Qnergy PowerGen 5650 Series User manual

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

© Qnergy 2021
This publication is intended for the exclusive use of Qnergy customers.
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.

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TABLE OF CONTENTS
1. WARRANTY AND LIABILITY ....................................................................................................... 1
2. SAFETY.............................................................................................................................................. 1
2.1 IMPORTANT SAFETY INSTRUCTIONS.................................................................................... 1
2.2 CLASSIFICATION OF WARNINGS ........................................................................................... 1
2.3 BASIC SAFETY INSTRUCTIONS ............................................................................................... 2
2.4 DEFINITION OF ACRONYMS.................................................................................................... 4
3. SYSTEM INTRODUCTION............................................................................................................. 5
3.1 SYSTEM SUMMARY .................................................................................................................... 5
3.2 POWERGEN SUBSYSTEMS ...................................................................................................... 13
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........................................................................................ 44
6.5 FPC & QEC FAULTS TAB........................................................................................................... 54
6.6 FPC, FEB & QEC FIRMWARE UPDATE................................................................................. 55
7. ENVIRONMENTAL CONDITIONS FOR STORAGE ................................................................. 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 TOOLS AND MATERIALS FOR INSTALLATION AND COMMISSIONING.................... 62
11.3 ELECTRICAL CONNECTION ...................................................................................................... 64
11.4 GAS CONNECTION ..................................................................................................................... 70
12. COMMISSIONING PROCEDURE ............................................................................................... 71
12.1 PANEL REMOVAL ...................................................................................................................... 71
12.2 BATTERY CONNECTION INSTRUCTIONS............................................................................ 72
12.3 OPT-CONNECT CELL MODEM INSTALL.............................................................................. 75
12.4 LYNX QEC3.5 CONFIGURATION FOR COMMISSIONING............................................... 75
12.5 HELIUM FILL................................................................................................................................ 76
12.6 GAS PRESSURE, CUSTOMER................................................................................................. 83
12.7 GAS VALVE TUNING, POWERGEN 5650........................................................................... 83
12.8 GAS VALVE TUNING, POWERGEN 600, 1200, 1800 (LOW TEMP SYSTEMS IN-
CLUDED)................................................................................................................................................................ 89
12.9 FEB GPIO CONFIGURATION .................................................................................................. 94
12.10 MODBUS .................................................................................................................................... 98
12.11 QEC CONFIGURATION FOR LOAD-FOLLOWING............................................................. 107
12.12 COOLANT TOP-OFF INSTRUCTIONS.................................................................................. 110

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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. LONG-TERM STORAGE ............................................................................................................. 139
16.1 POWERGEN LONG-TERM STORAGE................................................................................... 139
17. MAINTENANCE............................................................................................................................. 142
17.1 PREPARATION FOR MAINTENANCE................................................................................... 142
17.2 MAINTENANCE, BATTERY, 12VDC....................................................................................... 143
17.3 COOLANT FILL INSTRUCTIONS ............................................................................................. 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 SEQUENCE..................................................................................................... 155
19.2 POWERGEN COMMISSION REPORT................................................................................... 156
19.3 COMMISSION SEQUENCE....................................................................................................... 157
19.4 POWERGEN ANNUAL INSPECTION CHECKLIST ............................................................. 160
20. POWERGEN OPERATION ........................................................................................................ 162
20.1 OPERATION ................................................................................................................................ 162
20.2 LOCAL USER INTERFACE (LUI) ............................................................................................ 162
21. POWERGEN OPTIONAL FEATURE SETS .............................................................................. 166
21.1 GLYCOL HEAT TRACE (GHT) ................................................................................................... 166
21.2 LOW TEMPERATURE START (LTS) ...................................................................................... 171
21.3 GAS CONDITIONING UNIT (GCU).......................................................................................... 176
21.4 N+1 AUTOMATIC TRANSFER SWITCH (ATS) .................................................................... 179

