You are on page 1of 49

888 S.

Grenville Ave, Suite 302,
Richardson, Tx 7081, USA
+1-469-757-1787 (T).
sales@leap-power.com
GEN000231D www-leap-power.com.

GenLeap™
DC Generator Power System
CONTROLLER PRODUCT MANUAL

7/8/2010 Saved 9/5/2014

Confidential: This document contains confidential information proprietary to Leap Power. If you are not the
intended recipient, you are hereby notified that any dissemination, copying or distribution of this document, or the
taking of any action in reliance on the contents of this communication, is strictly prohibited. © 2009 Leap Power,
LLC. All rights reserved.

1 of 49 CONFIDENTIAL
© 2009 Leap Power, LLC
Date 10/28/11 This document contains proprietary information.
All rights reserved.
Saved9/5/2014

888 S. Grenville Ave, Suite 302,
Richardson, Tx 7081, USA
+1-469-757-1787 (T).
sales@leap-power.com
GEN000231D www-leap-power.com.

2 of 49 CONFIDENTIAL

Date 10/28/11 This document contains proprietary information.

Saved9/5/2014

888 S. Grenville Ave, Suite 302,
Richardson, Tx 7081, USA
+1-469-757-1787 (T).
sales@leap-power.com
GEN000231D www-leap-power.com.

Table of Contents
1.1 Introduction ............................................................................................................................................ 5
1.2 Getting Started ....................................................................................................................................... 5
1.2.1 Installation ........................................................................................................................... 5
1.2.1.1 System Network Setup .......................................................................................................... 5
1.2.2 First Startup .......................................................................................................................... 7
1.2.3 Logging In ............................................................................................................................ 7
1.2.4 Connecting to eConLeap™ controller ............................................................................. 9
1.2.5 Menu (left side bar) ............................................................................................................ 9
1.2.6 Access levels....................................................................................................................... 10
1.3 System Operating Modes & Control Methods ..................................................................................... 10
1.3.1 Standby Power Mode ....................................................................................................... 10
1.3.1.1 Voltage control method...................................................................................................... 11
1.3.1.2 Timer control method ........................................................................................................ 11
1.3.2 Primary Power Mode (Off-Grid).................................................................................... 11
1.3.3 Battery Extension Mode ................................................................................................... 13
1.3.4 Manual Mode:.................................................................................................................... 13
1.3.5 Redundant Operation with dual generator sets ............................................................... 13
1.4 System Setup & Configuration............................................................................................................. 14
1.4.1 Setup .................................................................................................................................... 14
1.4.2 Configuration..................................................................................................................... 25
1.4.3 Operations .......................................................................................................................... 28
1.5 Monitoring & Control .......................................................................................................................... 29
1.5.1 Alarms ................................................................................................................................. 29
1.5.2 Logs ...................................................................................................................................... 31
1.5.3 Status ................................................................................................................................... 32
1.5.4 Inventory ............................................................................................................................ 33
1.5.5 Debugging .......................................................................................................................... 34
1.6 Software Upgrade ................................................................................................................................. 36
1.7 Manual Connections & Controls.......................................................................................................... 37
1.7.1 Ebox Control Panel & Manual Switches ...................................................................... 37

3 of 49 CONFIDENTIAL

Date 10/28/11 This document contains proprietary information.

Saved9/5/2014

888 S. Grenville Ave, Suite 302,
Richardson, Tx 7081, USA
+1-469-757-1787 (T).
sales@leap-power.com
GEN000231D www-leap-power.com.

1.7.2 DC Distribution Monitoring & Control ....................................................................... 39
1.8 Serial Connection with Engine Control Unit (ECU) ........................................................................... 42
1.8.1 Operating through RS232 GUI ....................................................................................... 42
1.8.2 Calibrating through RS232 GUI ..................................................................................... 44
1.8.3 Monitoring through RS232 GUI..................................................................................... 45
1.9 Quick Guide To Starting GenLeap™ First Time ................................................................................. 47
1.10 System Layout & Trouble Shooting ................................................................................................... 48

4 of 49 CONFIDENTIAL

Date 10/28/11 This document contains proprietary information.

