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Qnergy PowerGen 5650 Series Installation & Operation Manual

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Installation & Operation
Manual
FOR A QUALIFIED INSTALLER
June 1, 2021
7045-102089-000

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Summary of Contents for Qnergy PowerGen 5650 Series

  • Page 1 Installation & Operation Manual FOR A QUALIFIED INSTALLER June 1, 2021 7045-102089-000...
  • Page 2 No part of 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, without prior written consent of Qnergy. Nor may the publication be disclosed to third parties.

  • Page 3: Table Of Contents

    4. DIMENSIONS........................... 21 5. POWERGEN INTERFACES ......................22 5.1 LOCAL USER INTERFACE (LUI) ....................22 5.2 COMMUNICATION AND CONTROL INTERFACE ..............22 6. QNERGY LYNX SOFTWARE......................26 6.1 FPC ..............................26 6.2 FPC DATA AND CONFIGURATION ..................27 6.3 QEC..............................43 6.4 QEC DATA AND CONFIGURATION..................
  • Page 4 12.13 HANDOVER TO USER ......................110 13. STARTUP PROCEDURE......................110 13.1 USER INTERFACE INDICATORS AND CONTROLS ............111 14. TROUBLESHOOTING ........................111 14.1 LOG FILES ............................. 111 15. FAULT MESSAGES, POWERGEN .................... 112 15.1 FPC & QEC FAULT MESSAGES....................112 16.
  • Page 5 List of Tables Table 2-1 Definitions of Acronyms ....................4 Table 3-1 Technical Specifications, QRP 2B-XXX-XXX............6 Table 3-2 PowerGen Model Numbers..................8 Table 3-3 PowerGen Electrical Power Output Options, 5650 ........10 Table 3-4 PowerGen Electrical Power Output Options, 1800........11 Table 3-5 PowerGen Electrical Power Output Options, 1200 ........12 Table 3-6 PowerGen Electrical Power Output Options, 600 .........13 Table 3-7 PowerGen Control and Local User Interface Description ......20 Table 4-1 PowerGen Dimensions &...
  • Page 6 Table 6-32 QEC, Data, DC Bus..................... 48 Table 6-33 QEC, Data, Piston....................... 48 Table 6-34 QEC, Data, Debug Data................... 49 Table 6-35 QEC, Data, PCB Temp ....................49 Table 6-36 QEC, Data, Counters....................50 Table 6-37 QEC, Config, Output A/B/C..................51 Table 6-38 QEC, Config, Battery Capacity ................
  • Page 7 Table 18-6 BRAHMA Replacement ...................150 Table 18-7 Over Flow Tank w/Sensor Replacement ............151 Table 18-8 Coolant Pump Replacement .................151 Table 18-9 Radiator Replacement.....................151 Table 18-10 Hose and Hose Clamp Replacement...............152 Table 18-12 Fan Replacement .....................152 Table 18-11 Battery Replacement....................152 Table 18-13 Filter Replacement....................153 Table 18-14 Sensor and/or Thermocouple Replacement ..........153 Table 18-15 QEC-3.5 Replacement .....................153 Table 18-16 FPC and/or FEB Replacement................153...
  • Page 9 List Of Figures Figure 3-1 PowerGen Base......................5 Figure 3-2 PowerGen Data Plate, 5650................9 Figure 3-3 PowerGen Data Plate, 1200................9 Figure 3-4 QB80 Stirling Engine and QEC ................14 Figure 3-5 Piping and Instrumentation Diagram (P&ID)..........15 Figure 3-6 P&ID Diagram ......................16 Figure 3-7 Heat Rejection Unit (HRU) ..................17 Figure 3-8 Heat Rejection Unit (HRU), Stand-alone ............18 Figure 3-9 Heat Rejection Unit (HRU), Mounted to PowerGen base...
  • Page 10 Figure 6-51 FPC & QEC, Faults Tab ..................54 Figure 6-52 FPC & QEC, Fault Log ..................54 Figure 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 &...
  • Page 11 Figure 12-27 Qnergy Lynx, QEC, Configuration Tab .............108 Figure 12-28 Qnergy Lynx, QEC, Configuration Tab, Output Power Limit...........................108 Figure 12-29 Qnergy Lynx, QEC, Load Following Setup Flow Chart .....109 Figure 13-1 User Interface Controls ..................111 Figure 16-1 Battery Warning Label ..................140 Figure 16-2 PowerGen Left-Hand-Side Door Removed ...........140...
  • Page 12 Figure 21-9 ATS Enclosure......................179 Figure 21-10 Battery Connection Schematic..............181...

  • Page 13: Warranty And Liability

    1. WARRANTY AND LIABILITY INSTALLATION, CONFIGURATION, ADJUSTMENT, SERVICE, MAINTENANCE, REPAIR, OR CONVERSION OF THE EQUIPMENT DESCRIBED HEREIN MAY ONLY BE PERFORMED BY QNERGY PERSONNEL OR BY PERSONS AUTHORIZED BY QNERGY. IF UNAUTHORIZED PERSONS PERFORM ANY OF THE PROCEDURES OUTLINED IN THIS MANUAL, ALL WARRANTIES ON THE SYSTEM ARE VOID IMMEDIATELY.

  • Page 14: Basic Safety Instructions

    AFETY CAUTION: Highlights an essential procedure, practice, condition, statement, and so on, which if not strictly observed could destroy or damage equipment. 2.3 BASIC SAFETY INSTRUCTIONS The PowerGen should only be installed and operated in accordance with the instructions contained in this manual and by technicians currently qualified for the part of the installation that they are performing.
  • Page 15 AFETY In general: • Do not wear any loose-fitting or dangling clothing or jewelry • While working on rotating parts. Protect long hair with a cap. Emissions • Depending on the installation and operating conditions, the sound pressure level may exceed 70 dB(A).

  • Page 16: Definition Of Acronyms

    Heat Rejection Unit Local User Interface P&ID Piping & Instrumentation Diagram PCK80 Power Conversion Kit, 80 tubes QB80 Qnergy “B” Series, 80 tubes (Stirling Engine) Power Interface Package Qnergy Engine Controller Qnergy Remote Power Remote Power Fueled Products Controller FPC Expansion Board...

  • Page 17: System Introduction

    YSTEM NTRODUCTION 3. SYSTEM INTRODUCTION 3.1 SYSTEM SUMMARY The PowerGen Remote Power generator is a turnkey power generating solution for the industrial remote power market. The product was specifically designed and built, as specified by various segments of the energy industry for a variety of power-needs marked by extreme reliability and low maintenance for use in remote and harsh conditions.

  • Page 18: Table 3-1 Technical Specifications, Qrp 2B-Xxx-Xxx

    YSTEM NTRODUCTION Table 3-1 Technical Specifications, QRP 2B-XXX-XXX Generator Design Life 10-15 years Fuel Quality No hydrate formation at 5°F up to 50 PSI Free of dust, oil, sand, etc. H2S content up to 7mg/m³, 10 ppm (approx.) Total sulfur up to 150mg/m³, 221 ppm (approx.) Fuel Content Gross heating value 750-3380 BTU/ft3 Wobbe index 830 –...
  • Page 19 YSTEM NTRODUCTION Table 3-1 Technical Specifications, QRP 2B-XXX-XXX Generator Design Life 10-15 years 2. ₂. Storage is allowed down to -13°F (-25°C) 1. ₁. Subject to well-based analysis 3. ₃. Beyond 5,000ft power output will de-rate by 5% per 1,000ft 4.

  • Page 20: Table 3-2 Powergen Model Numbers

    NTRODUCTION Table 3-2 PowerGen Model Numbers Model Nomenclature QRP 2B - HNS - GL 1__ 23__456__7 1 - QRP Qnergy Remote Power 2- Engine Package 1= N/A 2= PCK80.2 (QEC3.5) 3=PCK40.1 3 - Maximum Voltage / Current A = N/A Output B= +/-263VDC to +/- 365VDC –or-...

  • Page 21: Figure 3-2 Powergen Data Plate, 5650

    YSTEM NTRODUCTION 3.1.2 PowerGen Data Plates Figure 3-2 PowerGen Data Plate, 5650 Figure 3-3 PowerGen Data Plate, 1200...

  • Page 22: Table 3-3 Powergen Electrical Power Output Options, 5650

    YSTEM NTRODUCTION 3.1.3 Electrical Configuration Table 3-3 PowerGen Electrical Power Output Options, 5650 Configuration Electrical Configuration Max Power @ Connection Phase Angle 85°F | 120°F 120V/240VAC 5.65kW | 5.1kW 3 wire: L1, L2 & Common/Neutral A (Standard) Split Phase (Phase to A: 0°...