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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 & Weight ..........................................................................21
Table 5-1 User Interface, System Run Light ..........................................................................24
Table 5-2 User Interface, Warning Light.................................................................................24
Table 5-3 User Interface, Fault Light........................................................................................25
Table 6-1 System Status and Control.......................................................................................27
Table 6-2 FPC, Data, System Info ..............................................................................................28
Table 6-3 FPC, Data, Temperature............................................................................................29
Table 6-4 FPC, Data, Generator..................................................................................................30
Table 6-5 FPC, Data, Cooling........................................................................................................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 .................................................................................................35
Table 6-12 FPC, Data, Debug Data.............................................................................................35
Table 6-13 FDC, Data, General.....................................................................................................36
Table 6-14 FPC, Data, Meters.......................................................................................................36
Table 6-15 FPC, Config, System Settings.................................................................................38
Table 6-16 FPC, Config, Head Setpoint ....................................................................................38
Table 6-17 FPC, Config, Coolant Setpoint (GHT Only).........................................................39
Table 6-18 FPC, Config, Start PWM............................................................................................39
Table 6-19 FPC, Config, Max Blower.........................................................................................39
Table 6-20 FPC, Config, User Network Settings ..................................................................40
Table 6-21 FPC, Config, Internal Modem Network Settings............................................40
Table 6-22 FPC, Config, GPI Settings ........................................................................................41
Table 6-23 FPC, Config, GPO Settings ......................................................................................42
Table 6-24 FPC, Config, Manual Pump & Fan Controls.....................................................42
Table 6-25 FPC, Config, CAN Node Id.......................................................................................43
Table 6-26 QEC, System Status and Control .........................................................................44
Table 6-27 QEC, Data, Output A/B/C ........................................................................................45
Table 6-28 QEC, Data, Brake........................................................................................................45
Table 6-29 QEC, Data, Battery.....................................................................................................46
Table 6-30 QEC, Data, Engine .....................................................................................................47
Table 6-31 QEC, Data, Coolant .....................................................................................................47

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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 .............................................................................. 51
Table 6-39 QEC, Config, HVDC .................................................................................................... 52
Table 6-40 QEC, Config, Minimum Engine Power.............................................................. 52
Table 6-41 QEC, Config, Output Power Buffer ..................................................................... 52
Table 6-42 QEC, Config, Output Power Limit ....................................................................... 53
Table 6-43 QEC, Config, HHT Setpoint..................................................................................... 53
Table 6-44 QEC, Config, Hall Switchpoints ............................................................................ 53
Table 6-45 FPC & QEC, Faults...................................................................................................... 54
Table 11-1 Tools and Materials .................................................................................................... 62
Table 11-2 PowerGen Electrical Power Terminal Block Description............................ 66
Table 11-3 PowerGen FPC Expansion Board Input Description .................................... 67
Table 11-4 PowerGen FPC Expansion Board Output Description ................................ 67
Table 11-5 PowerGen FPC Expansion Board Terminal Block Description................. 68
Table 11-6 PowerGen FPC Expansion Board Emergency Stop Terminal Block 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/Warnings...................................................................... 99
Table 12-6 Modbus, Configuration............................................................................................ 99
Table 12-7 Modbus, FEB I/O Configuration............................................................................ 99
Table 12-8 Modbus, System Status and Information ....................................................... 100
Table 12-9 Modbus, Measurements ........................................................................................ 101
Table 12-10 Modbus, Debug Values ......................................................................................... 102
Table 12-11 Modbus, ENUM........................................................................................................... 105
Table 15-1 PowerGen Error Messages Levels Explained................................................. 112
Table 15-2 PowerGen Error Messages, Service Required............................................... 113
Table 15-3 PowerGen Error Messages, User Clearable.................................................... 117
Table 15-4 PowerGen Error Messages, Auto Reset.......................................................... 122
Table 15-5 PowerGen Error Messages, Warning................................................................ 123
Table 15-6 PowerGen Error Messages, Informative......................................................... 130
Table 15-7 QEC Error Messages, QEC 3 (Firmware 2.X.X)................................................. 131
Table 15-8 QEC Error Messages, QEC 3.5 (Firmware 3.X.X)............................................. 135
Table 18-1 Burner Seal Replacement*** ................................................................................ 149
Table 18-2 Burner Insulation Replacement***.................................................................... 149
Table 18-3 Igniter and/or Flame Sense Replacement ..................................................... 150
Table 18-4 Gas Blower Replacement...................................................................................... 150
Table 18-5 Gas Valve Replacement ......................................................................................... 150