Saved9/5/2014

wireless access and mod bus interface are also available with GenLeap™ .com. USA +1-469-757-1787 (T).1. monitoring and operation.1 Introduction This manual provides details of controller setup. c.0 subnet. Port 2 and 3 accepts static IP address 192. Saved9/5/2014 . Figure 1a. Please reference the GenLeap™ product manual for your configuration and associated functions and features.1 System Network Setup a. no application is required.1. Grenville Ave. Netmask is 255.168. 1. Tx 7081.168. d.2 Getting Started 1.1 Installation To install the eConLeap™ web interface in GenLeap™ system. Addresses 192. Customer may access GenLeap™ via ethernet interface using eConleap™ Mini controller or via LCD touch screen display. configuration. An external CAT5/6 LAN cable (marked Ethernet) is supplied outside of the control box. b. Suite 302. (factory default). Port 5 is internally connected to eConLeap™ Mini Controller and Port 4 is to uConLeap™ Generator controller.com GEN000231D www-leap-power. SNMP. Please note that a Basic Version o GenLeap™ is available without router for single port access to the controller.255. In case the system is not equipped with the CAT5/6 Ethernet connection.0 and there should be no default gateway specified. 888 S.99 are reserved and cannot be used. sales@leap-power.168.1.255.Installation 5 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. The port accepts dynamic IP address via DHCP server (factory default). A CAT5/6 LAN cable connection is supplied at the front panel of your GenLeap™ system to connect to Ethernet. Other optional interfaces like RS232. 1. dry contacts. Port 2 or 3 connection is for the customer's monitoring device. Richardson. 1. Locate the router mounted inside control box from the front access door.2. Port 1 is provided for the customer’s access via intranet or internet. The user must determine the actual address assigned by the customer e. The CAT5/6 LAN cable is included.230 and 192. The web interface only requires Google Chrome or Firefox browser. please check the configuration ordered and make sure that the system is equipped with the router and eConLeap™ system controller by visually checking inside the generator.2.

com. Grenville Ave. 888 S. RS-232 port (Recommended) or USB to RS-232 converter If using Windows Internet Explorer refer to the following URL.6 or Debian 6+ system Windows Vista later OpenSuSE 11.3+ Windows 7 Fedora Linux 14 Intel Pentium 3 / Athlon 64 Processor Intel Pentium 4 or later Intel or later Free disk space 100 MB RAM 128 MB In addition. USA +1-469-757-1787 (T).com/chrome/bin/answer.04+ Operating Pack 2+ Mac OS X 10.5. Saved9/5/2014 . sales@leap-power. http://support. Suite 302.com GEN000231D www-leap-power. http://windows.google.Installation Router connections to the customer's Internal connection between Router and computer or monitoring devices eConLeap™ and uConLeap™ controllers Recommended PC minimum requirements: DHCP for dynamic Router IP address eConLeap™ Mini Controller The system requirements depend on the browser that will be used to access the GenLeap™ system.com/en-US/internet-explorer/products/ie-9/system-requirements 6 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Tx 7081. Richardson. If using Google Chrome refer to the following URL.microsoft. Figure 1b.py?hl=en&answer=95411 Windows requirements Mac requirements Linux requirements Windows XP Service Ubuntu 10.

2.3 Logging In On startup. Saved9/5/2014 . tracking and data protection. Grenville Ave. 888 S. USA +1-469-757-1787 (T). Richardson. User login settings can be change later by logging out on exit 7 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Tx 7081.2 First Startup Network Setup if using INTRANET Setting Value Baud 57600 baud Flow Disable Parity None Data Bits 8-bit Stop Bits 1 Timeout 50ms 1. sales@leap-power. 1. it is necessary to log in for security.com GEN000231D www-leap-power.2. Suite 302. Three access levels are available for security administration: Name Password Access Level admin ********** 1 (High) operator ********** 2 (Medium) user ********** 3 (Low) Check the “Auto Login” option if you desire the settings to be saved for next time.com.

Login Login username and password Figure 3. Tx 7081.com GEN000231D www-leap-power.com. Grenville Ave. 888 S. Suite 302. USA +1-469-757-1787 (T). Richardson. sales@leap-power.Confirming Login or Logout Successful login will show the welcome bar below your web page 8 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Figure 2. Saved9/5/2014 .