  • Page 23: Table 3-4 Powergen Electrical Power Output Options, 1800

    YSTEM NTRODUCTION Table 3-4 PowerGen Electrical Power Output Options, 1800 Configuration Electrical Configuration Max Power Connection Phase Angle 120V/240VAC 1.8kW 3 wire: L1, L2 & Common/Neutral A (Standard) Split Phase (Phase to A: 0° Phase) B: 180° Output A: 120VAC/60Hz Output B: 120VAC/60Hz 120VAC SYNC 1.8kW...

  • Page 24: Table 3-5 Powergen Electrical Power Output Options, 1200

    YSTEM NTRODUCTION Table 3-5 PowerGen Electrical Power Output Options, 1200 Configuration Electrical Configuration Max Power Connection Phase Angle 120V/240VAC 1.2kW 3 wire: L1, L2 & Common/Neutral A (Standard) Split Phase (Phase to A: 0° Phase) B: 180° Output A: 120VAC/60Hz Output B: 120VAC/60Hz 120VAC SYNC 1.2kW...

  • Page 25: Powergen Subsystems

    YSTEM NTRODUCTION Table 3-6 PowerGen Electrical Power Output Options, 600 Configuration Electrical Configuration Max Power Connection Phase Angle 120V/240VAC 600W 3 wire: L1, L2 & Common/Neutral A (Standard) Split Phase (Phase to A: 0° Phase) B: 180° Output A: 120VAC/60Hz Output B: 120VAC/60Hz 120VAC SYNC 600W...

  • Page 26: Figure 3-4 Qb80 Stirling Engine And Qec

    • Local User Interface (LUI) 3.2.1 FPSE Motor-Generator with Engine Controller (QEC) – PCK80 The PowerGen is integrated around the Qnergy Power Conversion Kit (PCK) which is a FPSE motor-generator with Engine Controller - with all the necessary controls and ancillary equipment to maintain stable and controlled power output across a wide range of operating conditions.

  • Page 27: Figure 3-5 Piping And Instrumentation Diagram (P&Id)

    YSTEM NTRODUCTION Figure 3-5 Piping and Instrumentation Diagram (P&ID) 3.2.3 COOLANT LOOP Similar to an automotive cooling system, the PowerGen utilizes a high efficiency aluminum radiator to dissipate unused, excess heat. A high efficiency PWM controlled circulating pump circulates coolant throughout the PowerGen system at a controlled rate in order to maintain optimal coolant temperatures under varying ambient and operating conditions.

  • Page 28: Figure 3-6 P&Id Diagram

    YSTEM NTRODUCTION Figure 3-6 P&ID Diagram...

  • Page 29: Figure 3-7 Heat Rejection Unit (Hru)

    • The HRU is either at the same height or elevated above the engine. • The HRU must be located in a well ventilated area, with at least four feet of clearance from the sides and two feet of clearance from the fan intake. Contact Qnergy technical team for reduced clearance.

  • Page 30: Figure 3-8 Heat Rejection Unit (Hru), Stand-Alone

    YSTEM NTRODUCTION Figure 3-8 Heat Rejection Unit (HRU), Stand-alone Figure 3-9 Heat Rejection Unit (HRU), Mounted to PowerGen base Unit...

  • Page 31: Figure 3-10 Heat Rejection Unit (Hru), Split Apart

    YSTEM NTRODUCTION Figure 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 Control and Local User Interface...

  • Page 32: Table 3-7 Powergen Control And Local User Interface Description

    YSTEM NTRODUCTION Table 3-7 PowerGen Control and Local User Interface Description Item Number Description System Run Light Warning Light Fault Light Local/Remote Selector Switch Start/Stop (Reset) Pushbutton Output Power & Gas Controller Disconnect Switch Customer connection cable gland (3/8" NPT or PG11) Customer connection cable gland (1/2"...

  • Page 33: Dimensions

    IMENSIONS 4. DIMENSIONS Figure 4-1 PowerGen Base Unit Dimensions Table 4-1 PowerGen Dimensions & Weight Item Name Length Width Height Weight (inches) (inches) (inches) (lbs) PowerGen 69.4 28.1 57.2 HRU floor standing 25.4 HRU wall mounted 28.8 24.9 53.3 PowerGen Base Crate 43.3 32.3 62.8...

  • Page 34: Powergen Interfaces

    OWER NTERFACES 5. POWERGEN INTERFACES Stand-alone PowerGen installation requires minimum effort to connect into customer site infrastructure. There are only four points of interaction: incoming fuel supply, generator power output, communication and control interface and, if required, heat transfer hydronic connection. 5.1 LOCAL USER INTERFACE (LUI) Due to usual remote installation nature, the LUI for unmanned site was kept as minimal.

  • Page 35: Figure 5-1 User Interface Indicators And Controls

    OWER NTERFACES User Interface (UI) Indicators and Controls • Power Disconnect Switch (Isolation Switch) • System Run Light • Warning Light • Fault Light • Start/Stop (Fault Reset) Push Button • GHT Switch (if installed) • Local/Remote Selector Switch (2-position maintained) Figure 5-1 User Interface Indicators and Controls CAUTION: The Local/Remote selector switch allows the PowerGen to start remotely and/or automatically from the...

  • Page 36: Table 5-1 User Interface, System Run Light

    OWER NTERFACES 5.2.2 System Run Light The system run light is a green-colored light which provides indication of the system state per the table below. Table 5-1 User Interface, System Run Light Condition Indication Description PowerGen Base Power available running Fast continuous PowerGen is Power is not available at this stage...

  • Page 37: Table 5-3 User Interface, Fault Light

    OWER NTERFACES 5.2.4 Fault Light The fault light is a red-colored light which is used to indicate if there are any faults or conditions that require immediate attention, per the table below. Table 5-3 User Interface, Fault Light Condition Indication Description No issues 1 short blink every...

  • Page 38: Qnergy Lynx Software

    Qnergy Lynx provides advanced data gathering and full control of the PowerGen from a single software application, using a local CAN bus connection. Qnergy Lynx allows access to individual controllers (FPC, QEC and FEB) on the internal CAN bus network of the PowerGen. Each controller provides a subset of data values from various...

  • Page 39: Fpc Data And Configuration

    NERGY OFTWARE Table 6-1 System Status and Control System Description Commands FPC System Details the status of the PowerGen, which can be: Status • ACTIVATING - PowerGen is powering up • ENABLED - PowerGen is operating • STANDBY – PowerGen is going into standby mode •...

  • Page 40: Table 6-2 Fpc, Data, System Info

    NERGY OFTWARE Figure 6-4 FPC, Data, System Info Table 6-2 FPC, Data, System Info 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 System Serial Number PowerGen Serial Number Engine Serial Number...

  • Page 41: Table 6-3 Fpc, Data, Temperature

    NERGY OFTWARE Figure 6-5 FPC, Data, Temperature Table 6-3 FPC, Data, Temperature Control/Indication Description Temperatures Temperatures measured in the PowerGen Eng Bay Top 1 Top of engine bay Eng Bay Top 2 Top of engine bay Eng Bay Bottom Bottom of engine bay HRU Top Fan HRU air inlet Auxiliary...

  • Page 42: Table 6-4 Fpc, Data, Generator

    NERGY OFTWARE Figure 6-6 FDC, Data, Generator Table 6-4 FPC, Data, Generator Control/Indication Description QEC State Status of QEC Current 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 the basis of generator performance...

  • Page 43: Table 6-5 Fpc, Data, Cooling

    NERGY OFTWARE Figure 6-7 FDC, Data, Cooling Table 6-5 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 Coolant Loop flow rate (L/min) Coolant Level Inner Coolant Loop (%)

  • Page 44: Table 6-6 Fpc, Data, Hall Sensor

    NERGY OFTWARE Figure 6-8 FDC, Data, Hall Sensor Table 6-6 FPC, Data, Hall Sensor Control/Indication Description Amplitude A number between 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...

  • Page 45: Table 6-7 Fpc Data, Burner

    NERGY OFTWARE Figure 6-9 FDC, Data, Burner Table 6-7 FPC Data, Burner Control/Indication Description Blower PWM Blower command speed (%) Blower RPM Blower measured speed (rpm) Burner Status Status of the burner control unit Gas Pressure Gas pressure at inlet to gas controls (mbar) Lambda Stoichiometric ratio indicating exhaust O₂...