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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
Table 18-17 Local User Interface (LUI) Replacement..........................................................154
Table 18-18 Exhaust Parts Replacement ................................................................................154
Table 18-19 Kit, Fuses and Fasteners Replacement ..........................................................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, Commissioning................................................................156
Table 19-4 Commissioning Checklist ........................................................................................157
Table 19-5 FPC Expansion Board Discrete Input Configuration....................................159
Table 19-6 FPC Expansion Board Relay Output Configuration .....................................159
Table 19-7 General Information..................................................................................................160
Table 20-1 System Run Light.......................................................................................................164
Table 20-2 Start/Stop (Reset) Push Button ..........................................................................164
Table 20-3 Warning Light..............................................................................................................165
Table 20-4 Fault Light ....................................................................................................................165
Table 20-5 Local/Remote Selector Switch.............................................................................166
Table 21-1 GHT Components ........................................................................................................167
Table 21-2 GHT VFD Speed Settings .........................................................................................169
Table 21-3 LTS Components.........................................................................................................172
Table 21-4 LTS Troubleshooting .................................................................................................174
Table 21-5 GCU Troubleshooting................................................................................................178
Table 21-6 Field Wiring Terminals..............................................................................................180

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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
Unit ...............................................................................................................................18
Figure 3-10 Heat Rejection Unit (HRU), Split Apart ........................................................19
Figure 3-11 PowerGen Control and Local User Interface .............................................19
Figure 4-1 PowerGen Base Unit Dimensions ...................................................................21
Figure 5-1 User Interface Indicators and Controls.........................................................23
Figure 6-1 FPC, System Status ...............................................................................................26
Figure 6-2 FPC System Command buttons......................................................................26
Figure 6-3 FPC, Data Tab.......................................................................................................... 27
Figure 6-4 FPC, Data, System Info .......................................................................................28
Figure 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
Figure 6-11 FDC, Data, Ignitions .............................................................................................34
Figure 6-12 FDC, Data, FEB GPIOs .........................................................................................34
Figure 6-13 FDC, Data, FPC GPIOs .........................................................................................35
Figure 6-14 FDC, Data, Debug Data .....................................................................................35
Figure 6-15 FDC, Data, General..............................................................................................36
Figure 6-16 FDC, Data, Meters ...............................................................................................36
Figure 6-17 FPC, Configuration Tab...................................................................................... 37
Figure 6-18 FPC, Config, System Settings.......................................................................... 37
Figure 6-19 FPC Config, Head Setpoint ..............................................................................38
Figure 6-20 FPC, Config, Coolant Setpoint (GHT Only).................................................39
Figure 6-21 FPC, Config, Start PWM .....................................................................................39
Figure 6-22 FPC, Config, Max Blower .................................................................................39
Figure 6-23 FPC, Config, User Network Settings........................................................... 40
Figure 6-24 FPC, Config, Internal Modem Network Settings................................... 40
Figure 6-25 FPC, Config, GPI Settings ..................................................................................41
Figure 6-26 FPC, Config, GPO Settings ................................................................................41
Figure 6-27 FPC, Config, Manual Pump & Fan Controls..............................................42
Figure 6-28 FPC, Config, CAN Node Id................................................................................43
Figure 6-29 QEC, System Status ...........................................................................................43

