Qnergy PowerGen 5650 Series Installation & Operation Manual Download Page 16

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AFETY

2.4 DEFINITION OF ACRONYMS

Below is a table with a list of common acronyms that are used in this manual.

Table 2-1 Definitions of Acronyms

Acronym

Definition

D I/O

Digital Inputs/Outputs

FPSE

Free Piston Stirling Engine

HRU

Heat Rejection Unit

LUI

Local User Interface

P&ID

Piping & Instrumentation Diagram

PCK80

Power Conversion Kit, 80 tubes

QB80

Qnergy “B” Series, 80 tubes (Stirling Engine)

PIP

Power Interface Package

QEC

Qnergy Engine Controller

QRP

Qnergy Remote Power

Remote Power

FPC

Fueled Products Controller

FEB

FPC Expansion Board

GCU

Gas Conditioning Unit

GHT

Glycol Heat Trace

VFD

Variable Speed Drive

Tamb

Ambient Temperature

Low Temperature Option (-40C)

Summary of Contents for PowerGen 5650 Series

Page 1: ...7045 102089 000 June 1 2021 Installation Operation Manual FOR A QUALIFIED INSTALLER...

Page 2: ...this publication may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording scanning or using any information storage and retrieval system...

Page 3: ...E 58 8 TRANSPORTATION REQUIREMENTS 58 9 SITE PREPARATION REQUIREMENTS 60 9 1 FLOOR 60 9 2 GAS SUPPLY 61 10 UNPACKING PROCEDURE 62 11 INSTALLATION PROCEDURE 62 11 1 SAFETY DURING INSTALLATION 62 11 2 T...

Page 4: ...TRUCTIONS 144 17 4 BURNER BURNER CERAMIC BURNER SEAL REPLACEMENT 147 17 5 JUMP START PROCEDURE 148 18 SPARE PARTS 149 18 1 SPARE PARTS 149 19 POWERGEN REPORTS AND CHECKLISTS 155 19 1 INSTALLATION SEQU...

Page 5: ...ooling 31 Table 6 6 FPC Data Hall Sensor 32 Table 6 7 FPC Data Burner 33 Table 6 8 FPC Data Networking 33 Table 6 9 FPC Data Ignitions 34 Table 6 10 FPC Data FEB GPIOs 34 Table 6 11 FPC Data FPC GPIOs...

Page 6: ...lock De scription 69 Table 12 1 Target Charging Pressure 82 Table 12 2 FEB I O Inputs Defined 96 Table 12 3 FEB I O Outputs Defined 97 Table 12 4 Modbus General 98 Table 12 5 Modbus System Faults Warn...

Page 7: ...ment 154 Table 18 20 Kit Engine Vibration Isolators Replacement 154 Table 19 1 Installation Checklist 155 Table 19 2 Safety Checks and Basic Information 155 Table 19 3 General Information Commissionin...

Page 8: ...iv...

Page 9: ...re 6 5 FPC Data Temperature 29 Figure 6 6 FDC Data Generator 30 Figure 6 7 FDC Data Cooling 31 Figure 6 8 FDC Data Hall Sensor 32 Figure 6 9 FDC Data Burner 33 Figure 6 10 FDC Data Networking 33 Figur...

Page 10: ...ure 6 53 Qnergy Lynx Setpoints Modified Condition 55 Figure 6 54 Qnergy Lynx Setpoints Illegal Condition 55 Figure 6 55 Qnergy Lynx Setpoints Acceptable Values 55 Figure 6 56 FPC FEB QEC Firmware Tab...

Page 11: ...onfiguration Tab Minimum Engine Power 93 Figure 12 25 FEB GPIO Configuration 95 Figure 12 26 FEB Inputs Outputs and LD Disconnect Locations 98 Figure 12 27 Qnergy Lynx QEC Configuration Tab 108 Figure...

Page 12: ...iv Figure 21 9 ATS Enclosure 179 Figure 21 10 Battery Connection Schematic 181...

Page 13: ...Y DISREGARDING THE CONTENTS OF THIS MANUAL 2 SAFETY 2 1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for installing the PowerGen that should be fol...

Page 14: ...ell of gas If possible open doors and windows fully and ensure air is circulating Avoid the use of bare flames e g lighters and matches Do not smoke Do not use any electrical switches plugs doorbells...

Page 15: ...ith a cap Emissions Depending on the installation and operating conditions the sound pressure level may exceed 70 dB A Risk of noise induced hearing loss Take appropriate technical safety measures Pro...

Page 16: ...Rejection Unit LUI Local User Interface P ID Piping Instrumentation Diagram PCK80 Power Conversion Kit 80 tubes QB80 Qnergy B Series 80 tubes Stirling Engine PIP Power Interface Package QEC Qnergy Eng...

Page 17: ...nt values at electric power outputs of up to 5 650 Watts of electricity In addition to electricity a secondary product of the generator is up to 24 kW of thermal heat which can be utilized for area he...

Page 18: ...ral Gas Propane 1 433 3 964 ft day 15 2 44 4 gal day Max Fuel Consumption STP PG1800 Dry Natural Gas Propane 1 300 ft day 10 gal day Max Fuel Consumption STP PG1200 Dry Natural Gas Propane 935 ft day...

Page 19: ...sed analysis 2 Storage is allowed down to 13 F 25 C 3 Beyond 5 000ft power output will de rate by 5 per 1 000ft 4 RP Base Unit voltage Power Interface Package PIP voltage per PIP design 5 Minimal main...