  • Page 46: Table 6-9 Fpc, Data, Ignitions

    NERGY OFTWARE Figure 6-11 FDC, Data, Ignitions Table 6-9 FPC, Data, Ignitions Control/Indication Description Ignition Cycles Counts every ignition attempt Ignition Failures Counts 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 Starts...

  • Page 47: Table 6-11 Fpc, Data, Fpc Gpios

    NERGY OFTWARE Figure 6-13 FDC, Data, FPC GPIOs Table 6-11 FPC, Data, FPC GPIOs Control/Indication 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 Figure 6-14 FDC, Data, Debug Data Table 6-12 FPC, Data, Debug Data Control/Indication...

  • Page 48: Table 6-13 Fdc, Data, General

    NERGY OFTWARE Figure 6-15 FDC, Data, General Table 6-13 FDC, Data, General Control/Indication Description 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 systems only) Figure 6-16 FDC, Data, Meters Table 6-14 FPC, Data, Meters Control/Indication...

  • Page 49: Figure 6-17 Fpc, Configuration Tab

    NERGY OFTWARE Figure 6-17 FPC, Configuration Tab Figure 6-18 FPC, Config, System Settings...

  • Page 50: Table 6-15 Fpc, Config, System Settings

    NERGY OFTWARE Table 6-15 FPC, Config, System Settings Control/Indication Description System Serial Number Qnergy personnel only, do not adjust Engine Serial Number Qnergy personnel only, do not adjust System Version Qnergy personnel only, do not adjust System Type Qnergy personnel only, do not adjust...

  • Page 51: Table 6-17 Fpc, Config, Coolant Setpoint (Ght Only)

    NERGY OFTWARE Figure 6-20 FPC, Config, Coolant Setpoint (GHT Only) Table 6-17 FPC, Config, Coolant Setpoint (GHT Only) Control/Indication Description High Coolant Setpoint (GHT) Sets maximum GHT Coolant setpoint Low Coolant Setpoint (GHT) Sets GHT target temperature Figure 6-21 FPC, Config, Start PWM Table 6-18 FPC, Config, Start PWM Control/Indication Description...

  • Page 52: Table 6-20 Fpc, Config, User Network Settings

    NERGY OFTWARE Figure 6-23 FPC, Config, User Network Settings Table 6-20 FPC, Config, User Network Settings Control/Indication Description 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...

  • Page 53: Table 6-22 Fpc, Config, Gpi Settings

    NERGY OFTWARE Figure 6-25 FPC, Config, GPI 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 to FEB #4 GPI #5 General Input to FEB #5 GPI #6...

  • Page 54: Table 6-23 Fpc, Config, Gpo Settings

    General Output to FEB #8 Figure 6-27 FPC, Config, Manual Pump & Fan Controls Table 6-24 FPC, Config, Manual Pump & Fan Controls Control/Indication Description Pump Control Qnergy personnel only, do not adjust Fan Control Qnergy personnel only, do not adjust...

  • Page 55: Qec

    NERGY OFTWARE Figure 6-28 FPC, Config, CAN Node Id Table 6-25 FPC, Config, CAN Node Id Control/Indication Description Node Id FPC Factory Default set to: 10 6.3 QEC 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...

  • Page 56: Qec Data And Configuration

    NERGY OFTWARE Table 6-26 QEC, System Status and Control Control/Indication Description QEC System Status Details the status of the engine controller, which can be: • CHARGING - QEC is charging its internal busses • BUMPING – Trying to start the engine, waiting for heat •...

  • Page 57: Table 6-27 Qec, Data, Output A/B/C

    NERGY OFTWARE Figure 6-32 QEC, Data, Output A Table 6-27 QEC, Data, Output A/B/C Control/Indication Description Power Measured output power (W) Voltage Measured output voltage (V) Current Measured output current (A) Figure 6-33 QEC, Data, Brake Table 6-28 QEC, Data, Brake Control/Indication Description Power...

  • Page 58: Table 6-29 Qec, Data, Battery

    NERGY OFTWARE Figure 6-34 QEC Data, Battery Table 6-29 QEC, Data, Battery Control/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 Current fed to/from the internal positive bus (A) BBI Negative Current Current fed to/from the internal negative bus (A)

  • Page 59: Table 6-30 Qec, Data, Engine

    NERGY OFTWARE Table 6-30 QEC, Data, Engine Control/Indication Description Engine Power Gross engine power (W) Engine RMS Current Gross engine current (A) 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 generator performance (°C)

  • Page 60: Table 6-32 Qec, Data, Dc Bus

    NERGY OFTWARE Figure 6-37 QEC, Data, DC Bus Table 6-32 QEC, Data, DC Bus Control/Indication Description Positive HVDC Bus Internal DC Bus positive voltage (V) Negative HVDC Bus Internal DC Bus negative voltage (V) Figure 6-38 QEC, Data, Piston Table 6-33 QEC, Data, Piston Control/Indication Description Amplitude...

  • Page 61: Table 6-34 Qec, Data, Debug Data

    OFTWARE Figure 6-39 QEC, Data, Debug Data Table 6-34 QEC, Data, Debug Data Control/Indication Description #0 - #15 Qnergy internal use Figure 6-40 QEC, Data, PCB Temp Table 6-35 QEC, Data, PCB Temp Control/Indication Description Internal Temperature 1 QEC circuit board temperature (°C) Internal Temperature 2 QEC circuit board temperature (°C)

  • Page 62: Table 6-36 Qec, Data, Counters

    NERGY OFTWARE Figure 6-41 QEC, Data, Counters Table 6-36 QEC, Data, Counters Control/Indication Description Hour Meter QEC run time (h) Heartbeat Counter Indicates that the QEC CAN bus communication is connected and functional (s) Figure 6-42 QEC, Configuration Tab Figure 6-43 QEC, Config, Output A...

  • Page 63: Table 6-37 Qec, Config, Output A/B/C

    NERGY OFTWARE Table 6-37 QEC, Config, Output A/B/C Control/Indication Description Type Boost Rectifier Input – N/A Passive Input – N/A Real Output – source-only output (typically used for DC output) Reactive – source-sink output (typically used for AC output) Options Enable –...

  • Page 64: Table 6-39 Qec, Config, Hvdc

    OFTWARE Figure 6-45 QEC, Config, HVDC Table 6-39 QEC, Config, HVDC Control/Indication Description HVDC Maximum Voltage N/A (Qnergy only) Figure 6-46 QEC, Config, Minimum Engine Power Table 6-40 QEC, Config, Minimum Engine Power Control/Indication Description Minimum Engine Power Minimum power setpoint which the engine should try to...

  • Page 65: Table 6-42 Qec, Config, Output Power Limit

    Table 6-43 QEC, Config, HHT Setpoint Control/Indication Description HHT Setpoint Head temperature set point (°C) Figure 6-50 QEC, Config, Hall Switchpoints Table 6-44 QEC, Config, Hall Switchpoints Control/Indication Description All settings N/A (Qnergy Service Only) Import File Button Used to import engine converter calibration file...

  • Page 66: Fpc & Qec Faults Tab

    Button used to clear Faults CHANGING FPC and QEC SETPOINTS AND PARAMETERS • When changing a setpoint 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.

  • Page 67: Fpc, Feb & Qec Firmware Update

    Figure 6-55 Qnergy Lynx, Setpoints, Acceptable Values 6.6 FPC, FEB & QEC FIRMWARE UPDATE CAUTION: Make sure that you have the most up-to-date firmware file available from Qnergy customer support. Do not disconnect the communication cables or turn off the power during the firmware upgrade process!

  • Page 68: Figure 6-56 Fpc, Feb & Qec, Firmware Tab

    NERGY OFTWARE NOTE: Before upgrading firmware, the PowerGen must be disabled. FPC, FEB & QEC Firmware Update The firmware section is used to update FPC, FEB & QEC firmware. Figure 6-56 FPC, FEB & QEC, Firmware Tab Firmware UPLOAD instructions: •...

  • Page 69: Figure 6-57 Fpc, Feb & Qec, Firmware Update

    NERGY OFTWARE Figure 6-57 FPC, FEB & QEC, Firmware Update...

  • Page 70: Environmental Conditions For Storage

    NVIRONMENTAL ONDITIONS FOR TORAGE 7. ENVIRONMENTAL CONDITIONS FOR STORAGE The PowerGen battery should be disconnected during storage or connected using a battery trickle charger. It should be stored in the following conditions: • Maximum Temperature: 158°F (70°C) • Minimum Temperature for Standard Systems: -4°F (-20°C) •...