The dash board can be placed anywhere on the computer without having the full web pages turned on. minor and warning alarms is supplied. an eight-wire connector used commonly to connect computers with local-area networks (LAN). Dashboard: Dashboard. Some customers may need to setup a RS-232 port to access the controller for higher configuration and troubleshooting needs. Saved9/5/2014 . Status of system and each module is shown under the horizontal bar menu.2. ensure that the controller is powered on and that a Jack-45.4 Connecting to eConLeap™ controller To establish a link with the GenLeap™controller. Grenville Ave. Many factory default settings are accessible through RS232 port and it's GUI application. Once connected to the controller. The system setup allows configuration of the mode of operation and battery charging method. Data and Event logs can be downloaded. Alarm logs can be accessed and downloaded from this page.com.1. Please reference GenLeap™ GUI application programming and user manual for details. 1. major. Logs: Alarm. sales@leap-power.168. Customer can setup site information from this setup menu. Inventory: A static inventory allowing tracking of the site modules and capacities is available under the inventory menu.5 Menu (left side bar) Alarms: A table for critical. A higher level access is required. 1. 888 S. Suite 302. launch browser with IP address 192. is properly connected.2. Tx 7081.com GEN000231D www-leap-power. Maximum storage capacity 4G is available. Configuration: Allows threshold settings and system configurations. Debug/Alarm-Reset allows clearing of latching alarms and monitoring of calibration items. 9 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Status: Status of key variables are shown on the status page. Richardson. provides a high level summary of the system's operating parameters. shown on the right side bar. USA +1-469-757-1787 (T). Operation: System operations like start/stop and battery tests are available under Generator or Battery operations menu. Debug: Allows items for debugging or troubleshooting.230 if you are connected to a static IP address (Port 2 & 3) or assigned IP address if connected to dynamic IP address (Port 1). Setup: A system setup can be accessed from any module (horizontal bar) menu. Ethernet cable can be used to connect the controller to technician's computer for local access during installation or for remote access to GenLeap™ system via Internet or Intranet.

1 Admin Can view and modify items that may affect performance. 1.com GEN000231D www-leap-power. Customer can also select the battery charging modes (or generator transition modes) to provide a seamless transition between multiple power sources. Saved9/5/2014 . Richardson. environment and fuel supply management.3 System Operating Modes & Control Methods GenLeap™ DC Generator Power Systems are designed for a standalone generator operation or a complete unified system for BTS and Telecom loads for on/off grid applications. 888 S. DC power rectifiers.6 Access levels There are 2 user access levels User Name Description used to filter and protect data on GenLeap™ controllers.com. These levels are divided as follows: Level Can monitor commonly used 3 User data. Many functions may be disabled or hidden. Customer may setup different operating modes based on the configurations purchased for on- grid or off-grid systems. Can monitor 2 Operator commonly used data. GenLeap™ system can be deployed in the following modes of operation: 1. Able to modify commonly used settings and configurations. ATS. battery charging. view faults and logs. Suite 302. view faults and logs.3. the primary power is supplied by AC grid.2. 1. Allowed to tune engine. system controller. Tx 7081. sales@leap-power. Grenville Ave. and change critical data items. A standby operation is where customer requires a short battery backup and extended GenLeap™ backup when AC failure is 10 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. batteries. GenLeap™ systems include the functions of a 48V DC power generation source replacing AC generators. Information such as site ID and locations may be assigned to each site by the administrator.1 Standby Power Mode In this mode. USA +1-469-757-1787 (T).