Page 20: ...tput A N A B 263VDC to 365VDC or 110 to 120 VAC 50 60 Hz Up to 25 0Amps per output 4 Power Range A N A B 263VDC to 365VDC or 110 to 120 VAC 50 60 Hz Up to 25 0Amps per output 5 Gas Codes N Non corrosi...

Page 21: ...SYSTEM INTRODUCTION 9 3 1 2 PowerGen Data Plates Figure 3 2 PowerGen Data Plate 5650 Figure 3 3 PowerGen Data Plate 1200...

Page 22: ...60Hz 5 65kW 5 1kW 3 wire L1 L2 Common Neutral A 0 B 0 D 120V 240VAC 2 Phase Output A 120VAC 60Hz Output B 240VAC 50Hz or 60Hz 5 65kW 5 1kW 3 wire L1 L2 Common Neutral A 0 B 180 E 240VAC SYNC Output A...

Page 23: ...z 1 8kW 3 wire L1 L2 Common Neutral A 0 B 0 D 120V 240VAC 2 Phase Output A 120VAC 60Hz Output B 240VAC 50Hz or 60Hz 1 8kW 3 wire L1 L2 Common Neutral A 0 B 180 E 240VAC SYNC Output A 240VAC 50Hz or 60...

Page 24: ...z 1 2kW 3 wire L1 L2 Common Neutral A 0 B 0 D 120V 240VAC 2 Phase Output A 120VAC 60Hz Output B 240VAC 50Hz or 60Hz 1 2kW 3 wire L1 L2 Common Neutral A 0 B 180 E 240VAC SYNC Output A 240VAC 50Hz or 60...

Page 25: ...1 L2 Common Neutral A 0 B 180 B 120VAC SYNC Output A 120VAC 60Hz Output B 120VAC 60Hz 600W 3 wire L1 L2 Common Neutral A 0 B 0 D 120V 240VAC 2 Phase Output A 120VAC 60Hz Output B 240VAC 50Hz or 60Hz 6...

Page 26: ...ctions to ensure that the generator burner receives the right quality and pressure of combustible mixture of gaseous fuel and air The air gas mixer fan blower is under the control of the Fueled Produc...

Page 27: ...e coolant is routed through the QEC the motor generator as well as a number of other components requiring active cooling To monitor and control the fluid flow rate there is a flow sensor to identify t...

Page 28: ...SYSTEM INTRODUCTION 16 Figure 3 6 P ID Diagram...

Page 29: ...gure 3 7 Heat Rejection Unit HRU The HRU is designed to be coupled with base generator unit module or mounted remotely from the engine under the following conditions The HRU is either at the same heig...

Page 30: ...SYSTEM INTRODUCTION 18 Figure 3 8 Heat Rejection Unit HRU Stand alone Figure 3 9 Heat Rejection Unit HRU Mounted to PowerGen base Unit...

Page 31: ...re 3 10 Heat Rejection Unit HRU Split Apart 3 2 5 CONTROL AND LOCAL USER INTERFACE Control and Local User Interface information is located in PowerGen Interfaces on page 22 Figure 3 11 PowerGen Contro...

Page 32: ...cal Remote Selector Switch 5 Start Stop Reset Pushbutton 6 Output Power Gas Controller Disconnect Switch 7 Customer connection cable gland 3 8 NPT or PG11 8 Customer connection cable gland 1 2 NPT or...

Page 33: ...Unit Dimensions Table 4 1 PowerGen Dimensions Weight Item Name Length inches Width inches Height inches Weight lbs PowerGen 69 4 28 1 57 2 866 HRU floor standing 19 25 4 54 176 HRU wall mounted 28 8 2...

Page 34: ...t is OFF the generator unit is not running and is not ready to start The third possible condition of the light is blinking green which means that the unit is ready to start and might be started locall...

Page 35: ...Disconnect Switch Isolation Switch The Power Disconnect Switch is used to disconnect PowerGen voltage output s Please note If the Power Disconnect Switch is in the OFF 0 position the PowerGen system...

Page 36: ...3 short blinks every 3 5 seconds PowerGen is in standby May be started either locally or remotely depends on condition of Local Remote selector switch OFF Not running and NOT ready to start A fault ma...

Page 37: ...determines if the control functions are controlled from the PowerGen panel or from customer controls via the discrete inputs outputs Local mode PowerGen Stop Stop Reset push button is ACTIVE Customer...

Page 38: ...n the internal CAN bus network of the PowerGen Each controller provides a subset of data values from various sensors across the system while also providing the ability to perform firmware upgrades con...

Page 39: ...Commands Description FPC System Status Details the status of the PowerGen which can be ACTIVATING PowerGen is powering up ENABLED PowerGen is operating STANDBY PowerGen is going into standby mode DEA...

Page 40: ...nfo Control Indication Description FPC Firmware Version Current Firmware loaded into FPC FEB Firmware Version Current Firmware loaded into FEB QEC Firmware Version Current Firmware loaded into QEC Sys...

Page 41: ...Eng Bay Top 2 Top of engine bay Eng Bay Bottom Bottom of engine bay HRU Top Fan HRU air inlet Auxiliary Optional will read 999 C if not used Duct Jacket Temperature of coolant at exhaust duct Head 1 E...

Page 42: ...rent Generator gross current A Power Generator gross power W Peak Voltage Measured generator RMS voltage V Drive voltage Commanded generator voltage AC Estimated HHT Engine Temperature calculated on t...

Page 43: ...5 FPC Data Cooling Control Indication Description Pump PWM Pump speed Pump feedback Measured load on pump Fan PWM Fan speed Coolant Temperature Inner Coolant Loop temperature C Coolant Flow Inner Coo...