  • Page 71: Figure 8-1 Powergen Base Without Hru, Lifting By Rings Or Fork

    RANSPORTATION EQUIREMENTS Figure 8-1 PowerGen Base without HRU, Lifting by Rings or Fork Figure 8-2 PowerGen Base with HRU, Lifting by Forklift...

  • Page 72: Site Preparation Requirements

    REPARATION EQUIREMENTS Figure 8-3 PowerGen 6-person 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 skid without tying it directly to I-beam (or similar) supports.

  • Page 73: Gas Supply

    REPARATION EQUIREMENTS 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.

  • Page 74: Unpacking Procedure

    NPACKING ROCEDURE 10. UNPACKING PROCEDURE CAUTION: Report any damage to Qnergy immediately. 1. Remove the wooden top panel and wooden side panels. 2. Remove all anchoring bolts. 3. Place the PowerGen on a solid, level surface. 11. INSTALLATION PROCEDURE 11.1 SAFETY DURING INSTALLATION Installation of the PowerGen should be performed as follows: •...
  • Page 75 Helium Fill, measuring engine ambient to FPC. Read Head 1 and/or 2 temperature temperature readings Laptop, pre-configured with Commissioning PowerGen Qnergy Lynx Software, CAN bus Driver 4520-101097-000, CAN bus Cable Communicate to FPC for Commissioning PN: 3837, LM-2 Hand-held Gas Valve Tuning...

  • Page 76: Electrical Connection

    NSTALLATION ROCEDURE Table 11-1 Tools and Materials Description Quantity Purpose Gas Leak Detector Spray or 1 (bottle) Gas Connection Sensor *PowerGen is shipped full of coolant from the factory. However topping-off the coolant level may be required during commissioning. 11.3 ELECTRICAL CONNECTION WARNING: There is a danger of fatal electric shock from touching live connections.

  • Page 77: Figure 11-1 Power And Communications Feed Location

    NSTALLATION ROCEDURE WARNING: All field wiring must be 90°C (194°F) minimum, copper conductor wire only. CAUTION: Make sure that the wires are securely fixed in the terminal block. The PowerGen has pre-drilled 1.05” holes in the frame to feed through the Output Power and the Communications cables (see Table 11-1 on 62).

  • Page 78: Table 11-2 Powergen Electrical Power Terminal Block Description

    NSTALLATION ROCEDURE 11.3.3 Connection to POWERGEN 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 Common 6 - 20 Output A (Hot Leg) Output B (Hot Leg)

  • Page 79: Table 11-3 Powergen Fpc Expansion Board Input Description

    • Tamb below limit • Coolant low flow • Note: The disable/enable function within Qnergy Lynx and e-stop will override any remote signal. LUI enable/disable push button will not function while in remote mode. Further information can be found in see Section 12.9...

  • Page 80: Table 11-5 Powergen Fpc Expansion Board Terminal Block Description

    11.3.5 External (Customer) Emergency Stop connection Located on the FEB, the PowerGen emergency stop (Orange Terminal Block) circuit is a normally open, discrete input (dry contact) allowing the customer to enable/disable the system. For further information please contact Qnergy Customer Support.

  • Page 81: Table 11-6 Powergen Fpc Expansion Board Emergency Stop Terminal Block Description

    The PowerGen uses the CAN bus communication protocol to communicate to external devices such as computers. Using the optional CAN to USB cable and Qnergy Lynx software, communicating to the FPC board is possible. The communication data rate is 125kpps.

  • Page 82: Gas Connection

    Note: The PowerGen generates slight vertical vibration while in operation due to the movement of the Stirling engine. If the use of flexible metal-sheathed pipe or flexible expansion loop is not acceptable please contact Qnergy technical support to discuss other options.

  • Page 83: Commissioning Procedure

    OMMISSIONING ROCEDURE 12. COMMISSIONING PROCEDURE 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 Allen wrench. Figure 12-1 Side Panel Latch Locations...

  • Page 84: Battery Connection Instructions

    Deep cycle, 12 VDC VRLA 40 Ah, M5 - M6 threaded terminals. Remove the negative terminal first and replace last. Contact Qnergy Customer Support for adding additional battery capacity. WARNING: Do not dispose of the battery on a fire as it is capable of exploding.

  • Page 85: Figure 12-2 Battery Warning Label

    PowerGen. Figure 12-2 Battery Warning Label Prior to shipping the PowerGen to the customer Qnergy disconnects the 12VDC battery cable from all loads. The 12VDC battery will need to be connected during the commissioning of the PowerGen. To reconnect the battery cable, perform the following: 1.

  • Page 86: Figure 12-3 Powergen Left-Hand-Side Door Removed

    OMMISSIONING ROCEDURE Figure 12-3 PowerGen Left-Hand-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 Jump-start procedure (see “Jump-Start Procedure” on page 148).

  • Page 87: Opt-Connect Cell Modem Install

    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 hardware version (QEC serial number starts with a 5xxxxxxxx).

  • Page 88: Helium Fill

    -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 pressure. Never hammer, weld, or drill on any part of the engine. Never transport the engine while filled with greater than 2 bar (30 PSI) of helium.

  • Page 89: Figure 12-5 Helium Fill Kit

    12.5.1 SAFETY REGULATOR FITTING, INLET NUT The Qnergy Fill Kit is shipped with a CGA 580 regulator fitting, 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.

  • Page 90: Figure 12-6 Regulator Fitting, Inlet Nut, Cga 580

    OMMISSIONING ROCEDURE 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: Figure 12-8 Helium Kit, Regulator Spring

    OMMISSIONING ROCEDURE WARNING: Both pressure gauges must read the same value. If they do not, then replace one or both gauges until an accurate pressure measurement can be determined through two independent gauges. NOTE – The Digital pressure gauge uses an LCD and will not function properly during exposure to cold temperatures.

  • Page 92: Figure 12-9 Helium Tank

    OMMISSIONING ROCEDURE Figure 12-9 Helium Tank 6. PURGE any residual air from the Kit. NOTE: Pressure gauges only display PSI. 7. Tighten the regulator (clockwise). 8. Pressurize the fill kit to 100 PSI. 9. Loosen the regulator (anti-clockwise). 10.Reduce pressure to 30psi through self-venting of the regulator. 11.

  • Page 93: Figure 12-11 Helium Fill Rate

    OMMISSIONING ROCEDURE CAUTION: To avoid damaging the Stäubli coupling, it should be attached as close to perpendicular as possible 12. Adjust the regulator as needed to stop gas flow if the pressure of the engine needs to be assessed. NOTE: IF the engine was already pressurized for some reason, working gas will immediately begin back flowing rapidly through the regulator self-venting feature.

  • Page 94: Table 12-1 Target Charging Pressure

    OMMISSIONING ROCEDURE 16.Once the target charge pressure has been reached, WAIT at least five additional minutes for pressure to stabilize. Make any fine adjustments to pressure during this time and then disconnect the Staubli valve from the engine. 17. Close the helium source tank valve and bleed helium from the Helium Fill Kit prior to removing the helium kit from source tank.

  • Page 95: Gas Pressure, Customer

    OMMISSIONING ROCEDURE 12.6 GAS PRESSURE, CUSTOMER Verify the customer gas pressure as read on the 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) only. WARNING: Danger of burning and scalding! Beware of hot surfaces near the Lambda sensor and burner.

  • Page 96: Figure 12-13 Blower Tuning Screws

    ROCEDURE WARNING: Gas valve tuning should be carried out by Qnergy-approved technicians only. Note: Prior to commissioning the PowerGen please verify that the Qnergy Lynx, QEC Load-following parameters are set-up correctly, per the customer electrical load see Table 12.11. Note: The PowerGen is factory set and tested to Natural Gas. If application requires the use of Propane (LPG), turn screw #3 clockwise 3 turns prior to enabling the PowerGen.

  • Page 97: Figure 12-14 Head Temp Setpoint

    OMMISSIONING ROCEDURE 2. Attach a Lambda sensor to the exhaust outlet, at the threaded boss. Turn on the gage and make sure it is calibrated; the reading should be 20.9. 3. On the Lynx FPC/Config Tab, Set Head Setpoint to 600°C and click Set. Figure 12-14 Head Temp Setpoint 4.

  • Page 98: Figure 12-15 Lynx, Max Blower To 80

    OMMISSIONING ROCEDURE 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: Figure 12-17 Fpc Tab, Enable

    If the PowerGen does not start (ignition failure fault): Adjust the #3 screw (shown in Figure 12-13 on page 84) counter-clockwise a half a turn to start 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.