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Figure 6-30 QEC, System Command Buttons................................................................. 43
Figure 6-31 QEC, Data Tab....................................................................................................... 44
Figure 6-32 QEC, Data, Output A.......................................................................................... 45
Figure 6-33 QEC, Data, Brake................................................................................................. 45
Figure 6-34 QEC Data, Battery ..............................................................................................46
Figure 6-35 QEC, Data, Engine ..............................................................................................46
Figure 6-36 QEC, Data, Coolant............................................................................................. 47
Figure 6-37 QEC, Data, DC Bus ..............................................................................................48
Figure 6-38 QEC, Data, Piston ...............................................................................................48
Figure 6-39 QEC, Data, Debug Data....................................................................................49
Figure 6-40 QEC, Data, PCB Temp.......................................................................................49
Figure 6-41 QEC, Data, Counters........................................................................................... 50
Figure 6-42 QEC, Configuration Tab.................................................................................... 50
Figure 6-43 QEC, Config, Output A ...................................................................................... 50
Figure 6-44 QEC, Config, Battery Capacity ........................................................................ 51
Figure 6-45 QEC, Config, HVDC...............................................................................................52
Figure 6-46 QEC, Config, Minimum Engine Power........................................................52
Figure 6-47 QEC, Config, Output Power Buffer...............................................................52
Figure 6-48 QEC, Config, Output Power Limit .................................................................53
Figure 6-49 QEC, Config, HHT Setpoint...............................................................................53
Figure 6-50 QEC, Config, Hall Switchpoints ......................................................................53
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 & QEC, Firmware Tab..................................................................... 56
Figure 6-57 FPC, FEB & QEC, Firmware Update ..............................................................57
Figure 8-1 PowerGen Base without HRU, Lifting by Rings or Fork ....................... 59
Figure 8-2 PowerGen Base with HRU, Lifting by Forklift .......................................... 59
Figure 8-3 PowerGen 6-person carrying option...........................................................60
Figure 9-1 PowerGen Mounting Dimensions...................................................................61
Figure 11-1 Power and Communications Feed Location............................................. 65
Figure 11-2 PowerGen Electrical Terminal Blocks, Customer Connection
Point..........................................................................................................................66
Figure 11-3 PowerGen FPC Expansion Board Terminal Blocks, Customer
Connection Points ...............................................................................................68
Figure 11-4 PowerGen FPC Expansion Board Emergency Stop Terminal
Blocks, Customer Connection Points...........................................................69
Figure 11-5 Gas Connection Location.................................................................................. 70
Figure 12-1 Side Panel Latch Locations................................................................................71
Figure 12-2 Battery Warning Label.......................................................................................73
Figure 12-3 PowerGen Left-Hand-Side Door Removed............................................. 74
Figure 12-4 PowerGen Left-Hand-Side QEC Battery/CAN bus/Flow Sensor
Connection ............................................................................................................. 74