Page 44: ...ween 0 and 15 coarsely approximating peak converter amplitude 0 Minimal stroke 15 Maximal stroke mm Offset Engine piston bias mm Frequency Engine piston frequency Hz Phase Internal value resembling th...

Page 45: ...e burner control unit Gas Pressure Gas pressure at inlet to gas controls mbar Lambda Stoichiometric ratio indicating exhaust O emission quality Table 6 8 FPC Data Networking Control Indication Descrip...

Page 46: ...ounts every unsuccessful ignition attempt Fast Thermal Cycles Head cools down 200 C and system starts back up 1 hr Slow Thermal Cycles Head cools down 200 C and system starts back up 1 hr Extreme Cold...

Page 47: ...ndication Description FPC GPIs 1 2 General purpose input pin 1 2 on the FPC board FPC GPOs 1 2 General purpose output pin 1 2 on the FPC board Table 6 12 FPC Data Debug Data Control Indication Descrip...

Page 48: ...n CPU Temperature Central processing unit temperature Board Temperature Printed circuit board temperature Door Open Indicates electrical cabinet door is open Valve Heater Status of gas valve heater LT...

Page 49: ...QNERGY LYNX SOFTWARE 37 Figure 6 17 FPC Configuration Tab Figure 6 18 FPC Config System Settings...

Page 50: ...t Pump Type Qnergy personnel only do not adjust Fan Type Qnergy personnel only do not adjust Blower Type Qnergy personnel only do not adjust BCU Type Qnergy personnel only do not adjust NTC Type Qnerg...

Page 51: ...etpoint GHT Only Control Indication Description High Coolant Setpoint GHT Sets maximum GHT Coolant setpoint Low Coolant Setpoint GHT Sets GHT target temperature Table 6 18 FPC Config Start PWM Control...

Page 52: ...DHCP Check to use the network s DHCP server uncheck to use a static IP address IP Address Static IP address for the FPC Subnet Subnet mask of the FPC IP address Gateway Internet gateway IP address Tab...

Page 53: ...26 FPC Config GPO Settings Table 6 22 FPC Config GPI Settings Control Indication Description GPI 1 General Input to FEB 1 GPI 2 General Input to FEB 2 GPI 3 General Input to FEB 3 GPI 4 General Input...

Page 54: ...neral Output to FEB 2 GPO 3 General Output to FEB 3 GPO 4 General Output to FEB 4 GPO 5 General Output to FEB 5 GPO 6 General Output to FEB 6 GPO 7 General Output to FEB 7 GPO 8 General Output to FEB...

Page 55: ...To access the QEC controller select QEC in the controller list for the connected PowerGen unit Figure 6 29 QEC System Status Figure 6 30 QEC System Command Buttons Table 6 25 FPC Config CAN Node Id Co...

Page 56: ...he engine controller which can be CHARGING QEC is charging its internal busses BUMPING Trying to start the engine waiting for heat RUNNING Engine is running SLEEPING QEC is in 12Vdc battery power save...

Page 57: ...ption Power Measured output power W Voltage Measured output voltage V Current Measured output current A Table 6 28 QEC Data Brake Control Indication Description Power Excess standby power that is bein...

Page 58: ...trol Indication Description Voltage 12V battery voltage V State Battery charging state Temperature Battery temperature C Current Current coming from or going to the battery A BBI Positive Current Curr...

Page 59: ...Engine RMS Voltage Measured engine voltage V Command Drive Voltage Commanded engine voltage V HHT Setpoint Heater Head setpoint temperature C Estimated HHT Temperature calculated on the basis of gener...

Page 60: ...ltage V Negative HVDC Bus Internal DC Bus negative voltage V Table 6 33 QEC Data Piston Control Indication Description Amplitude A number between 0 and 15 approximating peak converter amplitude 0 Mini...

Page 61: ...Data PCB Temp Table 6 34 QEC Data Debug Data Control Indication Description 0 15 Qnergy internal use Table 6 35 QEC Data PCB Temp Control Indication Description Internal Temperature 1 QEC circuit boa...

Page 62: ...ters Figure 6 42 QEC Configuration Tab Figure 6 43 QEC Config Output A Table 6 36 QEC Data Counters Control Indication Description Hour Meter QEC run time h Heartbeat Counter Indicates that the QEC CA...

Page 63: ...res priority over the other outputs when total available power is insufficient to support all loads Mirrored Output A only Set if Output B is 180 from Output A This option syncs the control between th...

Page 64: ...um Voltage N A Qnergy only Table 6 40 QEC Config Minimum Engine Power Control Indication Description Minimum Engine Power Minimum power setpoint which the engine should try to reach and maintain 600 t...

Page 65: ...escription Power Limit Set to either 5650 for PG5650 600 for PG600 1200 for PG1200 or 1800 for PG1800 W Distributor only Table 6 43 QEC Config HHT Setpoint Control Indication Description HHT Setpoint...

Page 66: ...int or a parameter within the Qnergy Lynx software the Border of the parameter setting will change color and a SET or UNDO button will appear When making a parameter change an ORANGE border color will...

Page 67: ...l Condition If you move the computer mouse over the setpoint value a box will appear with acceptable data points for the particular parameter Type in an acceptable value and then click SET Figure 6 55...

Page 68: ...Firmware Tab Firmware UPLOAD instructions If PowerGen is running disable the PowerGen Wait for the engine to come to a complete stop takes approximately 5 7 minutes Browse to the correct firmware file...

Page 69: ...QNERGY LYNX SOFTWARE 57 Figure 6 57 FPC FEB QEC Firmware Update...