  • Page 100: Figure 12-18 Qnergy Lynx, Qec, Configuration Tab, Minimum Engine

    OMMISSIONING ROCEDURE Figure 12-18 Qnergy Lynx, QEC, Configuration Tab, Minimum Engine Power CAUTION: Never set Minimum Engine Power greater than 5000 W. 10.Allow up to 5 minutes for the unit head temperature to stabilize. 11. The Lambda reading should be 1.18 +/- 0.01.

  • Page 101: Gas Valve Tuning, Powergen 600, 1200, 1800 (Low Temp Systems Included)

    OMMISSIONING ROCEDURE Figure 12-19 Qnergy Lynx, Output Power Limit to 600W NOTE: The #2 screw has a cover (plug) that must be removed prior to turning the screw. 15. To decrease Lambda, turn screw #2 clockwise (see Figure 12-13 on page 84) 16.To increase Lambda, turn screw #2 counter-clockwise (see Figure 12-13 on page 84).
  • Page 102 ROCEDURE WARNING: Gas valve tuning should only be carried out by Qnergy-approved technicians. NOTE: Prior to commissioning the PowerGen please verify that the Qnergy Lynx, QEC Load-following parameters are set-up correctly, per the customer electrical load see (Chapter 12.10) NOTE: The PowerGen 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.

  • Page 103: Figure 12-20 Blower Tuning Screws

    OMMISSIONING ROCEDURE Figure 12-20 Blower Tuning 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 600 °C and click set. Figure 12-21 Head Temp Setpoint...

  • Page 104: Figure 12-22 Qnergy Lynx, Max Blower To 80

    PowerGen for the first time and while setting-up QEC Load-following parameters. Contact Qnergy Customer Support if unfamiliar about how to correctly setup the PowerGen, Qnergy Lynx, Load-following parameters: +1(801)413-7668 (Customer Support Hotline). 7. Start the PowerGen by clicking Enable in Qnergy Lynx.

  • Page 105: Figure 12-23 Fpc Tab, Enable

    8. If the PowerGen does not start (ignition failure fault): adjust the #3 screw (shown in Figure 12-20 on page 91) counter-clockwise a half a turn to start with a richer combustion. This can be repeated up to six times. If the unit still does not ignite, contact Qnergy customer support, (801) 413-7668.

  • Page 106: Feb Gpio Configuration

    17. Repeat steps #6 through #16 until the gas regulator is tuned correctly. 18.Verify head temperature is 530°C 12.9 FEB GPIO CONFIGURATION Configuring the FEB board I/O via the Qnergy Lynx software CAUTION: Never adjust or configure the FEB I/O settings while the PowerGen system is enabled.

  • Page 107: Figure 12-25 Feb Gpio Configuration

    OMMISSIONING ROCEDURE Figure 12-25 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 Set GPIO button to make choices active.

  • Page 108: Table 12-2 Feb I/O Inputs Defined

    OMMISSIONING ROCEDURE Table 12-2 FEB I/O Inputs Defined Input Closed Circuit Open Circuit System Toggle System enabled System disabled System Enabled System enabled No behavior System Disabled No behavior System disabled Load Toggle LD disconnect relay open LD disconnect relay closed (used on LD Disconnect relay on FEB)

  • Page 109: Table 12-3 Feb I/O Outputs Defined

    OMMISSIONING ROCEDURE Table 12-3 FEB I/O Outputs Defined Outputs Closed Circuit Open Circuit System Enabled PowerGen enabled PowerGen disabled Engine Running Engine running Engine not running System Faulted System has a fault No active faults System Warning System has a warning No active warnings E-Stop Active E-stop is activated...

  • Page 110: Modbus

    OMMISSIONING ROCEDURE Figure 12-26 FEB Inputs, Outputs, and LD Disconnect Locations 12.10 MODBUS Table 12-4 Modbus, General Access Modbus Modbus Type Size Description Notes (Read, Register Coil Write Write, Write (06) (05) Clear) 40001 WORD 16 bit System Always reads 0 commands BOOL System...

  • Page 111: Table 12-5 Modbus, System Faults/Warnings

    OMMISSIONING ROCEDURE Table 12-5 Modbus, System Faults/Warnings Access Modbus Modbus Type Size Description Notes (Read, Register Register Write, Read Write Clear) (03) (06) 40002 UINT Number of present faults 40003 40003 UINT Selected fault Write the index to select a fault 40004 40004...

  • Page 112: Table 12-8 Modbus, System Status And Information

    OMMISSIONING ROCEDURE Table 12-8 Modbus, System Status and Information Access Modbus Type Size Description Unit Notes (Read, Register Write, Read Clear) (03) 40045 ENUM 16 bit System operation See ENUM table state 40049 UINT 16 bit FPC firmware version {hh.hh} Patch.Build (hh - 8bit hex) [Low Word] 40050...

  • Page 113: Table 12-9 Modbus, Measurements

    OMMISSIONING ROCEDURE Table 12-9 Modbus, Measurements Access Modbus Type Size Description Unit Notes (Read, Register Write, Read Clear) (03) 40060 16 bit Engine bay 1 temp [°C]*10 40061 16 bit Engine bay 2 temp [°C]*10 40062 16 bit Engine bay bottom temp [°C]*10 40063 16 bit...

  • Page 114: Table 12-10 Modbus, Debug Values

    OMMISSIONING ROCEDURE Table 12-10 Modbus, Debug Values Access Modbus Modbus Type Size Description Units Notes (Read, Register Coil Write, Read (03) Read Clear) (01) 40096 16 Bit QEC output [V]*10 QEC firmware 1 voltage 3.0.0+ 40097 16 Bit QEC output [V]*10 QEC firmware 2 voltage...
  • Page 115 OMMISSIONING ROCEDURE Table 12-10 Modbus, Debug Values Access Modbus Modbus Type Size Description Units Notes (Read, Register Coil Write, Read (03) Read Clear) (01) GPI5 GHT level warning GPI6 GHT on/off switch Disconnect switch 40201 UINT 16 Bit Active fault code 1 40202 UINT...
  • Page 116 OMMISSIONING ROCEDURE Table 12-10 Modbus, Debug Values Access Modbus Modbus Type Size Description Units Notes (Read, Register Coil Write, Read (03) Read Clear) (01) 40214 UINT 16 Bit Active fault code 14 40215 UINT 16 Bit Active fault code 15 40216 UINT 16 Bit...

  • Page 117: Table 12-11 Modbus, Enum

    OMMISSIONING ROCEDURE Table 12-11 Modbus, ENUM Register Name Value Description 40042 - Input UNUSED functions for START_STOP Unit will start if selected input assigning to input channel is shorted. Will stop if channel selected in the channel is opened 40041 START Unit will start if selected input channel is shorted.
  • Page 118 OMMISSIONING ROCEDURE Table 12-11 Modbus, ENUM Register Name Value Description 40044 - Output ENABLED Close if engine is enabled or function for assigning disabling. to output channel RUNNING Close if engine is running selected in 40043 (power>0W). FAULT Close if there is a fault active. WARNING Close if there is an active warning.

  • Page 119: Qec Configuration For Load-Following

    CAUTION: Disconnect customer electrical load prior to enabling the PowerGen for the first time and while setting-up QEC Load-following parameters. Contact Qnergy Customer Support if unfamiliar about how to correctly setup the PowerGen, Qnergy Lynx, Load-following parameters: +1(801)413-7668 (Customer Support Hotline)

  • Page 120: Figure 12-27 Qnergy Lynx, Qec, Configuration Tab

    Load-following allows for the PowerGen to use less fuel when there is less power required while still being able to meet peak power demand. NOTE: Prior to commissioning the PowerGen please verify that the Qnergy Lynx, QEC Load-following parameters are set-up correctly, per the customer electrical load.

  • Page 121: Figure 12-29 Qnergy Lynx, Qec, Load Following Setup Flow Chart

    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 two outputs reconnect the second output. 12. Verify all loads start as normal. Figure 12-29 Qnergy Lynx, QEC, Load Following Setup Flow Chart...

  • Page 122: Coolant Top-Off Instructions

    TARTUP ROCEDURE 12.12 COOLANT TOP-OFF INSTRUCTIONS The PowerGen’s coolant loop is shipped full to the customer location. During commissioning the coolant loop may need to be topped-off. Approximately 4.2 gallons of 50/50, Antifreeze coolant mixture will be required to fill entire coolant loop. The PowerGen requires Preston AF2000 Cor-Guard antifreeze coolant, 50/50, coolant/water mix (4.2 gal total).

  • Page 123: User Interface Indicators And Controls

    The gas is off. The PowerGen is turned off and cooled down. 14.1 LOG FILES Log files are created when the Qnergy Lynx software is running. The log files for FPC and QEC are in one of the following directories:...