solar or generator may be programmed using voltage mode. The transition between multiple source like rectifiers. Tx 7081.2.3. Saved9/5/2014 . Richardson. increasing the life of the DC Generator with lower start/stop cycles.2 Timer control method Timer control method allows customers to decide how much (time) battery backup should be available before DC Generator is turned on. GenLeap™ system allows the integration of an external DC source like solar power (SunLeap™) or Wind Turbine (WindLeap™) for a hybrid system configuration. thereby. In the standby mode. converters.2 Primary Power Mode (Off-Grid) In this mode. The DC Generator provides an extended backup subject to the availability of the fuel. A typical backup operation can be divided between DC Generator and batteries such that all brownouts and smaller duration outages are absorbed by the batteries.com GEN000231D www-leap-power. The capacity of the battery bank and the rate of discharge will determine the depth of discharge (DoD) and the duration that batteries will provide backup. and split DC distribution from Leap Power maybe deployed and monitored as a unified system. The DC Generator operating (float) voltage is normally set to 52 Vdc.1. Suite 302. USA +1-469-757-1787 (T). A factory default 30 days exercise function and battery test is set in the system for all Standby systems. 1. batteries.3. The transfer between the different power sources will occur according to the configuration selected in the battery charging control method. The system provides a timer function to enable this maintenance feature automatically. 1. GenLeap™ system provides optional use of batteries in conjunction with the DC Generator.1. Other factors like temperature and load variation will impact the duration and rate of discharge of the battery backup. The DC Generator starts based on a pre set voltage threshold.3. 888 S.com.1 Voltage control method Battery discharge starts immediately upon the loss of AC. sales@leap-power. rectifiers. timer mode or SOC modes.3. The battery charging or cycling control is customer selectable based on the following methods: 1. 1. GenLeap™ and batteries must be exercised regularly when there are no AC outages for an extended period (>30 days) to keep the DC Generator cranking and fuel supply checked. Grenville Ave. the primary power is supplied by GenLeap™ system and no AC grid power is available. An integrated system with AC distribution. A typical setting involves battery discharge to 52Vdc after AC (or rectifier) failure and DC Generator start at 47Vdc. detected. The system automatically allows switching from AC to battery to generator mode based on the thresholds set by the customer.1 Voltage control method 11 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.

Other factors like temperature and load variation will impact the duration and the depth of discharge of the battery backup. the DC Generator will continue to operate until the fuel supply is exhausted. sales@leap-power. For example. Normally. the capacity of the battery bank and the rate of discharge installed by the customer determines the depth of discharge and the duration that batteries will provide backup. Grenville Ave. The DC Generator provides an extended backup subject to the availability of the fuel. the DC Generator will start at battery stop discharge point (default 47Vdc) and provide load and/or charging power up to the DC Generator stop or battery stop charge voltage (default 52Vdc).com. the battery cut off voltage is set at 43 Vdc. The Generator starts based on a pre set voltage threshold. 888 S. -54V Battery Discharge -52V -48V Battery GenLeap™ ON Charge 12 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. The reserve batteries will be charged to the programmed stop charge voltage (default 52Vdc) and discharged to the stop discharge voltage (default 47Vdc) during the voltage mode cycling. In the event of a complete failure of batteries. the batteries will be discharged to Low Voltage Battery Disconnect (LVBD) set point. if the system load is very small. customer may bring the generator on line before it reaches the start threshold. Simultaneously. GenLeap™ Voltage Mode operations allows 3 levels of Generator Start and Two levels of Generator Stop conditions to maximize the system efficiency and utilization. Similarly.com GEN000231D www-leap-power. Suite 302. A typical setting involves battery discharge at 52Vdc and DC Generator start at 47Vdc. Tx 7081. On the other hand. if the load has suddenly increased and additional power is required. in the event of DC Generator failure (or no gas supply). USA +1-469-757-1787 (T). Richardson. customer may elect to deviate from the normal CDC cycle and continue to discharge the batteries. Saved9/5/2014 . In the voltage control method.