Page 70: ...r If the HRU is installed to the PowerGen base the PowerGen can be lifted with one tongue under the HRU flush with the PowerGen base and the other tongue under the PowerGen base anywhere past the cent...

Page 71: ...TRANSPORTATION REQUIREMENTS 59 Figure 8 1 PowerGen Base without HRU Lifting by Rings or Fork Figure 8 2 PowerGen Base with HRU Lifting by Forklift...

Page 72: ...carrying option 9 SITE PREPARATION REQUIREMENTS 9 1 FLOOR The PowerGen requires a solid flat level pad preferably wood skid typically 6 x6 wood posts or concrete Do not install the PowerGen on a metal...

Page 73: ...A marine rated PowerGen is available Contact your distributer for more information 9 2 GAS SUPPLY The gas supply inlet is fitted with 1 2 NPT male fitting The minimum pressure Natural Gas should be 3...

Page 74: ...ith applicable local codes and regulations In accordance with the instructions in this manual 11 2 TOOLS AND MATERIALS FOR INSTALLATION AND COMMISSIONING Installation and Commissioning of the PowerGen...

Page 75: ...d HRU 1 System Location 5000 103913 000 Helium Fill Kit 1 Helium Fill 6000 103634 000 Helium Gas Cylinder UN 1046 1 Helium Fill 12 liters engine Laptop CAN bus cable connected to FPC Read Head 1 and o...

Page 76: ...wer and Communication Feeds Gas Leak Detector Spray or Sensor 1 bottle Gas Connection Table 11 1 Tools and Materials Description Quantity Purpose WARNING There is a danger of fatal electric shock from...

Page 77: ...er and the Communications cables see Table 11 1 on 62 These holes are suitable for conduit glands or PG21 Figure 11 1 Power and Communications Feed Location WARNING All field wiring must be 90 C 194 F...

Page 78: ...POWER TERMINAL BLOCKS Figure 11 2 PowerGen Electrical Terminal Blocks Customer Connection Point Table 11 2 PowerGen Electrical Power Terminal Block Description Position Designation Wire Gauge GND GND...

Page 79: ...not function while in remote mode Further information can be found in see Section 12 9 Table 11 3 PowerGen FPC Expansion Board Input Description Discrete Inputs No Default Selectable Options 1 thru 6...

Page 80: ...ly open discrete input dry contact allowing the customer to enable disable the system For further information please contact Qnergy Customer Support Table 11 5 PowerGen FPC Expansion Board Terminal Bl...

Page 81: ...tion data rate is 125kpps Note Contact Qnergy prior to connecting CAN bus cables to FPC board To connect to CAN bus on PowerGen Connect the CAN bus cable to the FCP control circuit board P12 connector...

Page 82: ...inimum supply pressure to connect the PowerGen fuel inlet to the NPT male threaded pipe Be sure to use appropriate pipe sealant during installation 3 Use a leak indicator spray to check the gas connec...

Page 83: ...URE See Table 11 1 on 62 for detailed information about required tools and materials needed to commission the PowerGen system 12 1 PANEL REMOVAL Remove the PowerGen side panels two each using a 8mm Al...

Page 84: ...kin and eyes and to be toxic A battery presents a risk of electrical shock and a high short circuit current The following precautions must always be taken when working on batteries Remove watches ring...

Page 85: ...page 74 Note Other optional electrical loads may need to be reconnected by either re attaching the connectors or inserting the fuse WARNING There is a danger of fatal electric shock from touching liv...

Page 86: ...Side Door Removed Figure 12 4 PowerGen Left Hand Side QEC Battery CAN bus Flow Sensor Connection Note Measure the PowerGen 12Vdc battery voltage If battery voltage measures below 12 3Vdc perform the...

Page 87: ...NG Note Prior to commissioning the PowerGen please verify that the field support laptop is configured with the following Qnergy Lynx Software v0 4 0 or greater QEC Firmware v3 1 0 or greater QEC3 5 ha...

Page 88: ...mstance shall the engine be charged above 60bar Wear safety glasses during engine helium fill procedure Use only 99 99 purity helium UN1046 or greater WARNING Qnergy Engines use helium gas under high...

Page 89: ...itting which will safely connect to helium sources within the US Canada and Mexico DO NOT modify this fitting or the fill kit may become unsafe If an operator suspects that the nut or nipple have been...

Page 90: ...COMMISSIONING PROCEDURE 78 Figure 12 6 Regulator Fitting Inlet Nut CGA 580 12 5 2 PREPARATION 1 Fully close the Vent Valve clockwise Figure 12 7 Helium Kit Vent Valve...

Page 91: ...es pressurized Open the valve fully so that flow is not restricted WARNING Both pressure gauges must read the same value If they do not then replace one or both gauges until an accurate pressure measu...

Page 92: ...ise 10 Reduce pressure to 30psi through self venting of the regulator 11 Repeat steps 7 on 80and 9 on 80 to ensure that air in the flexible hose is diluted and washed out of the kit by purging with pr...

Page 93: ...rge pressure based on the engine metal temperature 14 REFER to Table 12 1 on 82 to CHOOSE the target charge pressure based on PRODUCT type and metal temperature Don t choose based on local ambient but...

Page 94: ...ed helium from the Helium Fill Kit prior to removing the helium kit from source tank Table 12 1 Target Charging Pressure PG600 PG1200 PG1800 LT systems included PG5650 LT systems included ENGINE TEMPE...

Page 95: ...PowerGen pressure transducer 32mbar FPC Data Burner Figure 12 12 Gas Pressure Reading 12 7 GAS VALVE TUNING POWERGEN 5650 Note This section 12 7 is for tuning a PowerGen 5650 Low Temp systems included...