  • Page 124: Fault Messages, Powergen

    AULT ESSAGES OWER C:\ProgramData\Qnergy\Logs See “Fault Messages, PowerGen” on page 112 for detailed description of PowerGen Fault Codes. 15. FAULT MESSAGES, POWERGEN 15.1 FPC & QEC FAULT MESSAGES When a fault occurs, the PowerGen will display the name of the fault in the table. Table 15-2, Table 15-3, Table 15-4, Table 15-5, and Table 15-6 lists the faults and their possible causes.

  • Page 125: Table 15-2 Powergen Error Messages, Service Required

    AULT ESSAGES OWER Table 15-2 PowerGen Error Messages, Service Required Fault Code Description Possible Causes 1001 No CAN response from QEC QEC has no terminating resistor on the CANBUS line, CAN harness damaged between the FPC and QEC, QEC CAN address is not configured correctly, hardware issue 1002...
  • Page 126 AULT ESSAGES OWER Table 15-2 PowerGen Error Messages, Service Required Fault Code Description Possible Causes 1006 Engine start timeout QEC did not report a “running” status within a specified time. • If head temperature is above 180C Verify helium pressure is correct. DO NOT PROCEED WITHOUT VERIFYING HELIUM PRESSURE and gas quality, Failure in doing so can result in...
  • Page 127 AULT ESSAGES OWER Table 15-2 PowerGen Error Messages, Service Required Fault Code Description Possible Causes 1009 Burner blower RPM out of range During startup, blower RPM readings are outside the thresholds. Power disconnect switch in OFF position, low battery charge or damaged battery, blower not programmed to speed mode (<PG153), incorrect blower setting, blocked filter or exhaust, damaged blower, blower...
  • Page 128 AULT ESSAGES OWER Table 15-2 PowerGen Error Messages, Service Required Fault Code Description Possible Causes 1012 Internal circulating pump Pump supply voltage is out of range electrical fault (Feedback 85%) or short on feedback signal (Feedback 100%), bad pump electronics. 1014 QEC did not wake up System wiring problem faulty QEC/FPC...

  • Page 129: Table 15-3 Powergen Error Messages, User Clearable

    AULT ESSAGES OWER Table 15-3 PowerGen Error Messages, User Clearable Fault Code Description Possible Causes 2003 Heater head temperature too Heater head temperature high reached the maximum allowed limit. Hall noise, power limit too low when blower rate is at minimum, incorrect HHT offset calibration, wrong converter file loaded, bad engine.
  • Page 130 AULT ESSAGES OWER Table 15-3 PowerGen Error Messages, User Clearable Fault Code Description Possible Causes 2013 No QEC heartbeat detected QEC firmware problem Powercycle QEC 2014 Burner ignition failure BCU does not detect a stable flame. Gas composition issue- condensate or bad caloric value, incorrect gas valve calibration, bad igniter, bad flame sensor, bad ground,...
  • Page 131 AULT ESSAGES OWER Table 15-3 PowerGen Error Messages, User Clearable Fault Code Description Possible Causes 2016 Internal circulating pump load Pump feedback is outside is out of range expected power draw range during initial startup test. Air in the cooling system, pump friction, incorrect glycol concentration on cold startups.
  • Page 132 AULT ESSAGES OWER Table 15-3 PowerGen Error Messages, User Clearable Fault Code Description Possible Causes 2017 Internal circulating pump is Pump feedback signal is 90% blocked suggesting too much flow resistance, pump motor is blocked, Bad pump. • Loosen blocked pump, If serial number is below PG260 and has a gold color coolant in it, flush...
  • Page 133 AULT ESSAGES OWER Table 15-3 PowerGen Error Messages, User Clearable Fault Code Description Possible Causes 2024 ‘Duct Jacket’ temperature Temperature on the cooled critical exhaust duct is above 230°F/110°C • If sensor readings are unstable, verify sensor seated well. Replace sensor.

  • Page 134: Table 15-4 Powergen Error Messages, Auto Reset

    AULT ESSAGES OWER Table 15-3 PowerGen Error Messages, User Clearable Fault Code Description Possible Causes 2026 Cooling capacity insufficient Fouled radiator on air side, seized HRU fan or failed fan, insufficient coolant, HRU panel left open, incorrect fan type configured, windy conditions. •...

  • Page 135: Table 15-5 Powergen Error Messages, Warning

    AULT ESSAGES OWER Table 15-5 PowerGen Error Messages, Warning Fault Code Description Possible Causes 4003 External E-Stop signal was The customer E-Stop circuit activated on orange terminal was opened by a safety device disabling the unit, low battery voltage. 4004 CAN node ID is out of range Illegal CAN node ID has been sent by an external command.
  • Page 136 AULT ESSAGES OWER Table 15-5 PowerGen Error Messages, Warning Fault Code Description Possible Causes 4008 ‘Engine Bay 2’ temp sensor Sensor failed open or short failed circuit, bad wiring. • Inspect the channel NTC2 on the FPC is connected • Inspect connector and cable for damage.
  • Page 137 AULT ESSAGES OWER Table 15-5 PowerGen Error Messages, Warning Fault Code Description Possible Causes 4011 ‘Exhaust Duct Jacket’ temp Sensor failed open or short sensor failed circuit, bad wiring. • Inspect the channel NTC5 on the FPC is seated well. •...
  • Page 138 AULT ESSAGES OWER Table 15-5 PowerGen Error Messages, Warning Fault Code Description Possible Causes 4016 Engine coolant level too low Insufficient engine coolant in the overflow tank caused by evaporation at the tank, permeation through rubber hoses or a leak. •...
  • Page 139 AULT ESSAGES OWER Table 15-5 PowerGen Error Messages, Warning Fault Code Description Possible Causes 4018 Cabinet door open Cabinet door is open, sensor cable is unplugged, magnet spacing incorrect, sensor failed. • Close cabinet door • Check black wire connected to FPC board at P11 (bottom right corner).
  • Page 140 AULT ESSAGES OWER Table 15-5 PowerGen Error Messages, Warning Fault Code Description Possible Causes 4023 GHT no flow detected Closed valve on customer circuit, more than 20gal of glycol in system, plugged GHT strainer (on PowerGen), GHT pump speed setting too low, damaged pump, bad wiring, power to pump unplugged.
  • Page 141 AULT ESSAGES OWER Table 15-5 PowerGen Error Messages, Warning Fault Code Description Possible Causes 4027 Burner blower false RPM Blower RPM <10 or reading RPM>10,000 during operation for more than 2 seconds. • Inspect harnesses to blower. • Verify QEC auxiliary output settings.

  • Page 142: Table 15-6 Powergen Error Messages, Informative

    AULT ESSAGES OWER Table 15-6 PowerGen Error Messages, Informative Fault Code Description Possible Causes 5001 Pump voltage is too low Overloaded auxiliary power line, incorrect QEC auxiliary voltage settings, problem with QEC hardware, bad pump, warning 4006 in FW prior to 1.8.0.

  • Page 143: Table 15-7 Qec Error Messages, Qec 3 (Firmware 2.X.x)

    AULT ESSAGES OWER Table 15-7 QEC Error Messages, QEC 3 (Firmware 2.X.X) Fault Code Description Possible Causes 11002 Engine at lowest stroke ADC calibration not done, command and halls still at limit engine measurements are wrong, burner issue, engine hardware issue. 11003 Positive bus voltage greater Battery is bad, brake is not...
  • Page 144 AULT ESSAGES OWER Table 15-7 QEC Error Messages, QEC 3 (Firmware 2.X.X) Fault Code Description Possible Causes 11505 Too many hall direction Noise changes detected 11506 Bump initiated when engine Firmware issue was already bumping 11507 System cannot run if the stall QEC haw failure is engaged 11508...
  • Page 145 AULT ESSAGES OWER Table 15-7 QEC Error Messages, QEC 3 (Firmware 2.X.X) Fault Code Description Possible Causes 12007 E-Stop is active Internal E-stop triggered. Can be caused by 12V supply to FEB pulled low. Check loads on 12V supply to FEB (gas valve Heater, etc.).
  • Page 146 AULT ESSAGES OWER Table 15-7 QEC Error Messages, QEC 3 (Firmware 2.X.X) Fault Code Description Possible Causes 13003 Coolant flow rate too low Check for air in the system, (below 5 Lpm) look for coolant leaks. Run the fill sequence and top up if needed.

