha Technologies for remote
	remote interface length usage.	interface length usage.
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
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
	remotely located generators. Full system control and status monitoring included
Sensors:	Gas hazard, pad shear, water intrusion & tamper
Safety shutdowns:	Low oil pressure	Over speed
	Water intrusion	Over crank
	Pad shear	Over temp
	Gas hazard (propane or Natural Gas)	Low fuel pressure shutdown (Propane only)
Optional Features
Optional Integrated Propane	For locations where gas is not available, Alpha offers the CE-G propane enclosure for use with the 5kW APU system.
Storage: (5kW APU only)	Contact local propane supplier for proper tank sizing. Fully CSA & NFPA compliant, and designed for curbside
	applications.

18	042-288-B0-001, Rev. A

1.0System Overview, continued 1.5 Specifications, continued

Engine Specifications, 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:	13.1
(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	Steel
Exhaust	Stellite® face
Number of Cylinders:	2
Cylinder Block Material:	Aluminum with cast iron liners
Cylinder Head Material:	Aluminum
Cylinder Head Tightening Torque,	30 (41)
ft. lb (Nm):
Piston Rings:	2 compression, 1 oil
Crankshaft Material:	Heat treated, ductile iron casting
Bearings:
Number	2
Type	Replaceable sleeve
Governor:	Electronic
Starter Motor:	Electric, 12Vdc, solenoid shift
Lubrication System:	Full pressure
Oil Capacity:
(with filter 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:	(Champion RC12YC)
(Kohler P/N 24 132 02-S)
Spark Plug Gap, in. (mm):	0.030 (0.75)
Spark Plug Tightening Torque, ft.	18-22 (24.4-29.8)
lb (Nm):
Ignition System:	Capacitive discharge
Cooling System:	Air cooled
High Engine Temperature, ºF (ºC):	305 (152)
Exhaust System:	USFS approved spark arrestor

48Vdc Generator Set Specification

Manufacturer:	Kohler
Dimensions (in/mm):	21.5"L x 20"W x 21.8"H
	546 x 508 x 554
Weight (lb/kg):	190/86
Rated* kW:	7.5
Rated Voltage:	52 ± 0.5Vdc @ no load
(after rectifier)
Rated Amps:	144 @ 52Vdc
Stator Resistance:	0.024
(ohms)
Stator Type:	3-phase, 3-lead,
	ungrounded
Excitation Method:	Permanent magnet,
	brushless
Coupling Type:	Direct-to-Engine
Insulation (stator):	Class 180,
	epoxy varnish,
	vacuum-impregnated
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).

042-288-B0-001, Rev. A

19

1.0System Overview, continued 1.5 Specifications, continued

Engine Specifications, 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:	10.5
(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	Steel
Exhaust	Stellite® face
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	2
Type	Replaceable sleeve
Governor:	Electronic
Starter Motor:	Electric, solenoid shift
Lubrication System:	Full pressure
Oil Capacity:
(with filter 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.	18-22 (24.4-29.8)
lb (Nm):
Ignition System:	Battery/Coil
Cooling System:	Integrated air cooled
High Engine Temperature, ºF (ºC):	305 (152)

48Vdc Generator Set Specification

Manufacturer:	Kohler
Dimensions (in/mm):	24"L x 26"W x 44"H
	546 x 508 x 554
Weight (lb/kg):	395/179
Rated* kW:	5kW
Rated Voltage:	52 ± 0.5Vdc @ no load
(after rectifier)
Rated Amps:	96 @ 52Vdc
Stator Resistance:	0.024
(ohms):
Stator Type:	3-phase, 3-lead,
	ungrounded
Excitation Method:	Permanent magnet,
	brushless
Coupling Type:	Direct-to-Engine
Insulation (stator):	Class 155,
	epoxy varnish,
	vacuum-impregnated
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).

20	042-288-B0-001, Rev. A

2.0Site Preparation

2.1Site Considerations

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

2.2Acoustics

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 reflection caused by the immediate surroundings).

Audible impact on neighborhoods is mitigated by recent advances in mufflers, flame resistant sound materials, intake air sound attenuators, along with improved cabinet airflow dynamics. The figures 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
	73.0dBA
North West		North East
72.8dBA		71.4dBA
West	Exhaust	East
71.9dBA	Intake	70.0dBA
5'
10'
South West		South East
70.1BA		70.5dBA

South 72.4dBA

dB a 56. 3

64.3

70.3

10'

20'

50' Feet

CE-3x2	PN-6x-T
	Fig. 2-1, Generator Sound Levels at 100% Load
042-288-B0-001, Rev. A	21

2.0Site 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

2.0Site Preparation, continued

2.3Enclosure 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 traffic 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 specific guidelines for when protection is needed or the nature of the protection. However, the intent is to provide sufficient 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 specific 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 specific guidelines for protecting the equipment. The numbers of bollard posts (or other protection devices) depend upon equipment locations, site surveys, and traffic 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 configurations and site installations. The collocated natural gas meter shown below may require two to four bollard posts depending on location, site surveys, and traffic patterns. Typical bollard post construction may change based on local codes regarding pipe material, concrete, or stanchion design.

Generator

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

042-288-B0-001, Rev. A

23

2.0Site Preparation, continued

2.3Enclosure 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 traffic 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

2.0Site Preparation, continued

2.4Natural Gas Meter Configurations

The gas utility company should have the meter installed prior to generator arrival. Meter configurations 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							Street Pressure
(optional)

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

042-288-B0-001, Rev. A

25

2.0Site Preparation, continued

2.4Natural Gas Meter Configurations, continued

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

Street Regulator

Manual Shutoff

Gas Utility Box

Natural Gas Meter

Excess Flow Valve

(optional)

Street Pressure

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

Street Regulator

Manual Shutoff

Natural Gas Meter

Manual

shutoff required if meter cannot be seen

Excess Flow Valve

(optional)

Street Pressure

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

26	042-288-B0-001, Rev. A

2.0Site Preparation, continued

2.5Liquid 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	User-provided LP Tank
	Shutoff

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

Manual

Shutoff User-provided LP Tank

Location

(Most Common)

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

042-288-B0-001, Rev. A

27

2.0Site Preparation, continued

2.6Grounding 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 sitespecific 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
5	7
	8
4	9

3

1

10

2

1

2

3

4

5

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

(for reference only)

	Service grounding (required). #6AWG Copper wire from	6	Burndy YGHP58C2W-3 or equivalent compression ground
	service entrance ground bar.		tap connector
	Two ground rods, 6' apart	7	Terminate at ground bar
	Lightning protection (optional). 1/2" x 8' Copper ground	8	Terminate at ground bar
	rods, 4 places.		#6 bare copper loop terminated at each ground rod, 30” below
		9
	Burndy YGHP58C2W-3 or equivalent compression ground		grade (min). Corrosion-proof (25 yr. life-span) connections
	tap connector		suitable for direct burial MUST be used
	#6 bare copper wire from loop to enclosure ground bar	10	#2 AWG wire

28	042-288-B0-001, Rev. A

2.0Site Preparation, continued

2.7Grounding 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

Front of Enclosure

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.

B• #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.

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

042-288-B0-001, Rev. A

29