1. USA +1-469-757-1787 (T). Grenville Ave. Redundant Cycle Mode: Allows units to operate in consecutive cycle mode with each unit cycling under its Voltage or Timer Control Method and providing full redundancy. Common methods for operation include: a. Suite 302. the operator is in total control of the system operation unless safety features or alarms are activated. Saved9/5/2014 . The total 24 hours operation can be divided between DC Generator. A failure of one unit is automatically backed up by the second unit.4 Manual Mode: In this mode. Timer mode also provides extensive scheduling capability with the Enhanced eConLeap™ controller option. the master controller external to GenLeap™ is in total control of the DC Generator start and stop. Two generators can be operated with independent distribution and battery bank or shared Leap Power's split distribution with common battery bank.3. Tx 7081. Richardson.3.com GEN000231D www-leap-power. Operator can manually (local or remote access) control the operation and run time of the system by executing manual start/stop via a web GUI or manual switch located on the front panel of the generator. 888 S. 1. sales@leap-power.3.com. batteries and an external power source like Solar (SunLeap™). A schedule such as charging of batteries at night under lower temperature improves the battery life. Timer mode allows customer to adapt to its environment. This capability allows operators to schedule GenLeap™ maintenance exercise (test) at non peak hours on a specific day or allow the shaving of peak billing hours when primary power source may be more expensive to operate. Typical settings involve voltage mode control for the DC Generator start and stop. The scheduling capability permits the customer to select a specific time of the day or calendar to start/stop the DC Generator operation. It is recommended that during initial setup.2 Timer control method Time control method allows customers to decide how many hours each power/reserve source should be operational. 1.2. 13 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. The external master controller unit takes the responsibility for charging the batteries and monitoring the start/stop cycle (if any) between the DC Generator and batteries. While discharging them during day under higher temperatures could provide higher capacity. The DC Generator provides an extension of the existing batteries (Battery Extender) and replaces stand alone AC generator set.3 Battery Extension Mode In this mode.5 Redundant Operation with dual generator sets GenLeap systems allow a parallel operation of multiple generators in a Timer Control and Voltage Control Method. customer should first exercise the manual RUN mode before starting the system in AUTO mode. 1. The communication between two generators provide intelligence for continuous operation with customer programmable cycle times and redundancy in case of a fault with one generator .3.

Generator & battery charge discharge cycles can be controlled with voltage methods or timer control methods. following steps 1. Voltage Control Primary Auto Timer Control Setup Manual RUN Standby Power Battery Extension a. Richardson. USA +1-469-757-1787 (T). When changing the operation mode or setup configuration. 1. distribution.4 must be followed. b.4.1. b. Tx 7081. Load Share Mode: Multiple generators can be programmed to operate simultaneously and share load. sales@leap-power. Saved9/5/2014 . shunts and other controls. Please note that during change of Operation Mode or Restart (Reset) 14 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Suite 302. LVBD. A load share option requires two units with a single DC distribution bus. A battery charger plant cannot be operated without 48Vdc main batteries. An administration level access is required to operate the system in Manual RUN Mode.1 Setup Setup Menu shown in Figure 4 & 5 allows selection of operating mode and charger control method. GenLeap™ systems can be configured as a standalone generator for non charging applications or used as a complete DC power plant for battery charging (telecom) applications. two generator cycle times can be defined by selecting the period each generator will operate using a timer control method or voltage control method.4.com. The customer must choose between charging vs non-charging application at the time of the order to allow proper system wiring and calibration. Similarly.4.1 to 1. 888 S.4 System Setup & Configuration 1. Grenville Ave. An optional system controller and DC distribution is specially designed to give customer full control of the multiple generator and operate as a single unified system. Setup menu allows administrator to setup GenLeap™ in fully programmed modes like Primary Auto or Standby Modes.com GEN000231D www-leap-power.1.

com. Richardson. an invalid setup or configuration alarm will be raised. customer connection will be lost until the reboot is complete. the following configuration details are required (Figure 5). Figure 4. eConLeap™ controller will go through a self reboot. Tx 7081. All alarms must be cleared prior to starting the system. c. Saved9/5/2014 . It is recommended to resubmit the configuration and wait for confirmation on the dash board. the default settings (recommended) in 15 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. e. You may need to reload the web page to return to the web GUI. USA +1-469-757-1787 (T). sales@leap-power. 888 S. The reboot process takes approximately one minute. Grenville Ave. Controller command. During the reboot. The system will only start if the alarms have been cleared. Dashboard provides the current mode of operation. If a communication failure occurs during setup.Timer Control Method Allows setting of time based charge discharge cycles: When executing the Primary AUTO Mode setup utilizing voltage control method in the above screen (Figure 4).com GEN000231D www-leap-power. and status of generator cycle. status of batteries. d. Suite 302. In case customer skips the following voltage method configuration setup.