  • Page 147: Table 15-8 Qec Error Messages, Qec 3.5 (Firmware 3.X.x)

    AULT ESSAGES OWER Table 15-7 QEC Error Messages, QEC 3 (Firmware 2.X.X) Fault Code Description Possible Causes 14006 Piston bias measures above High bias engine, hall limit calibration is wrong 14007 Check the hall sensor line for Firmware issue or noise in hall noise line 14008...
  • Page 148 AULT ESSAGES OWER Table 15-8 QEC Error Messages, QEC 3.5 (Firmware 3.X.X) Fault Code Description Possible Causes • Update QEC firmware to 11005 Hall watchdog timer has 3.2.1 or later expired • Problem with the engine hall sensors • Bad engine connection •...
  • Page 149 AULT ESSAGES OWER Table 15-8 QEC Error Messages, QEC 3.5 (Firmware 3.X.X) Fault Code Description Possible Causes 12006 Engine running detected while QEC hardware failure QEC is disabled 12007 E-stop is active Internal E-stop triggered. 12V supply to FEB pulled low, check battery voltage above 12V during startup, check loads on 12V supply to FEB (gas...
  • Page 150 AULT ESSAGES OWER Table 15-8 QEC Error Messages, QEC 3.5 (Firmware 3.X.X) Fault Code Description Possible Causes • Check for air in the 13003 Coolant flow rate too low system, look for coolant (below 5 lpm) leaks. Run the fill sequence and top up if needed.

  • Page 151: Long-Term Storage

    TORAGE Table 15-8 QEC Error Messages, QEC 3.5 (Firmware 3.X.X) Fault Code Description Possible Causes 14011 Output A tripped due to Output is shorted overload 14012 Output B tripped due to Output is shorted overload 14013 Output C tripped due to Output is shorted overload •...

  • Page 152: Figure 16-1 Battery Warning Label

    TORAGE Figure 16-1 Battery Warning Label If long-term storage of the PowerGen is required customer will need to verify that the internal 12VDC battery is disconnected from the QEC. The 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.

  • Page 153: Figure 16-3 Powergen Left-Hand-Side View

    The battery shall be a: Deep cycle, 12 VDC VRLA 40 Ah, M6 threaded terminals. Please note: Remove the negative terminal first and replace last. Contact Qnergy Customer Support for adding additional battery capacity.

  • Page 154: Maintenance

    AINTENANCE 17. MAINTENANCE CAUTION: Only original Qnergy-issued parts should be used when performing maintenance and repair work. For details of available spare 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 time for the components to cool down.

  • Page 155: Maintenance, Battery, 12Vdc

    Deep cycle, 12 VDC VRLA 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 on a fire as it is capable of exploding.

  • Page 156: Coolant Fill Instructions

    AINTENANCE WARNING: 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, rings, or other metal objects from your person. -Use tools with insulated handles. Wear rubber gloves and boots.

  • Page 157: Figure 17-1 Qnergy Lynx, Fill Sequence

    5. Top up the radiator (Figure 17-2) close caps. 6. Fill over flow tank to about 2” from top of black plastic lid (Figure 17-2). 7. Run FPC auto-fill sequence by clicking on Qnergy Lynx, Fill Sequence button (located on the bottom of the Qnergy Lynx software).

  • Page 158: Figure 17-2 Radiator And Over Flow Tank

    AINTENANCE Figure 17-2 Radiator and Over Flow Tank...

  • Page 159: Burner/Burner Ceramic/Burner Seal Replacement

    AINTENANCE Figure 17-3 Air Removal Plug 17.4 BURNER/BURNER CERAMIC/BURNER SEAL REPLACEMENT WARNING: Danger of Gas Leak and/or Gas Explosion! Extreme care must be taken when replacing 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.

  • Page 160: Jump-Start Procedure

    -Never cross-connect positive and negative terminals. -Cross connecting terminals will cause hardware failure in the Qnergy, PowerGen, Engine Controller (QEC). If the PowerGen 12VDC battery has low voltage due to being disabled for long periods of time or any other reason please follow steps below to jump-start PowerGen 12VDC battery.

  • Page 161: Spare Parts

    13. Once the PowerGen is enabled, remove the jumper cables from the PowerGen battery and truck. 14.Replace the PowerGen side panel. 18. SPARE PARTS CAUTION: Only original Qnergy-issued parts should be used when performing maintenance and repair work. For details of available spare parts, please contact Qnergy customer support.

  • Page 162: Table 18-3 Igniter And/Or Flame Sense Replacement

    PARE ARTS Table 18-3 Igniter and/or Flame Sense Replacement Part # Description 1500-101114-000 ELECTRODE, SPARK, MALE PLUG CONNECTOR 1500-101115-000 ELECTRODE, FLAME SENSOR, MALE PLUG CONNECTOR 1500-101083-000 GASKET, BURNER ELECTRODE, POWERGEN Table 18-4 Gas Blower Replacement Part # Description 6010-103116-000 BLOWER, 230 VAC 6000-103535-000 HOSE CLAMP, WORM DRIVE, 1/2"...

  • Page 163: Table 18-7 Over Flow Tank W/Sensor Replacement

    PARE ARTS Table 18-7 Over Flow Tank w/Sensor Replacement Part # Description 3520-101110-000 OVER FLOW TANK, 4 QUART, WITH SENSOR Table 18-8 Coolant Pump Replacement Part # Description 6000-103592-000 PUMP, CIRCULATOR, UPM GEO 25-85 180, 230 VAC PWM, 270 DEG. 6000-103588-000 O-RING, 2-220, EPDM, 70A Table 18-9 Radiator Replacement...

  • Page 164: Table 18-10 Hose And Hose Clamp Replacement

    PARE ARTS Table 18-10 Hose and Hose Clamp Replacement Part # Description 3520-101060-000 HOSE, COOLANT, MOLDED, FLOW SENSOR TO CLOSEOUT 6000-103236-000 HOSE, GREEN STRIPE, 1 IN ID, MAX 75 PSI, FLOW SENSOR TO QEC, 950mm 6000-103236-000 HOSE, GREEN STRIPE, 1 IN ID, MAX 75 PSI, QEC TO HRU PUMP, 375mm 6000-103236-000 HOSE, GREEN STRIPE, 1 IN ID, MAX 75 PSI, RADIATOR TO...

  • Page 165: Table 18-13 Filter Replacement

    PARE ARTS Table 18-13 Filter Replacement Part # Description 6000-103880-000 FILTER, 12"x12"x2”, POLYESTER, MERV 6 6000-103881-000 FILTER, 12”x12”x2”, POLYESTER, TACKIFIED Table 18-14 Sensor and/or Thermocouple Replacement Part # Description 6010-102555-000 FLOW SENSOR, VFS 5-100 V1.0, 97842266 4520-101216-000 TRANSDUCER, PRESSURE, FUEL 4520-101172-001 NTC, ENGINE TOP BAY, HARNESS 4520-101172-002...

  • Page 166: Table 18-17 Local User Interface (Lui) Replacement

    PARE ARTS Table 18-17 Local User Interface (LUI) Replacement Part # Description 6010-103085-000 PILOT LIGHT, 22MM TUFFLED, 5-28V, SCREW TERMINALS, IP67, -40C TO 80C, RED 6010-103087-000 PILOT LIGHT, 22MM TUFFLED, 5-28V, SCREW TERMINALS, IP67, -40C TO 80C, YELLOW 6010-103086-000 PILOT LIGHT, 22MM TUFFLED, 5-28V, SCREW TERMINALS, IP67, -40C TO 80C, GREEN Table 18-18 Exhaust Parts Replacement Part #...

  • Page 167: Powergen Reports And Checklists

    Gas Connection (Chapter 11.4, Installation Manual) Customer Gas Pressure to PowerGen • 3-50 PSI, Natural Gas • 2-10 PSI, LPG • Biogas (consult with Qnergy Engineering Dept.) Earth Ground Connection to front of PowerGen enclosure (Section 11.3.7 PowerGen earth ground connection) Customer Signature...

  • Page 168: Powergen Commission Report

    Appliance Site (Country, City and Place) Site Name GPS Location Commissioning Date PowerGen Serial Number OptConnect Modem SN PowerGen Model and 5650 1800 1200 Low Temp add-ons: Qnergy Gas Conditioning (GCU) Modbus Switch Commissioning Technician Name Commissioning Technician Authorized Serial Number...