Page 96: ...t and tested to Natural Gas If application requires the use of Propane LPG turn screw 3 clockwise 3 turns prior to enabling the PowerGen 1 Verify that the customer gas pressure is within the acceptabl...

Page 97: ...Config Tab Set Head Setpoint to 600 C and click Set Figure 12 14 Head Temp Setpoint 4 While commissioning the PowerGen equipped with QEC3 5 the following parameters must be changed to override the Loa...

Page 98: ...COMMISSIONING PROCEDURE 86 Figure 12 15 Lynx Max Blower to 80 6 Under the QEC Config Tab Set Output Power Limit to 5650W Click Set Figure 12 16 Qnergy Lynx QEC Configuration Tab Output Power Limit...

Page 99: ...tart with a richer combustion This can be repeated up to six times If unit still does not ignite contact Qnergy customer support 801 413 7668 9 Under the QEC Config Tab Set Minimum Engine Power to 500...

Page 100: ...Lambda reading should be 1 18 0 01 12 To decrease Lambda turn screw 3 counter clockwise see Figure 12 10 13 To increase Lambda turn screw 3 clockwise see Figure 12 10 14 Under the QEC Config Tab Set...

Page 101: ...increase Lambda turn screw 2 counter clockwise see Figure 12 13 on page 84 17 Repeat steps 6 through 16 until the gas regulator is tuned correctly 18 Verify head temperature is 600 C 12 8 GAS VALVE T...

Page 102: ...en is factory set and tested to Natural Gas If the application requires the use of Propane LPG turn screw 3 clockwise three turns prior to enabling the PowerGen 1 Verify that the customer gas pressure...

Page 103: ...ning Screws 2 Attach a Lambda sensor to the exhaust outlet at the threaded boss Turn on the gauge and make sure it is calibrated reading should be 20 9 3 In Lynx FPC Config Tab Set HHT Setpoint too 60...

Page 104: ...Set Figure 12 22 Qnergy Lynx Max Blower to 80 6 Disconnect customer electrical load from PowerGen prior to enabling the PowerGen for the first time 7 Start the PowerGen by clicking Enable in Qnergy L...

Page 105: ...413 7668 9 While the engine is running under the QEC Config Tab Set Minimum Engine Power to 1800W for the PG1800 1200W for the PG1200 and 600W for the PG600 Click Set Figure 12 24 Qnergy Lynx QEC Con...

Page 106: ...oftware If a customer chooses to use the PowerGen s digital I O initial configuration will be required using the Lynx Software during commissioning See Table 12 2 and Table 12 3 for explanations on th...

Page 107: ...25 FEB GPIO Configuration 1 Click on the Configuration Tab 2 Under the GPIO Settings section configure each I O point that has been used by customer 3 After selecting Input Output options press the Se...

Page 108: ...d System disabled System Enabled System enabled No behavior System Disabled No behavior System disabled Load Toggle used on LD Disconnect relay on FEB LD disconnect relay open LD disconnect relay clos...

Page 109: ...wer 5500W System power greater than 5500W System power less than 5500W Burner Ignition Fault System has a burner ignition fault No burner ignition fault Gas Pressure Low Gas pressure less than 15mb Ga...

Page 110: ...tions 12 10 MODBUS Table 12 4 Modbus General Access Read Write Clear Modbus Register Write 06 Modbus Coil Write 05 Type Size Bit Description Notes W 40001 WORD 16 bit System commands Always reads 0 W...

Page 111: ...Modbus Register Read 03 Modbus Register Write 06 Type Size Description Units R W 40005 40005 INT 16 bit GHT max supply temp C 10 R W 40006 40006 INT 16 bit GHT return set point C 10 R W 40007 40007 UI...

Page 112: ...High Word hh hh Major Minor hh 8bit hex R 40051 UINT 16 bit QEC firmware version Low Word hh hh Patch Build hh 8bit hex R 40052 UINT 16 bit QEC firmware version High Word hh hh Major Minor hh 8bit hex...

Page 113: ...16 bit Duct jacket temp C 10 R 40066 UINT 16 bit Gas pressure mbar R 40067 UINT 16 bit Coolant level R 40070 INT 16 bit Estimated head temperature C 10 R 40071 INT 16 Bit QEC coolant temperature C 10...

Page 114: ...0099 INT 16 Bit QEC output 1 current A 10 QEC firmware 3 0 0 R 40100 INT 16 Bit QEC output 2 current A 10 QEC firmware 3 0 0 R 40101 INT 16 Bit QEC output 3 current A 10 QEC firmware 3 0 0 R 40102 INT...

Page 115: ...6 Bit Active fault code 5 R 40206 UINT 16 Bit Active fault code 6 R 40207 UINT 16 Bit Active fault code 7 R 40208 UINT 16 Bit Active fault code 8 R 40209 UINT 16 Bit Active fault code 9 R 40210 UINT 1...

Page 116: ...Bit Active fault code 16 R 40217 UINT 16 Bit Active fault code 17 R 40218 UINT 16 Bit Active fault code 18 R 40219 UINT 16 Bit Active fault code 19 R 40220 UINT 16 Bit Active fault code 20 Table 12 10...

Page 117: ...nit will start if selected input channel is shorted Will stop if the channel is opened START 2 Unit will start if selected input channel is shorted STOP 3 Unit will stop if selected input channel is s...