Suite 302. 888 S.com GEN000231D www-leap-power. Grenville Ave. the example below will be activated. Saved9/5/2014 . The customer must calculate the battery capacity in accordance with the intended depth of discharge and operating hours to ensure that the cycles resemble the plan charge discharge time period during voltage mode operation.com. Richardson. USA +1-469-757-1787 (T). sales@leap-power. Tx 7081. 16 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.

Voltage Control Method Allows voltage & time based charge discharge cycles: Start Threshold Voltage Start Threshold Current Start Threshold Delay Condition 1. USA +1-469-757-1787 (T). Saved9/5/2014 . 2.com. & 3 discharger current time delay V0= 48 I1= -99 60 V1= 49 I2= 40 60 V2= 47 I3= 0 60 Stop Threshold Voltage Stop Threshold Current Stop Threshold Delay Condition 1 & 2 charge current time delay V0= 54 I1= -6 60 V1= 53 I2= -3 60 Enable Delays ON Delay OFF Delay 20 20 17 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Suite 302. 888 S. Figure 5. Tx 7081. Grenville Ave. Richardson.com GEN000231D www-leap-power. sales@leap-power.

Two settings are used for stopping the generator. A large negative number should be used for current to make sure that the generator starts at this voltage regardless of the current.Start generator If battery voltage is below 48 vdc AND Current0. Saved9/5/2014 . 18 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Suite 302. If below 40A load. AND Delay for 60 Second to start after battery voltage reaches the threshold. sales@leap-power. 888 S.If battery discharging current is above ZERO Amps.Start generator If battery voltage is below 49 vdc AND Current1. AND Delay for 60 Second to start after battery voltage and current reaches the threshold Note: Condition 3 will not be used for generator start since every time generator will start on Condition 1. USA +1-469-757-1787 (T). Grenville Ave. 1.If battery discharging current is above 40 Amps.com. Tx 7081. Start Generator if battery Voltage & Current meet one of the three (0. Delay is used to eliminate any transient or instantaneous change in the voltage or current. OR Second Condition: Voltage1. AND Delay for60 Second to start after battery voltage reaches the threshold OR Third Condition: Voltage2. Richardson.If battery discharging current is above -99 Amps.com GEN000231D www-leap-power.Start generator If battery voltage is below 47 vdc AND Current2. & 2) Conditions: First Condition: Voltage0. the batteries will continue to provide power. Three different voltage mode settings are used for starting the generator.

the batteries will continue to be charged.If battery charging current is above -6 Amps. If below -6A. Tx 7081. USA +1-469-757-1787 (T).If battery charging current is above -3 Amps. STOP Generator if battery Voltage & Current meet one of the two (1 & 2) Conditions: First Condition: Voltage0. Charging current is always negative and a large negative number will always stop the generator at 54Vdc AND Delay for 60 Second to start after battery voltage and current reaches the threshold OR Second Condition: Voltage1. the batteries will continue to be charged. Suite 302. If below -10A. ON Delay allows generator to stay OFF for configured time and OFF Delay allows it to stay ON for the selected time before and after each cycle. Charging current is always negative.Stop generator If battery voltage is above 53vdc AND Current1.Stop generator If battery voltage is above 54 vdc AND Current0. Grenville Ave. 888 S. AND Delay for 60 Second to start after battery voltage and current reaches the threshold Enable Generator ON and OFF Delays Voltage mode configuration allows customers to program a timer for ON/OFF Delay.com. Saved9/5/2014 .com GEN000231D www-leap-power. sales@leap-power. Richardson. 19 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.

