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PowerGen 5650 Series
Qnergy PowerGen 5650 Series User Manual
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7045
-
1020
89-000
June 1, 20
21
Install
at
ion
&
Op
era
t
ion
Manual
FOR A QUALIFIED INST
ALLER
2
Table of Contents
Table of Contents
3
Warranty and Liability
13
Safety
13
Important Safety Instructions
13
Classification of Warnings
13
Basic Safety Instructions
14
Definition of Acronyms
16
Table 2-1 Definitions of Acronyms
16
System Introduction
17
System Summary
17
Figure 3-1 Powergen Base
17
Table 3-1 Technical Specifications, QRP 2B-XXX-XXX
18
Table 3-2 Powergen Model Numbers
20
Figure 3-2 Powergen Data Plate, 5650
21
Figure 3-3 Powergen Data Plate, 1200
21
Table 3-3 Powergen Electrical Power Output Options, 5650
22
Table 3-4 Powergen Electrical Power Output Options, 1800
23
Table 3-5 Powergen Electrical Power Output Options, 1200
24
Powergen Subsystems
25
Table 3-6 Powergen Electrical Power Output Options, 600
25
Figure 3-4 QB80 Stirling Engine and QEC
26
Figure 3-5 Piping and Instrumentation Diagram (P&ID)
27
Figure 3-6 P&ID Diagram
28
Figure 3-7 Heat Rejection Unit (HRU)
29
Figure 3-8 Heat Rejection Unit (HRU), Stand-Alone
30
Figure 3-9 Heat Rejection Unit (HRU), Mounted to Powergen Base
30
Figure 3-10 Heat Rejection Unit (HRU), Split Apart
31
Figure 3-11 Powergen Control and Local User Interface
31
Table 3-7 Powergen Control and Local User Interface Description
32
Dimensions
33
Table 4-1 Powergen Dimensions & Weight
33
Figure 4-1 Powergen Base Unit Dimensions
33
Powergen Interfaces
34
Local User Interface (Lui)
34
Communication and Control Interface
34
Figure 5-1 User Interface Indicators and Controls
35
Table 5-1 User Interface, System Run Light
36
Table 5-2 User Interface, Warning Light
36
Table 5-3 User Interface, Fault Light
37
Qnergy Lynx Software
38
Fpc
38
Figure 6-1 FPC, System Status
38
Figure 6-2 FPC System Command Buttons
38
Fpc Data and Configuration
39
Table 6-1 System Status and Control
39
Figure 6-3 FPC, Data Tab
39
Table 6-2 FPC, Data, System Info
40
Figure 6-4 FPC, Data, System Info
40
Table 6-3 FPC, Data, Temperature
41
Figure 6-5 FPC, Data, Temperature
41
Table 6-4 FPC, Data, Generator
42
Figure 6-6 FDC, Data, Generator
42
Table 6-5 FPC, Data, Cooling
43
Figure 6-7 FDC, Data, Cooling
43
Table 6-6 FPC, Data, Hall Sensor
44
Figure 6-8 FDC, Data, Hall Sensor
44
Table 6-7 FPC Data, Burner
45
Table 6-8 FPC, Data, Networking
45
Figure 6-9 FDC, Data, Burner
45
Figure 6-10 FDC, Data, Networking
45
Table 6-9 FPC, Data, Ignitions
46
Table 6-10 FPC, Data, FEB Gpios
46
Figure 6-11 FDC, Data, Ignitions
46
Figure 6-12 FDC, Data, FEB Gpios
46
Table 6-11 FPC, Data, FPC Gpios
47
Table 6-12 FPC, Data, Debug Data
47
Figure 6-13 FDC, Data, FPC Gpios
47
Figure 6-14 FDC, Data, Debug Data
47
Table 6-13 FDC, Data, General
48
Table 6-14 FPC, Data, Meters
48
Figure 6-15 FDC, Data, General
48
Figure 6-16 FDC, Data, Meters
48
Figure 6-17 FPC, Configuration Tab
49
Figure 6-18 FPC, Config, System Settings
49
Table 6-15 FPC, Config, System Settings
50
Table 6-16 FPC, Config, Head Setpoint
50
Figure 6-19 FPC Config, Head Setpoint
50
Table 6-17 FPC, Config, Coolant Setpoint (GHT Only)
51
Table 6-18 FPC, Config, Start PWM
51
Table 6-19 FPC, Config, Max Blower
51
Figure 6-20 FPC, Config, Coolant Setpoint (GHT Only)