Page 118: ...wer 2500W open when power drops below 2200W POWER_GT_5500 8 Close when power 5500W open when power drops FAULT_IGNITION 8 Close when burner ignition fault is active FAULT_GAS_PRESSURE 9 Close when gas...

Page 119: ...nput such a gas pressure to self start GO_TO_STANDBY 15 System disabling because a condition is not met such as insufficient gas pressure FILL_SEQ_INPROCESS 17 Coolant fill sequence initiated to remov...

Page 120: ...rial number starts with a 5xxxxxxxx All load following parameters will be changed in the QEC Configuration for Load Following section Figure 12 27 Qnergy Lynx QEC Configuration Tab 1 Set Verify that t...

Page 121: ...the unit is warm enough 8 Turn on critical load 9 Did the critical load start as normal If yes skip to 11 if no continue to step 10 10 Increase Minimum Engine Power by 500W Go to step 9 11 If using tw...

Page 122: ...ed please follow the Coolant Fill procedure located in Coolant Fill Instructions on page 144 12 13 HANDOVER TO USER After installation of the PowerGen is complete the installer shall 1 Instruct the us...

Page 123: ...Fault Messages PowerGen on page 112 13 1 USER INTERFACE INDICATORS AND CONTROLS Figure 13 1 User Interface Controls 14 TROUBLESHOOTING 14 1 LOG FILES Log files are created when the Qnergy Lynx softwar...

Page 124: ...Messages Levels Explained PowerGen Fault Levels Explained Service Required System will shut down and be inoperable until service is performed and the fault is cleared by an authorized service personn...

Page 125: ...CANBUS line FPC QEC CAN hardware problem 1003 QEC does not enable QEC did not respond to an enable command from the FPC due to hardware issues 1005 HHT value is unavailable A timeout has occurred whi...

Page 126: ...connectors to BCU If head temperature is increasing by 20C or more before this event Test the lockout signal by disconnecting the Flame sensor harness while BCU light is green If fault 2014 does not i...

Page 127: ...figured to correct blower Verify Fasco blower has updated settings Verify Aux power is set to 220VAC 7Amps 1011 Invalid pump feedback reading Feedback value of the pump does not represent a normal run...

Page 128: ...ure downstream of the PowerGen internal regulator is above 70mBar for 2 seconds Gas liquids in fuel line regulator removed regulator malfunction regulator exposed to extreme low temperatures while sup...

Page 129: ...blower was at min rate 20 Increase QEC power limit 2004 Internal E Stop signal was activated The internal E Stop signal was pulled low by the QEC FEB or CANBUS interface bad CANBUS wiring typically a...

Page 130: ...and no prior 4005 warnings Purge non combustible gases from Fuel lines WARNING VERIFY NO GAS LEAKS IN THE ENGINE BAY AND ELECTRICAL CABINET PowerGen 1200 running on High BTU scf gases Start PWM may ne...

Page 131: ...ck fluctuates more than 1 look for leaks and perform coolant fill procedure Loosen blocked pump If serial number is below PG260 and has a gold color coolant in it flush out coolant with Preston AF2000...

Page 132: ...is below 5 F verify coolant is 60 40 mix and that pump heater operated during the cold start applicable for LTS systems only Drain coolant Remove pump motor by unscrewing 4x M6 screws verify the impe...

Page 133: ...mp feedback 2025 Burner blower not spinning Blower not getting power signal harness unplugged blower seized or damaged Verify disconnect switch in 1 position Inspect all fuses on FPC If pump feedback...

Page 134: ...ble 15 4 PowerGen Error Messages Auto Reset Fault Code Description Possible Causes 3003 No gas Gas pressure insufficient damaged pressure sensor PowerGen will activate automatically once pressure incr...

Page 135: ...ted While blower is increasing estimated head temperature is not increasing as expected Gas pressure low FPC FW below 1 9 0 Bad gas quality Incorrect gas valve calibration HHT offset incorrect actual...

Page 136: ...short circuit bad wiring Inspect the channel NTC3 on the FPC is seated well Inspect connector and cable for damage Replace sensor 4010 HRU Top temp sensor failed Sensor failed open or short circuit ba...

Page 137: ...e air exceeded 131 F 55 C Ambient temperature is above maximum rated operating range Bad sensor 4014 HRU Top temperature too low Temperature of HRU intake air is below 13 F 25 C or 40 F 40 C for LTS u...

Page 138: ...apacity is reduced Fouled radiator on air side seized HRU fan or failed fan insufficient coolant HRU panel left open incorrect fan type configured windy conditions Verify all panels secured in place V...

Page 139: ...xhaust leak into engine bay bad sensor 4020 Cold Protection Applicable for LTS units only Gas valve temperature below 15 C see LTS cold start procedure Gas valve heater will turn off at 20 C 4021 GHT...

Page 140: ...t demand Not enough heat demand Setpoint temperature was reduced too drastically 4025 GHT return temperature above 150 f 65 C Insufficient heat load Reduce return setpoint to below 130 F 55 C on Power...

Page 141: ...raining is required Stuck or damaged lower level sensor open wiring 4029 Gas valve temp sensor bad Sensor failed open or short circuit bad wiring Inspect that the channel NTC6 on the FPC is seated wel...

Page 142: ...r exceeded 131 F 55 C ambient temperature is above maximum rated operating range bad sensor 5003 HRU Top temperature is too low Temperature of HRU intake air is below 13 F 25 C or 40 F 40 C for LTS un...

Page 143: ...greater than hardware limit QEC hardware failure 11501 Engine frequency is above or below expected value Hall calibration is wrong noise incorrect engine pressure 11502 Incorrect hall readings at res...

