AlphaGen DCX3000 Operation Manual

DCX3000 Portable Generator

Operation Manual

3.0kW, 36/48V, DC Portable Generator

Effective: September 2006

Alpha Technologies

Alpha Technologies

Power

®

AlphaGen DCX3000

3.0kW, 36/48V DC Portable Generator

Operation Manual

041-028-B0-003, Rev. C

Effective Date: September 2006

Copyright© 2006

Alpha Technologies, Inc. member of The Group

TM

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, 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

4

Table of Contents

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

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

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

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

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

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

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

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

041-028-B0-003, Rev. C

List of Figures

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

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

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

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

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

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

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

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

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

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

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

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

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

6

Safety Notes

Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference.

To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.

ATTENTION:

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

NOTE:

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

CAUTION!

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

WARNING!

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

041-028-B0-003, Rev. C

General Safety Information

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

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

• Generator must be properly grounded.

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

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

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

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

codes and regulations.

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

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

• Never operate the generator near combustible materials.

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

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

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

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

• Use only vendor-authorized repair parts.

• Do not operate generator unattended.

ATTENTION:

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

• This product is manufactured to conform to the Federal Communications Commissions (FCC) Part 15,

Class A regulations. It is intended to be used for commercial, industrial or business environments.

• This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions:

(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

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

8

1.0 Introduction

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

9

1 Status LEDs

2 Engine Switch

3 Choke

4 Fuel Valve

5 Voltmeter

6 Output Off Button

7 DC Out

8 Pull-start

9 Fuel Tank

1

5

2

3

4

6

7

8

Fig. 1-1, DCX3000 Overview

Engine Alternator Rectifier

Load

(batteries)

Controller

DC Sense Feedback

Fig. 1-2, Basic Block Diagram

041-028-B0-003, Rev. C

2.0 Specifi cations

E ngine

Fuel/Fuel Tank

Rated Power

Alternator

Output Voltage

Dual range selector

Output Regulation

Control Features

Cable Interface

Runtime

Audible Noise

Frame

Dry Weight

Dimensions

Operating Temp

Required Accessories

Agency Compliance

Optional Accessories

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

Unleaded gasoline/3.5 gallon metal tank with level gauge

2800W continuous, 3000W maximum

Permanent magnet, brushless, bearingless

36V: 39.5VDC, nominal at generator output connector

48V: 52.5VDC, nominal at generator output connector

+/-1VDC

Automatic Voltage Regulation

Electronic Governor

Overcurrent Protection

Analog voltmeter with back light

Anderson type SBE-80 connector

@25% load (48V): 15.4 hours

@25% load (36V): 17.5 hours

@100% rated load: 6.5 hours

Approximately 65dBA @ 7 meters under full load

Fully enclosed

117 lb

22" H X 17.6" W X 25.9" D (557mm x 447mm x 657mm)

5°F to 104°F (-15°C to 40°C)

Output Interface Cable: Available in 10', 30', or 50' lengths

Battery Interface Cable: Choose Ring Lug, Heavy-duty Alligator Clamp, or Y-adapter (Connects the power supply’s battery input directly to the generator. See Section 3.0 for more information)

CSA 22.2 No. 100-95

FCC part 15B Class A

CARB

UL 50, Section 30

NFPA 37, 70

EPA

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

Punch Tool Kit for Enclosures, 2.5" dia: P/N 745-131-20

Enclosure Upgrade Kit: P/N 745-131-21

Cable Bag and Cable Key Lanyard: P/N 745-764-21

Locking Handle: P/N 745-792-20

NOTE:

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

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

3.0 Battery Cable Connections

3.1 Enclosures with Generator Access Door

Tools and Materials Needed:

• Portable Generator Battery Cable Kit

Procedure:

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

2. Observing polarity (red to positive, black to negative), connect the Battery Pack

Adapter Cable to the connections located in Step 1. Attach Ring Lug or Alligator Clamp connections directly to the battery post. See Fig. 3-5 and Fig. 3-6 for Novus-style and Ystyle connections. Do not connect the extension cable to the DC OUT jack on the

front panel of the generator at this time.