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Figure 12-5 Helium Fill Kit......................................................................................................... 77
Figure 12-6 Regulator Fitting, Inlet Nut, CGA 580..........................................................78
Figure 12-7 Helium Kit, Vent Valve.......................................................................................78
Figure 12-8 Helium Kit, Regulator Spring ..........................................................................79
Figure 12-9 Helium Tank.......................................................................................................... 80
Figure 12-10 Helium Kit, Purge.............................................................................................. 80
Figure 12-11 Helium Fill Rate.....................................................................................................81
Figure 12-12 Gas Pressure Reading......................................................................................83
Figure 12-13 Blower Tuning Screws.................................................................................... 84
Figure 12-14 Head Temp Setpoint ........................................................................................85
Figure 12-15 Lynx, Max Blower to 80%............................................................................. 86
Figure 12-16 Qnergy Lynx, QEC, Configuration Tab, Output Power
Limit............................................................................................................................ 86
Figure 12-17 FPC Tab, Enable...................................................................................................87
Figure 12-18 Qnergy Lynx, QEC, Configuration Tab, Minimum Engine
Power ........................................................................................................................ 88
Figure 12-19 Qnergy Lynx, Output Power Limit to 600W.......................................... 89
Figure 12-20 Blower Tuning Screws.....................................................................................91
Figure 12-21 Head Temp Setpoint..........................................................................................91
Figure 12-22 Qnergy Lynx, Max Blower to 80%.............................................................92
Figure 12-23 FPC Tab, Enable..................................................................................................93
Figure 12-24 Qnergy Lynx, QEC, Configuration 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 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
Figure 16-3 PowerGen Left-Hand-Side View .................................................................141
Figure 17-1 Qnergy Lynx, Fill Sequence ............................................................................ 145
Figure 17-2 Radiator and Over Flow Tank.......................................................................146
Figure 17-3 Air Removal Plug............................................................................................... 147
Figure 20-1 User Interface Indicators and Controls .................................................... 163
Figure 21-1 GHT Components................................................................................................ 167
Figure 21-2 LUI, with GHT Switch ........................................................................................168
Figure 21-3 Coolant Setpoints in Lynx ..............................................................................169
Figure 21-4 LTS Components.................................................................................................172
Figure 21-5 Gas Valve Heater and Temperature sensor to FEB ............................175
Figure 21-6 Fuse Box ................................................................................................................175
Figure 21-7 PowerGen with GCU Installed ...................................................................... 176
Figure 21-8 Drum Emptying Valve (Shown in Open Position) ................................177

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Figure 21-9 ATS Enclosure......................................................................................................179
Figure 21-10 Battery Connection Schematic....................................................................181

WARRANTY AND LIABILITY
1
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.
ALL PERSONS INVOLVED IN THE INSTALLATION, OPERATION, CONFIGURATION,
ADJUSTMENT, SERVICE, MAINTENANCE, REPAIR, OR CONVERSION OF THE EQUIPMENT
DESCRIBED HEREIN MUST READ, UNDERSTAND, AND OBSERVE THE INFORMATION AND
INSTRUCTIONS GIVEN IN THIS MANUAL.
QNERGY ASSUMES NO LIABILITY FOR ANY INJURY, DAMAGE, AND/OR MALFUNCTIONING
CAUSED DIRECTLY OR INDIRECTLY BY 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 followed during installation and maintenance of the generator
and/or batteries.
When installing and operating the PowerGen, you must observe the basic safety instructions
and the warnings that appear before all of the actions described in the manual.
2.2 CLASSIFICATION OF WARNINGS
Warnings are classified in accordance with the severity of the possible risk, using the
following symbols: They highlight an essential procedure, practice, condition, statement, and
so on, which if not strictly observed could result in death, injury, or long-term poor health.
WARNING: Highlights an essential procedure, practice,
condition, statement, and so on, which if not strictly observed
could result in death, injury, or long-term poor health.

SAFETY
2
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. Configuration, inspection, adjustment, service, maintenance, repair, or
conversion of the appliance should also be performed by qualified technicians. All relevant
regulations, rules, and guidelines must be observed at all times.
Installation errors, damage, tampering with the appliance, unauthorized installation sites, or
similar, can cause gas and/or exhaust fumes to escape and result in a risk of poisoning and/or
explosion.
If there is a smell of gas near the PowerGen, proceed as follows:
• Avoid rooms that smell 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, telephones, or other communication
systems in the building.
• Close the gas meter isolator device or the main isolator device.
• If possible, close the gas stopcock on the appliance.
• Leave the area.
• Alert the police and fire services.
• Using the wrong gas group may cause faults, shutdown, and/or ignition and combustion
noise.
If there is a smell of exhaust fumes in the building, proceed as follows:
• If possible, open doors and windows fully and ensure adequate ventilation.
• Turn the PowerGen off.
Hot surface:
• High temperature on exposed components
• Risk of burns
• Ensure sufficient protection against accidental contact.
CAUTION: Highlights an essential procedure, practice, condition,
statement, and so on, which if not strictly observed could
destroy or damage equipment.