1 Selecting Setup Configuration: Selecting your configuration (see Figure 4 & 5 for more details): 20 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Richardson. Causes: Start Condition 0: Battery module requests start 50 seconds after shutdown. Enable Delay. In case of dual redundant or backup generators. However.OFF delay: Stop 6000 seconds after battery module requests stop. Stop Condition 1: Battery module requests shut off 20 seconds after voltage >56 amps AND current < 4 amps. a time window selection allows the user to decide how dual generators and batteries should cycle. Following figure shows cycling between two generators using voltage control method: Cycle Time T Customer selectable Generator A cycle time -54V Battery Discharge -52V GenLeap™ A ON -48V Battery Charge GenLeap™B ON 1. Effectively starting every time voltage falls below 44 volts. This time will be enforced every time since V should always be < 100 and current > -999 regardless of charge or discharge.ON delay: Start 600 seconds after battery module requests startup. Saved9/5/2014 . Primary Voltage method will utilize battery voltage and current as the key parameters for its operation. Start Condition 1: Battery module requests start 1 second after V < 44.com. no impact.4. time delays allow the user to configure a hybrid configuration that allows a charging method based on voltage within a time window. 888 S.1. Tx 7081. USA +1-469-757-1787 (T).com GEN000231D www-leap-power. sales@leap-power. Enable Delay. Suite 302. Start Condition 2: Effectively. Grenville Ave. Stop Condition 0: Battery module requests shut off 1800 seconds after startup provided a voltage > 40 volts.

com.4. Richardson. USA +1-469-757-1787 (T). Saved9/5/2014 . Tx 7081. system will reboot itself. 888 S. Grenville Ave. 21 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Suite 302.1.2 Confirming Setup Configuration: Once the setup configuration is confirmed. sales@leap-power. Power to the eConLeap™ master controller will be lost. You could lose any unsaved data or configuration at this point. New method selected is Voltage 1.com GEN000231D www-leap-power. Present control method is Timer.

Suite 302. sales@leap-power. Saved9/5/2014 . Grenville Ave. 1.1.com GEN000231D www-leap-power.com.3 Confirming Setup Configuration: Before starting the controller reboot. please make sure that the selection on dash board matches with the desired operation mode and control method in your configuration. USA +1-469-757-1787 (T). 22 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Tx 7081. Richardson.4. It may take 10-20 seconds for controller to switch to the new configuration and show up on the dash board. 888 S.

your connection to the controller (IP Address) will be lost. Please note the system will continue to operate without interruption until te reboot is completed. Grenville Ave.1.4. New control method Voltage and mode matches now.com. Saved9/5/2014 . 888 S.ready to reboot. 23 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. You will need to refresh the page or re-enter the URL. Richardson.com GEN000231D www-leap-power. Tx 7081.4 Reconnecting after reboot: During reboot.It may take 20-30 seconds for controller to re-establish the connection. Suite 302. 1. USA +1-469-757-1787 (T). sales@leap-power.

Saved9/5/2014 . Suite 302.com. sales@leap-power. Richardson.com GEN000231D www-leap-power. USA +1-469-757-1787 (T). Grenville Ave. Tx 7081. 24 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. 888 S.

25 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Customer may select LVBD disconnect and reconnect settings based on their batteries selection. Please note that the LVBD disconnect voltage and temperature thresholds are mutually exclusive but both reconnect conditions must be met to reconnect the batteries.1. 1. Battery or Environment menu configurations unless recommended by Leap Power's application engineer or qualified service technician. Grenville Ave. Saved9/5/2014 .4.2 Configuration Customer shall not change any Generator.4. 1.com GEN000231D www-leap-power. Any maintenance items like air filter change. sales@leap-power.com. you will see new setup configuration on setup and dash board. Now your setup is complete. Richardson. oil change and fuel filter change should be logged by resetting the counter. Suite 302. The tracking of service items allow system to generate service alarms on time.5 New setup: Once the controller has completed a reboot process. USA +1-469-757-1787 (T). All maintenance items shall be reset under Service thresholds by the customer to ensure service alarms work properly. Any changes in these thresholds can result in failure of the engine or generator safety stop. 888 S. Tx 7081.

Tx 7081. Saved9/5/2014 . USA +1-469-757-1787 (T). Richardson. Grenville Ave. sales@leap-power.Configuration of Generator Parameters 26 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Suite 302. Figure 5.com GEN000231D www-leap-power.com. 888 S.

Tx 7081.com GEN000231D www-leap-power. USA +1-469-757-1787 (T). sales@leap-power. Suite 302. Richardson. Saved9/5/2014 . Figure 6. Grenville Ave. 888 S.com.Configuration of Environment Parameters 27 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.