51
Figure 6-21 FPC, Config, Start PWM
51
Figure 6-22 FPC, Config, Max Blower
51
Table 6-20 FPC, Config, User Network Settings
52
Table 6-21 FPC, Config, Internal Modem Network Settings
52
Figure 6-23 FPC, Config, User Network Settings
52
Figure 6-24 FPC, Config, Internal Modem Network Settings
52
Table 6-22 FPC, Config, GPI Settings
53
Figure 6-25 FPC, Config, GPI Settings
53
Figure 6-26 FPC, Config, GPO Settings
53
Table 6-23 FPC, Config, GPO Settings
54
Table 6-24 FPC, Config, Manual Pump & Fan Controls
54
Figure 6-27 FPC, Config, Manual Pump & Fan Controls
54
Qec
55
Table 6-25 FPC, Config, CAN Node ID
55
Figure 6-28 FPC, Config, CAN Node ID
55
Figure 6-29 QEC, System Status
55
Figure 6-30 QEC, System Command Buttons
55
Qec Data and Configuration
56
Table 6-26 QEC, System Status and Control
56
Figure 6-31 QEC, Data Tab
56
Table 6-27 QEC, Data, Output A/B/C
57
Table 6-28 QEC, Data, Brake
57
Figure 6-32 QEC, Data, Output a
57
Figure 6-33 QEC, Data, Brake
57
Table 6-29 QEC, Data, Battery
58
Figure 6-34 QEC Data, Battery
58
Figure 6-35 QEC, Data, Engine
58
Table 6-30 QEC, Data, Engine
59
Table 6-31 QEC, Data, Coolant
59
Figure 6-36 QEC, Data, Coolant
59
Table 6-32 QEC, Data, DC Bus
60
Table 6-33 QEC, Data, Piston
60
Figure 6-37 QEC, Data, DC Bus
60
Figure 6-38 QEC, Data, Piston
60
Table 6-34 QEC, Data, Debug Data
61
Table 6-35 QEC, Data, PCB Temp
61
Figure 6-39 QEC, Data, Debug Data
61
Figure 6-40 QEC, Data, PCB Temp
61
Table 6-36 QEC, Data, Counters
62
Figure 6-41 QEC, Data, Counters
62
Figure 6-42 QEC, Configuration Tab
62
Figure 6-43 QEC, Config, Output a
62
Table 6-37 QEC, Config, Output A/B/C
63
Table 6-38 QEC, Config, Battery Capacity
63
Figure 6-44 QEC, Config, Battery Capacity
63
Table 6-39 QEC, Config, HVDC
64
Table 6-40 QEC, Config, Minimum Engine Power
64
Table 6-41 QEC, Config, Output Power Buffer
64
Figure 6-45 QEC, Config, HVDC
64
Figure 6-46 QEC, Config, Minimum Engine Power
64
Figure 6-47 QEC, Config, Output Power Buffer
64
Table 6-42 QEC, Config, Output Power Limit
65
Table 6-43 QEC, Config, HHT Setpoint
65
Table 6-44 QEC, Config, Hall Switchpoints
65
Figure 6-48 QEC, Config, Output Power Limit
65
Figure 6-49 QEC, Config, HHT Setpoint
65
Figure 6-50 QEC, Config, Hall Switchpoints
65
Fpc & Qec Faults Tab
66
Table 6-45 FPC & QEC, Faults
66
Figure 6-51 FPC & QEC, Faults Tab
66
Figure 6-52 FPC & QEC, Fault Log
66
Fpc, Feb & Qec Firmware Update
67
Figure 6-53 Qnergy Lynx, Setpoints, Modified Condition
67
Figure 6-54 Qnergy Lynx, Setpoints, Illegal Condition
67
Figure 6-55 Qnergy Lynx, Setpoints, Acceptable Values
67
Figure 6-56 FPC, FEB & QEC, Firmware Tab
68
Figure 6-57 FPC, FEB & QEC, Firmware Update
69
Environmental Conditions for Storage
70
Transportation Requirements
70
Figure 8-1 Powergen Base Without HRU, Lifting by Rings or Fork
71
Figure 8-2 Powergen Base with HRU, Lifting by Forklift
71
Site Preparation Requirements
72
Floor
72
Figure 8-3 Powergen 6-Person Carrying Option
72
Gas Supply
73
Figure 9-1 Powergen Mounting Dimensions
73
Unpacking Procedure
74
Installation Procedure
74
Safety During Installation
74
Tools and Materials for Installation and Commissioning
74
Table 11-1 Tools and Materials
74
Electrical Connection
76
Figure 11-1 Power and Communications Feed Location
77
Table 11-2 Powergen Electrical Power Terminal Block Description