SAFETY
3
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). Risk of noise-induced hearing loss
• Take appropriate technical safety measures.
• Protect operating personnel with appropriate safety equipment such as hearing
protection.
• Also observe the requirements of local agencies.

SAFETY
4
2.4 DEFINITION OF ACRONYMS
Below is a table with a list of common acronyms that are used in this manual.
Table 2-1 Definitions of Acronyms
Acronym Definition
D I/O Digital Inputs/Outputs
FPSE Free Piston Stirling Engine
HRU Heat Rejection Unit
LUI Local User Interface
P&ID Piping & Instrumentation Diagram
PCK80 Power Conversion Kit, 80 tubes
QB80 Qnergy “B” Series, 80 tubes (Stirling Engine)
PIP Power Interface Package
QEC Qnergy Engine Controller
QRP Qnergy Remote Power
RP Remote Power
FPC Fueled Products Controller
FEB FPC Expansion Board
GCU Gas Conditioning Unit
GHT Glycol Heat Trace
VFD Variable Speed Drive
Tamb Ambient Temperature
LT Low Temperature Option (-40C)

SYSTEM INTRODUCTION
5
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. The generator with its
complementing “Power Interface” package provide locally generated electricity at the
required voltage and current 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 heating via a liquid heat-distribution loop with
heat dissipation radiators.
The primary product of the PowerGen generator is up to 5,650 Watts of electricity which is
made by the efficient conversion of gaseous fuel energy into electric power. This conversion
process is based on the Free Piston Stirling cycle which takes advantage of high temperature
heat (from the combustion of any gaseous fuel) to create an oscillating harmonic pressure
wave within the generator that is used to produce output electricity.
Figure 3-1 PowerGen Base

SYSTEM INTRODUCTION
6
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 – 2160 BTU/ft3₁
Fuel Supply 3 – 50 PSI, Natural gas
2 – 10 PSI, LPG
Min/Max Fuel
Consumption STP,
PG5650
Dry Natural Gas
Propane
1,433/3,964 ft³/day
15.2/44.4 gal/day
Max Fuel
Consumption STP,
PG1800
Dry Natural Gas
Propane
1,300 ft³/day
10 gal/day
Max Fuel
Consumption STP,
PG1200
Dry Natural Gas
Propane
935 ft³/day
7.2 gal/day
Max Fuel
Consumption STP,
PG600
Dry Natural Gas
Propane
550 ft³/day
4.3 gal/day
Rated Altitude 5,000ft₃
Number of power
outputs
2
Max Output Current 25A
RP Base Unit DC
Output Voltage
±[265-365] VDC Bipolar4
RP Base Unit AC
Output Voltage
settings (factory
programmable)
Output voltage, 110-240 VAC (factory settable)
Phase angle, 0-180 deg. (factory settable)
AC Frequency, 50/60 Hz (factory settable)
Maintenance Cycle 1 -2 events per year₅

SYSTEM INTRODUCTION
7
3.1.1 PowerGen Model Number Nomenclature
The PowerGen Base Unit model numbers are show in Table 3-2.
1. ₁. Subject to well-based analysis
2.₂. Storage is allowed down to -13°F (-25°C)
3. ₃. Beyond 5,000ft power output will de-rate by 5% per 1,000ft
4. ₄. RP Base Unit voltage, Power Interface Package (PIP) voltage per PIP design
5. ₅. Minimal maintenance such as cleaning, adjustments or filter replacement
Table 3-1 Technical Specifications, QRP 2B-XXX-XXX
Generator Design Life 10-15 years

SYSTEM INTRODUCTION
8
Table 3-2 PowerGen Model Numbers
QRP
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
Output
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-corrosive
C = Corrosive
6 - Ambient Temperature Codes S = -15°C (5°F) to 50°C (122°F)
L= -40°C (-38°F) to 40°C (104°F)
H= -15°C (5°F) to 60°C (140°F)
T = -40°C (-38°F) to 50°C (122°F)
7 - Optional Add on GL= Glycol Heating Loop
GCU = Gas Conditioning Unit