  • Page 169: Commission Sequence

    OWER EPORTS AND HECKLISTS 19.3 COMMISSION SEQUENCE Table 19-4 Commissioning Checklist Step # Step Initials Connect 12VDC Battery in PowerGen • Connect ring terminal on black wire to the black terminal on the battery Disconnect customer electrical load Engine Helium Fill (See “Helium Fill” on page 76) •...
  • Page 170 • Customer load to be connected only after initial running of the PowerGen • Check wiring, check grounding Reconnect customer electrical load to Qnergy terminal blocks after verifying customer loads (See “Electrical Connection” on page 64): • Measure voltage and current output from PowerGen •...

  • Page 171: Table 19-5 Fpc Expansion Board Discrete Input Configuration

    OWER EPORTS AND HECKLISTS Table 19-5 FPC Expansion Board Discrete Input Configuration Input Default Configured to: Initials Table 19-6 FPC Expansion Board Relay Output Configuration Input Default Configured to: Initials...

  • Page 172: Powergen Annual Inspection Checklist

    OWER EPORTS AND HECKLISTS 19.4 POWERGEN ANNUAL INSPECTION CHECKLIST Annual Inspection Start Time: ____________AM PM End Time: ____________AM PM Table 19-7 General Information General Information Customer Name Site Name Annual Inspection Date PowerGen Serial Number Technician Name/Distributor Name PowerGen Annual Inspection Checklist Initials Inspect the flue, fuel piping, and electrical connections for signs of damage, blockage, or deterioration...
  • Page 173 OWER EPORTS AND HECKLISTS PowerGen Annual Inspection Checklist Initials Update FPC firmware to latest released version FPC v. (record version type): Update QEC firmware to latest released version QEC v. (record version type): Update FEB firmware to latest released version FEB v.

  • Page 174: Powergen Operation

    OWER PERATION 20. POWERGEN OPERATION 20.1 OPERATION WARNING: FOR YOUR OWN SAFETY READ THIS CHAPTER CAREFULLY 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 malfunction and may lead to a dangerous operating condition.

  • Page 175: Figure 20-1 User Interface Indicators And Controls

    OWER PERATION Figure 20-1 User Interface Indicators and Controls The Power Disconnect Switch is 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 is wired to the Power Disconnect Switch, which prevents the system from running when int the OFF position.

  • Page 176: Table 20-1 System Run Light

    OWER PERATION Table 20-1 System Run Light Condition Indication Description PowerGen Base running Power available Fast PowerGen is currently starting Power is not available at this stage Continuous Blinking 1 short blink PowerGen is currently Power is not available at this stage every 3 deactivating seconds...

  • Page 177: Table 20-3 Warning Light

    OWER PERATION Table 20-3 Warning Light Condition Indication Description No issues 1 short blink every 3 Low or no gas pressure Resets automatically when gas pressure seconds recovers 2 short blinks every Low coolant level Resets automatically once coolant is 3 seconds filled 3 short blinks...

  • Page 178: Powergen Optional Feature Sets

    Pump life and PowerGen efficiency is increased by doing so. Pump speed can be adjusted manually using the speed dial. Qnergy provides a recommended speed for each tube length so as to optimize performance and pump life. See Table 21-2 on...

  • Page 179: Table 21-1 Ght Components

    OWER PTIONAL EATURE 21.1.1 GHT Components Figure 21-1 GHT Components Table 21-1 GHT Components Item Number Description Supply Temp Sensor Supply Port, 1/2” NPT Female Fill Cap Reservoir Tank Visual Fill Indicator Return Port, 1/2” NPT Female Y Strainer Return Temp Sensor Plate Heat Exchanger Variable Frequency Drive (VFD) Pump...

  • Page 180: Figure 21-2 Lui, With Ght Switch

    Follow the instructions on the tag if your unit arrived without the Y strainer factory installed. Qnergy recommends adding a shutoff valve at the return port. The Y strainer can be used to drain the system if needed for maintenance, therefore a separate drain is not necessary.

  • Page 181: Table 21-2 Ght Vfd Speed Settings

    OWER PTIONAL EATURE 10.Remove and clean the Y strainer. Ensure a catch-pan or bucket is placed under the strainer in order to catch liquid when strainer is removed. 11. Reinstall Y strainer 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 Heat Trace...
  • Page 182 OWER PTIONAL EATURE 21.1.4 Setting Temperature Setpoint The temperature set point can be modified remotely by Modbus (see “Modbus” on page 98) or by the Lynx application. See Figure 21-3 on page 169 for how to access the setpoints in Lynx. The “Max Supply Limit”...

  • Page 183: Low Temperature Start (Lts)

    OWER PTIONAL EATURE 21.1.6 GHT Servicing Procedure In order to service any on the internal components (pump, heat exchanger, etc.), the internal system will need to be drained, not including the user heat trace line. If the Y strainer is installed on the return port, open the strainer and drain the coolant into a pan.

  • Page 184: Table 21-3 Lts Components

    OWER PTIONAL EATURE Figure 21-4 LTS Components Table 21-3 LTS Components Item number Description Engine Mounts Heater (4x) Fuse Box Coolant Pump Heater Jumper Cables Gas Valve Heater and Temp Sensor 21.2.1 LTS Helium Fill Chart for QB80 Engine Refer to “Helium 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, &...
  • Page 185 OWER PTIONAL EATURE 21.2.2 LTS Start-Up Procedure Below is the procedure for starting an LTS equipped PowerGen if the ambient temperature is below -15°C (5°F): 1. Locate a vehicle within 30 ft of the PowerGen. 2. Inspect the HRU fans to ensure they can freely spin. 3.

  • Page 186: Table 21-4 Lts Troubleshooting

    OWER PTIONAL EATURE 21.2.3 LTS Troubleshooting Table 21-4 LTS Troubleshooting Issue Possible Cause Remedy • Measure voltage at the No lights turn on QEC not receiving 12V power PowerGen 12V posts • Check fuse on jumper cables • Inspect wiring •...

  • Page 187: Figure 21-5 Gas Valve Heater And Temperature Sensor To Feb

    OWER PTIONAL EATURE 21.2.4 LTS Schematic Figure 21-5 Gas Valve Heater and Temperature sensor to FEB Figure 21-6 Fuse Box...

  • Page 188: Gas Conditioning Unit (Gcu)

    OWER PTIONAL EATURE 21.3 GAS CONDITIONING UNIT (GCU) Figure 21-7 PowerGen with GCU Installed The GCU feature provides the PowerGen with a knockout drum and heat trace line to ensure no condensates or liquids from the customer gas line penetrate the fuel train and impede it. The GCU achieves this through 2 main components.

  • Page 189: Figure 21-8 Drum Emptying Valve (Shown In Open Position)

    OWER PTIONAL EATURE 21.3.2 GCU Drum Emptying Procedure WARNING: Liquids and solids will exit the knockout drum at a high velocity. Be sure to clear path of emptying valve before opening. Eye and ear protection are required. The knockout drum is emptied by actuating the valve at the bottom of the drum. See Figure 21-8 below for valve location.

  • Page 190: Table 21-5 Gcu Troubleshooting

    OWER PTIONAL EATURE 21.3.3 GCU Troubleshooting Table 21-5 GCU Troubleshooting Issue Possible Cause Remedy Warning 4028 Knockout drum nearing Empty drum (see “GCU Drum capacity Emptying Procedure” on page 177) Fault 3004 Knockout drum at max Empty drum (see “GCU Drum capacity Emptying Procedure”...

  • Page 191: N+1 Automatic Transfer Switch (Ats)

    OWER PTIONAL EATURE 21.4 N+1 AUTOMATIC TRANSFER SWITCH (ATS) Figure 21-9 ATS Enclosure When two PowerGen systems are to be used with one as a redundant backup system, an Automatic Transfer Switch (ATS) is used to automatically transfer power to the customer load. The ATS is setup for a residential type 120/240 Vac Split Phase supply with the coils for the contactors being powered by 120 Vac.

  • Page 192: Table 21-6 Field Wiring Terminals

    OWER PTIONAL EATURE Connections to the enclosure are made to the field wiring terminals (Figure 21-9, “5”), as detailed in below in Table 21-6. Table 21-6 Field Wiring Terminals Position Designation Wire Gauge Torque X1 - Input GND/PE PowerGen A Common (Neutral) PowerGen A L1 PowerGen A L2 20-6 AWG...
  • Page 193 OWER PTIONAL EATURE 21.4.2 Battery Connections Each PowerGen system is equipped with an internal 40 Ah battery for system control power which will last up to 72 hours when the system is in ‘Standby’. Due to the nature of operation, the system may be in standby in excess of a 72 hour period.
  • Page 194 OWER PTIONAL EATURE...

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Powergen 1800 seriesPowergen 1200 seriesPowergen 600 series

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