78
Figure 11-2 Powergen Electrical Terminal Blocks, Customer Connection Point
78
Table 11-3 Powergen FPC Expansion Board Input Description
79
Table 11-4 Powergen FPC Expansion Board Output Description
79
Table 11-5 Powergen FPC Expansion Board Terminal Block Description
80
Figure 11-3 Powergen FPC Expansion Board Terminal Blocks, Customer Connection Points
80
Table 11-6 Powergen FPC Expansion Board Emergency Stop Terminal Block Description
81
Figure 11-4 Powergen FPC Expansion Board Emergency Stop Terminal Blocks, Customer Connection Points
81
Gas Connection
82
Figure 11-5 Gas Connection Location
82
Commissioning Procedure
83
Panel Removal
83
Figure 12-1 Side Panel Latch Locations
83
Battery Connection Instructions
84
Figure 12-2 Battery Warning Label
85
Figure 12-3 Powergen Left-Hand-Side Door Removed
86
Figure 12-4 Powergen Left-Hand-Side QEC Battery/Can Bus/Flow Sensor
86
Opt-Connect Cell Modem Install
87
Lynx Qec3.5 Configuration for Commissioning
87
Helium Fill
88
Figure 12-5 Helium Fill Kit
89
Figure 12-6 Regulator Fitting, Inlet Nut, CGA 580
90
Figure 12-7 Helium Kit, Vent Valve
90
Figure 12-8 Helium Kit, Regulator Spring
91
Figure 12-9 Helium Tank
92
Figure 12-10 Helium Kit, Purge
92
Figure 12-11 Helium Fill Rate
93
Table 12-1 Target Charging Pressure
94
Gas Pressure, Customer
95
Gas Valve Tuning, Powergen 5650
95
Figure 12-12 Gas Pressure Reading
95
Figure 12-13 Blower Tuning Screws
96
Figure 12-14 Head Temp Setpoint
97
Figure 12-15 Lynx, Max Blower to 80
98
Figure 12-16 Qnergy Lynx, QEC, Configuration Tab, Output Power
98
Figure 12-17 FPC Tab, Enable
99
Figure 12-18 Qnergy Lynx, QEC, Configuration Tab, Minimum Engine
100
Gas Valve Tuning, Powergen 600, 1200, 1800 (Low Temp Systems Included)
101
Figure 12-19 Qnergy Lynx, Output Power Limit to 600W
101
Figure 12-20 Blower Tuning Screws
103
Figure 12-21 Head Temp Setpoint
103
Figure 12-22 Qnergy Lynx, Max Blower to 80
104
Figure 12-23 FPC Tab, Enable
105
Figure 12-24 Qnergy Lynx, QEC, Configuration Tab, Minimum Engine Power
105
Feb Gpio Configuration
106
Figure 12-25 FEB GPIO Configuration
107
Table 12-2 FEB I/O Inputs Defined
108
Table 12-3 FEB I/O Outputs Defined
109
Modbus
110
Table 12-4 Modbus, General
110
Figure 12-26 FEB Inputs, Outputs, and LD Disconnect Locations
110
Table 12-5 Modbus, System Faults/Warnings
111
Table 12-6 Modbus, Configuration
111
Table 12-7 Modbus, FEB I/O Configuration
111
Table 12-8 Modbus, System Status and Information
112
Table 12-9 Modbus, Measurements
113
Unit
113
Table 12-10 Modbus, Debug Values
114
Table 12-11 Modbus, ENUM
117
Qec Configuration for Load-Following
119
Figure 12-27 Qnergy Lynx, QEC, Configuration Tab
120
Figure 12-28 Qnergy Lynx, QEC, Configuration Tab, Output Power Limit
120
Figure 12-29 Qnergy Lynx, QEC, Load Following Setup Flow Chart
121
Coolant Top-Off Instructions
122
Handover to User
122
Startup Procedure
122
User Interface Indicators and Controls
123
Troubleshooting
123
Log Files
123
Figure 13-1 User Interface Controls
123
Fault Messages, Powergen
124
Fpc & Qec Fault Messages
124
Table 15-1 Powergen Error Messages Levels Explained
124
Table 15-2 Powergen Error Messages, Service Required
125
Table 15-3 Powergen Error Messages, User Clearable
129
Table 15-4 Powergen Error Messages, Auto Reset
134
Table 15-5 Powergen Error Messages, Warning