Page 144: ...ve DC buses fail to reach setpoint during BBI operation Battery is bad QEC hardware failure 12002 Positive bus voltage too low Battery is bad ADC calibration not done QEC hardware failure 12003 Positi...

Page 145: ...the battery 12009 Battery is too hot or cold for operation Battery out of temperature operating range 12010 Battery needs service Battery performance is bad 12011 OUT_A current greater than hardware c...

Page 146: ...ad temperature estimate too high Firmware issue coolant sensor failure 13005 E Stop fault for slow burner only Signal bad unless done intentionally 13006 Engine current greater than hardware current l...

Page 147: ...ult table access Firmware warning 14015 Configuration read failed Eeprom read failure 14016 Engine current greater than hardware current limit Overload detected at engine output 14017 Battery is not c...

Page 148: ...pressure is low problem with the heat source 11013 Hall fit quality poor Hall switch point calibration is wrong problem with the engine hall sensors 11014 Engine frequency is above or below expected...

Page 149: ...ugh power available for auxiliary loads and charging the battery Faulty battery 12010 Battery needs service Faulty battery replace 12014 Engine current too high Heat source provides too much heat 1201...

Page 150: ...above 35 and fault occurs during operation test glycol concentration in coolant at the radiator and not overflow tank If ambient temperature is cold below 2 C and power is low below 2500W increase mi...

Page 151: ...failed Battery temp sensor is missing or bad Table 15 8 QEC Error Messages QEC 3 5 Firmware 3 X X Fault Code Description Possible Causes WARNING Danger of fatal electric shock from touching live conne...

Page 152: ...e failure to disconnect the 12VDC battery from the QEC could result in failure to the battery and or QEC To disconnect the 12VDC battery from the QEC perform the following 1 Remove the left hand side...

Page 153: ...eplacing the battery use a battery of the exact type being replaced The battery shall be a Deep cycle 12 VDC VRLA 40 Ah M6 threaded terminals Please note Remove the negative terminal first and replace...

Page 154: ...parts please contact Qnergy customer support WARNING Maintenance should be performed by a trained service technician Before disassembling any internal parts shut down the PowerGen and allow ample tim...

Page 155: ...A 40 Ah M5 M6 threaded terminals NOTE Remove the negative terminal first and replace last Contact Qnergy Customer Support for adding additional battery capacity WARNING Do not dispose of the battery o...

Page 156: ...nnecting or disconnecting battery terminals Determine whether the battery is inadvertently grounded When inadvertently grounded remove the ground source Making contact with any part of a grounded batt...

Page 157: ...open end wrench Figure 17 3 by 2 2 5 complete turns 4 Add coolant while inspecting the air removal plug Once coolant begins to flow through the air removal plug close the plug using a 9 16 open end w...

Page 158: ...MAINTENANCE 146 Figure 17 2 Radiator and Over Flow Tank...

Page 159: ...lacing the Burner Burner Ceramic Burner Seal If Flexible Gas Pre mix duct to Burner is not properly fitted a gas leak may occur causing a gas leak and or gas explosion Personal injury death and proper...

Page 160: ...led for long periods of time or any other reason please follow steps below to jump start PowerGen 12VDC battery 7 Use an 8AWG or thicker Jumper cable to jump start no longer than 30ft 8 Remove the Pow...

Page 161: ...placement Part Description QTY 1500 101098 000 SEAL CAVITY BURNER OMEGA FKM BLACK 1 1500 101121 000 SEAL CAVITY BURNER OMEGA LOW TEMP ORANGE 1 6000 103178 000 CLAMP WRAPLOCK SCREW DRIVE 0 5 x 48 IN ST...

Page 162: ...scription QTY 6010 103116 000 BLOWER 230 VAC 1 6000 103535 000 HOSE CLAMP WORM DRIVE 1 2 W 1 9 16 TO 2 1 2 SS 2 Table 18 5 Gas Valve Replacement Part Description QTY 6000 103623 000 GAS VALVE 1 6000 1...

Page 163: ...10 000 OVER FLOW TANK 4 QUART WITH SENSOR 1 Table 18 8 Coolant Pump Replacement Part Description QTY 6000 103592 000 PUMP CIRCULATOR UPM GEO 25 85 180 230 VAC PWM 270 DEG 1 6000 103588 000 O RING 2 22...

Page 164: ...TO RADIATOR also EXHAUST to BPHX in GHT 1950mm 1 3520 101061 000 HOSE COOLANT MOLDED EXHAUST TO HHX ENGINE HOT END 1 6000 103236 000 HOSE GREEN STRIPE 1 IN ID MAX 75 PSI COC to HHX 279mm 1 6000 103236...

Page 165: ...520 101216 000 TRANSDUCER PRESSURE FUEL 1 4520 101172 001 NTC ENGINE TOP BAY HARNESS 1 4520 101172 002 NTC ENGINE BOTTOM BAY HARNESS 1 4520 101172 003 NTC HRU BATTERY HARNESS 1 4520 101173 000 HARNESS...

Page 166: ...ED 5 28V SCREW TERMINALS IP67 40C TO 80C YELLOW 1 6010 103086 000 PILOT LIGHT 22MM TUFFLED 5 28V SCREW TERMINALS IP67 40C TO 80C GREEN 1 Table 18 18 Exhaust Parts Replacement Part Description QTY 1530...

Page 167: ...y Engineering Dept 5 Earth Ground Connection to front of PowerGen enclosure Section 11 3 7 PowerGen earth ground connection Customer Signature Date DD MM YYYY Table 19 2 Safety Checks and Basic Inform...

