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REPARATION

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EQUIREMENTS

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Figure 9-1 PowerGen Mounting Dimensions

The maximum allowed slope is 2.5%. PowerGen should be located such that the long plane is

parallel to the slope direction and that the radiator fill cap is elevated above the generator.
The PowerGen is not intended to be operated in a marine, hazardous, or chemical intensive

environments. 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:

• 3PSIG

The maximum pressure (Natural Gas) should be:

• 50PSIG

A flexible gas line of at least two feet must be used to connect the RP to a rigid fuel supply

line.

WARNING:

Danger of death by gas escape if the

gas supply is not properly installed. The gas supply

must only be installed by a qualified technician. All

local regulations for fuel supply must be observed.

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Содержание PowerGen 5650 Series

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...iv...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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