135
Table 15-6 Powergen Error Messages, Informative
142
Table 15-7 QEC Error Messages, QEC 3 (Firmware 2.X.X)
143
Table 15-8 QEC Error Messages, QEC 3.5 (Firmware 3.X.X)
147
Long-Term Storage
151
Powergen Long-Term Storage
151
Figure 16-1 Battery Warning Label
152
Figure 16-2 Powergen Left-Hand-Side Door Removed
152
Figure 16-3 Powergen Left-Hand-Side View
153
Maintenance
154
Preparation for Maintenance
154
Maintenance, Battery, 12Vdc
155
Coolant Fill Instructions
156
Figure 17-1 Qnergy Lynx, Fill Sequence
157
Figure 17-2 Radiator and over Flow Tank
158
Burner/Burner Ceramic/Burner Seal Replacement
159
Figure 17-3 Air Removal Plug
159
Jump-Start Procedure
160
Spare Parts
161
Table 18-1 Burner Seal Replacement
161
Table 18-2 Burner Insulation Replacement
161
Table 18-3 Igniter And/Or Flame Sense Replacement
162
Table 18-4 Gas Blower Replacement
162
Table 18-5 Gas Valve Replacement
162
Table 18-6 BRAHMA Replacement
162
Table 18-7 over Flow Tank W/Sensor Replacement
163
Table 18-8 Coolant Pump Replacement
163
Table 18-9 Radiator Replacement
163
Table 18-10 Hose and Hose Clamp Replacement
164
Table 18-12 Fan Replacement
164
Table 18-11 Battery Replacement
164
Table 18-13 Filter Replacement
165
Table 18-14 Sensor And/Or Thermocouple Replacement
165
Table 18-15 QEC-3.5 Replacement
165
Table 18-16 FPC And/Or FEB Replacement
165
Table 18-17 Local User Interface (LUI) Replacement
166
Table 18-18 Exhaust Parts Replacement
166
Table 18-19 Kit, Fuses and Fasteners Replacement
166
Table 18-20 Kit, Engine, Vibration Isolators Replacement
166
Powergen Reports and Checklists
167
Installation Sequence
167
Table 19-1 Installation Checklist
167
Table 19-2 Safety Checks and Basic Information
167
Powergen Commission Report
168
Table 19-3 General Information, Commissioning
168
Commission Sequence
169
Table 19-4 Commissioning Checklist
169
Table 19-5 FPC Expansion Board Discrete Input Configuration
171
Table 19-6 FPC Expansion Board Relay Output Configuration
171
Powergen Annual Inspection Checklist
172
Table 19-7 General Information
172
Powergen Operation
174
Operation
174
Local User Interface (Lui)
174
Figure 20-1 User Interface Indicators and Controls
175
Table 20-1 System Run Light
176
Table 20-2 Start/Stop (Reset) Push Button
176
Table 20-3 Warning Light
177
Table 20-4 Fault Light
177
Powergen Optional Feature Sets
178
Glycol Heat Trace (Ght)
178
Table 20-5 Local/Remote Selector Switch
178
Table 21-1 GHT Components
179
Figure 21-1 GHT Components
179
Figure 21-2 LUI, with GHT Switch
180
Table 21-2 GHT VFD Speed Settings
181
Figure 21-3 Coolant Setpoints in Lynx
181
Low Temperature Start (Lts)
183
Table 21-3 LTS Components
184
Figure 21-4 LTS Components
184
Table 21-4 LTS Troubleshooting
186
Figure 21-5 Gas Valve Heater and Temperature Sensor to FEB
187
Figure 21-6 Fuse Box
187
Gas Conditioning Unit (Gcu)
188
Figure 21-7 Powergen with GCU Installed
188
Figure 21-8 Drum Emptying Valve (Shown in Open Position)
189
Table 21-5 GCU Troubleshooting
190
N+1 Automatic Transfer Switch (Ats)
191
Table 21-6 Field Wiring Terminals
192
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Qnergy PowerGen 5650 Series Specifications
General
Brand
Qnergy
Model
PowerGen 5650 Series
Category
Industrial Equipment
Language
English
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