3. Route the extension cable (10’, 30’, or 50’) into the enclosure’s battery compartment.

Protect cable from chafi ng against sharp edges.

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

191-10).

CAUTION!

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

10

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

041-028-B0-003, Rev. C

3.0 Battery Cable Connections, continued

3.2 Enclosures without Generator Access Door


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

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

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

• #2 Phillips screwdriver

WARNING!

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

Procedure:

1. If not previously installed, punch or cut a 2.5” hole in the enclosure (shown below) to route the generator’s battery cable. Ensure area is clear of electrical wires and boxes.

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

3. Using the #7 or #9 drill bit, drill a hole approximately 2” below and to one side of the grommet, attach the lanyard on the inside of the enclosure with the #10 bolt and nut provided.

Suggested location of battery cable hole for PWE enclosures

Fig. 3-2, Enclosure without Generator Access Door

Hole for lanyard bolt

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


12

Extension Cable Set,

50’ P/N 875-324-21

30’ P/N 875-324-20

10’ P/N 875-324-22

3

Red

2

Fuse

1

Alligator Clamp-style

Battery Pack Adapter Cable,

P/N 874-946-20

Black

Ensure clamps lay fl at against batteries, facing inward

Fig. 3-3, Alligator Clamp-style Connection

041-028-B0-003, Rev. C


041-028-B0-003, Rev. C


50’ P/N 875-324-21

30’ P/N 875-324-20

10’ P/N 875-324-22

3

Red

2

Ring Lug-style

Battery Pack Adapter Cable,

P/N 874-946-21

Fuse

1

Black

Cable rings connect directly to the battery terminals

Fig. 3-4, Ring Lug-style Connection

13

14


EXT GENERATOR

Circuit Breaker must be CLOSED

GENERATOR

BREAKER

60A

CONVENIENCE FROM XT1

UPS

BYPAS

S

HEATING PADS

Novus Power

Panel

BLACK RED

Novus-style

Battery Pack Adapter Cable

P/N 875-324-23


50’ P/N 875-324-21

30’ P/N 875-324-20

10’ P/N 875-324-22

Fig. 3-5, Novus-style Connection

OUTPUTS

041-028-B0-003, Rev. C



50’ P/N 875-324-21

30’ P/N 875-324-20

10’ P/N 875-324-22

3

2

Fuse

1

Fig. 3-6, Y-style Connection

041-028-B0-003, Rev. C

Y-style

Battery Pack Adapter Cable

P/N 874-946-22

15


3.3 Grounding


#8AWG copper ground wire and clamps

Procedure:

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

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

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

WARNING!

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

Generator Grounding Lug

16

Fig. 3-7, Generator Grounding

041-028-B0-003, Rev. C


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

Power Meter

041-028-B0-003, Rev. C

Ground Stake

Ground Wire

Fig. 3-8, Overview of PWE Installation

17

18

4.0 Starting the Engine

Prior to starting the generator, review the Safety Information on page 6 of this manual.

Set the generator on a fl at, level surface, free of standing or running water, or combustible materials.

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

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


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

Procedure:

1. Verify fuel is in the fuel tank.

2. Open the maintenance cover on the left side panel of the generator.

Set the Voltage Select switch to match the battery pack voltage (36V or

48V). Close cover before starting engine.

Voltage Select Switch

3. Verify polarity and battery voltage continuity on extension cables.

Connect the extension cable coupler to the DC OUT jack on the generator. Verify the voltmeter indicates the voltage of the battery pack.

NOTE:

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

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

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

6. Turn the FUEL VALVE to the ON position.

7. Pull the starter handle (right side panel) until the engine starts. Verify the OUTPUT INDICATOR

LED is a steady green (not blinking). If the OUTPUT INDICATOR LED is fl ashing red, a voltage mis-match has occurred, or the battery pack is excessively discharged. Refer to the voltage table on page 19 for more information.