Page 168: ...on Commissioning General Information Customer Name Customer Engineer Name s Appliance Site Country City and Place Site Name GPS Location Commissioning Date PowerGen Serial Number OptConnect Modem SN P...

Page 169: ...helium fill port Engine Temperature indicated by FPC C Engine Helium pressure after filling PSI BAR 4 Gas type connected to PowerGen NG LGP Biogas Gas static pressure FPC Data Tap Gas Pressure mbar 5...

Page 170: ...Electrical Connection on page 64 Measure voltage and current output from PowerGen Verify load does not exceed generated power 11 Side panels installed and front access door closed See Panel Removal o...

Page 171: ...STS 159 Table 19 5 FPC Expansion Board Discrete Input Configuration Input Default Configured to Initials 1 2 3 4 5 6 Table 19 6 FPC Expansion Board Relay Output Configuration Input Default Configured...

Page 172: ...2 Inspect the cabinet filter If filter is dirty and or damaged clean or replace the filter 3 Check the internal coolant loop for signs of leaks Hoses fittings joints 4 Inspect the burner seal flexibl...

Page 173: ...n the engine body if loose replace washers with spring lock washers and tighten 12 Enable the PowerGen and measure the Lambda emissions at the exhaust outlet port Tune if necessary per the gas valve t...

Page 174: ...EFULLY BEFORE STARTING the PowerGen WARNING Continue to this next section ONLY AFTER all previous Chapters have been fully completed by a qualified technician Failure to do so will result in a malfunc...

Page 175: ...used to disconnect the PowerGen voltage outputs Note If the Power Disconnect Switch is in the OFF 0 position the PowerGen system will not start or will stop if already running The internal AC supply...

Page 176: ...owerGen is in standby May be started either locally or remotely depends on condition of Local Remote selector switch OFF Not running and NOT ready to start A fault may be present see Fault Messages Po...

Page 177: ...or disconnect switch Detects if DC disconnect switch is OFF or e stop is activated light will stop blinking once e stop disengages 2 short blinks every 3 seconds Battery low Internal battery voltage...

Page 178: ...ecting the pump in addition there is a reservoir tank that enables the media to expand separates the air from the media and allows for easy self priming filling of the GHT circuit Lastly there is a me...

Page 179: ...ts Table 21 1 GHT Components Item Number Description 1 Supply Temp Sensor 2 Supply Port 1 2 NPT Female 3 Fill Cap 4 Reservoir Tank 5 Visual Fill Indicator 6 Return Port 1 2 NPT Female 7 Y Strainer 8 R...

Page 180: ...ith a wrench to prevent excess torque on internal components 21 1 3 GHT Fill Procedure Once the heat trace line has been installed on site and connected to the PowerGen follow the steps below for fill...

Page 181: ...rainer and open valve if installed by user 12 Fill the reservoir back to the max line and set GHT switch to desired state ON OFF Figure 21 3 Coolant Setpoints in Lynx Table 21 2 GHT VFD Speed Settings...

Page 182: ...ntire system 1 Enable the PowerGen if not already running 2 Toggle the GHT switch to the OFF position found on the front panel LUI 3 Prepare a catch pan or bucket to catch the coolant 4 Disconnect the...

Page 183: ...nd operate and ambient temperatures down to 40 C Challenges at these low temperatures are having materials such as low carbon steel and rubbers losing their elastic characteristics and becoming brittl...

Page 184: ...um Fill on page 76 for charge pressures of the QB80 LTS equipped systems take the same charge pressure as the corresponding non LTS systems PG600 1200 1800 5650 Table 21 3 LTS Components Item number D...

Page 185: ...Details tab in SmartView verify greater than 13VDC on PowerGen battery terminals 6 Verify PowerGen electrical cabinet door is closed 7 Clear faults on the PowerGen by pressing and holding the START S...

Page 186: ...2017 Pump heater not operating Check if pump is warm Check fuses and wiring Very loud hammering noise upon startup Engine mount heater not operating Disable PowerGen Check if all 4 engine mounts are w...

Page 187: ...POWERGEN OPTIONAL FEATURE SETS 175 21 2 4 LTS Schematic Figure 21 5 Gas Valve Heater and Temperature sensor to FEB Figure 21 6 Fuse Box...

Page 188: ...eat trace prevents condensates from forming as pressure drops throughout the fuel system The heat trace is wrapped around the fuel system within the PowerGen Additional heat trace is provided to the c...

Page 189: ...of the drum See Figure 21 8 below for valve location The emptying valve is shown in the open position in Figure 21 8 Figure 21 8 Drum Emptying Valve Shown in Open Position WARNING Liquids and solids w...

Page 190: ...Use sniffer or snoop to check connections to PowerGen and all joints on knockout drum Loud rattle coming from area of knockout drum Connections and or fasteners not properly tightened Check sensor con...

Page 191: ...ocked AC3 inductive load contactors Figure 21 9 6 Only one contactor can supply power to the load and is energized by the active PowerGen Each contactor also has an auxiliary contact block which can b...

Page 192: ...8 Nm 1 PowerGen A Common Neutral 2 PowerGen A L1 3 PowerGen A L2 4 PowerGen B Common Neutral 5 PowerGen B L1 6 PowerGen B L2 GND GND PE X2 Output GND GND PE 20 6 AWG 0 5 16 mm 13 3 16 lbf in 1 5 1 8...

Page 193: ...on page 23 When controlled by the customer or automatically from the ATS the PowerGen may be enabled and disabled remotely through the FEB input which is set to System toggle Normal connection is to...

Page 194: ...POWERGEN OPTIONAL FEATURE SETS 182...

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