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

OUTPUT INDICATOR LED

(Step 7)

DC OUT

(Step 3)

ENGINE SW

(Step 4)

CHOKE

(Steps 5, 8)

FUEL VALVE

(Step 6)

Fig. 4-1, Starting the Engine

041-028-B0-003, Rev. C

4.0 Starting the Engine, continued

Battery Voltage

1

0V to 2V

2V to 27V

27V to 42V

42V to 55V

>56V

Voltage Select

Switch Position

36V

48V

36V

48V

36V

48V

36V

48V

36V

48V

Output Indicator

(Green LED)

OFF

OFF

OFF

OFF

ON

OFF

OFF

ON

OFF

OFF

Overload Alarm

(Red LED)

OFF

OFF

FLASHING

FLASHING

OFF

FLASHING

FLASHING

OFF

FLASHING

FLASHING

Forced Output

2

Not Available

Not Available

ENABLED

ENABLED

Not Available

ENABLED

Not Available

Not Available

Not Available 3

Not Available 3

1 All battery voltage measurements are ± 1V

2 To enable forced output when the Overload Alarm LED is fl ashing, press the output button for at least 5 seconds. The Overload Alarm LED stops fl ashing. Release the output button, and then press it again for at least fi ve seconds. The Output Indicator LED turns on steady, and power output begins. The operator may then release the output button.

3 Engine shuts down after 1 second.

Table 4-1, Battery Voltage and Output Indications

NOTE:

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

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

4.0, Starting the Engine.

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

20

5.0 Engine Shut-Down and Cable Removal

WARNING!

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

Procedure:

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

2. Turn the ENGINE SW OFF.

3. Turn the FUEL VALVE OFF.

4 Disconnect the battery pack adaptor from the extension cable.

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

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

7. Remove #8AWG copper ground wire.

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

CAUTION!

Drain fuel system before extended storage. Inspect fuel system and cable sets prior to restarting generator after extended storage.

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

5.3 Transporting the Generator

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

STORAGE section.

041-028-B0-003, Rev. C

5.0 Engine Shut-Down and Cable Removal, continued


• 10mm and 8mm socket

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

Procedure:

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

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

3. Locate the fuse cover below the OUTPUT SW.

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

Remove the cover.

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

3.2 to 6.4 N m

2.4 to 4.7 ft-lbs.

28 to 56 in-lbs.

041-028-B0-003, Rev. C

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

21

6.0 Maintenance Record

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

Maintenance Record

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

Serial Number Model Number

Date

Hour

Meter

Action Initials

22 041-028-B0-003, Rev. C

®

Alpha Technologies

Power

Alpha Technologies

3767 Alpha Way

Bellingham, WA 98226

USA

Tel: +1 360 647 2360

Fax: +1 360 671 4936

Web: www.alpha.com

Alpha Technologies Ltd.

4084 McConnell Court

Burnaby, BC, V5A 3N7

CANADA

Tel: +1 604 430 1476

Fax: +1 604 430 8908

Alpha Technologies

Europe Ltd.

Twyford House

Thorley

Bishop's Stortford

Hertfordshire

CM22 7PA

UNITED KINGDOM

Tel: +44 01279 501110

Fax: +44 01279 659870

Alpha Technologies GmbH

Hansastrasse 8

D 91126 Schwabach

GERMANY

Tel: +49 9122 79889 0

Fax: +49 9122 79889 21

Alphatec, Ltd

P.O. Box 56468

Limassol, Cyprus

CYPRUS

Tel: +357 25 375675

Fax: +357 25 359595

AlphaTEK ooo

Khokhlovskiy Pereulok 16

Stroenie 1

109028 Moscow

RUSSIA

Tel: +7 495 916 1854

Fax: +7 495 916 1349

Alphatec Baltics

S. Konarskio G. 49

Vilnius 2009

LITHUANIA

Tel: +350 5 210 5291

Fax: +350 5 210 5292

Alpha Technologies

5 Avenue Victor Hugo

F 92140 Clamart France

FRANCE

Tel: +33 1 41 90 07 07

Fax: +33 1 41 90 93 12

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

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

AlphaGen DCX3000 Operation Manual

DCX3000 Portable Generator

Operation Manual

3.0kW, 36/48V, DC Portable Generator

Effective: September 2006

Alpha Technologies

Power