Figure 8. It is always recommended to make a copy of the original configuration before overwriting your configuration file. generator current. USA +1-469-757-1787 (T). Generator operations (admin permission required) allows setting a new generator target voltage.Operations 28 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.4. 888 S. battery charging current limit and discharge current limit. Tx 7081.Configuration of Battery Disconnect 1. Suite 302.3 Operations Customer may test different voltage and current settings prior to changing their factory default configuration.com. These values do not change customer configuration during testing unless customer elects to permanently write to configuration file by electing "Persist". Richardson. Saved9/5/2014 . sales@leap-power. Grenville Ave. battery charge voltage.com GEN000231D www-leap-power. Figure 7.

5.com. 1. sales@leap-power. Saved9/5/2014 .com GEN000231D www-leap-power.1 Alarms Figure 9. Tx 7081. 888 S.5 Monitoring & Control 1. Grenville Ave. USA +1-469-757-1787 (T). Suite 302.Alarms & Logs 29 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Richardson.

sales@leap-power. Key Alarms (Severity: C=Critical. Saved9/5/2014 . M= Major. USA +1-469-757-1787 (T). Suite 302. W= Warning & I = Information) Air/Cabinet Inlet Temp High (C) Air/Cabinet Inlet Temp Low (C) Air/Cabinet Outlet (Exhaust) Temp High (C) Air/Cabinet Outlet (Exhaust)Temp Low Alternator Temp High (M) Battery over current Limit (C) Battery over voltage (M) Battery over voltage (M) Battery under Voltage (C) Bridge Regulator Temp High (M) Communication Loss (C) Coolant Level Low (C) Coolant Temp High (C) Coolant Temp Low (M) Crank Battery Charger Off (M) Crank Battery Temp High (C) Crank Battery Temp Low (M) Crank Battery Voltage High (M) Crank Battery Voltage Low (C) Crank Failure (M) Door Open Alarm ECU Fault (C) Engine Temp High (C) FAN 1(inlet) Failure (C) FAN 2 (Exhaust) Failure (C) Fan1 (inlet) RPM Low (M) Fan2 (Exhaust) RPM Low (M) Fuel Level Low (C) Generator Over Current (C) Generator Over Speed (M) Generator Over Voltage (C) Generator Running Hours High (W) Generator Under Speed (M) Generator Under Voltage (M) Incorrect Software Setting (C) LVBD Connect Time Out (M) LVBD Disconnected (C) Low Oil Pressure (C) Main Battery Temperature High (C) Main Battery Temperature Low (M) Max crank attempts failed (M) Redundant Generator Failure (M) Service Time Coolant Change (I) 30 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. 888 S.com GEN000231D www-leap-power. Grenville Ave.com. Tx 7081. Richardson.

Service Time Crank Battery (I) Service Time Fuel Filter (I) Service Time Oil Change (I) Service Time Oil Filter (I) Service Time Radiator Fan Belt (I) System Emergency Stop Active (C) 1. Data and Alarm logs in a tab separated format.Data & Event History Logs 31 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. USA +1-469-757-1787 (T). Figure 10. Grenville Ave.2 Logs Logs provide downloading option for Event. Tx 7081. sales@leap-power.com GEN000231D www-leap-power.5. 888 S. A log file may be copied to excel or access file by copy and paste.com. Suite 302. Richardson. Saved9/5/2014 .

Grenville Ave. 888 S. Richardson.5. sales@leap-power. Tx 7081. Saved9/5/2014 . Suite 302.com.3 Status Figure 11. USA +1-469-757-1787 (T). 1.Status 32 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.com GEN000231D www-leap-power.

sales@leap-power.4 Inventory Inventory items shall be completed during installation of GenLeap™ and other modules.com. Figure 12. 33 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.com GEN000231D www-leap-power. USA +1-469-757-1787 (T).Inventory Inventory items shall be completed during installation of GenLeap™ and other modules. Suite 302. Richardson. Grenville Ave. 888 S.5. Saved9/5/2014 . Tx 7081. 1.

All alarms initiating estop condition must be cleared before clearing an eStop. Suite 302. USA +1-469-757-1787 (T). Richardson. If a safety stop condition is generated from Engine Control Unit (ECU). A clear safety stop under Operation/Generator menu or engine control unit Reset under Operation/Controller menu must be executed to clear the engine safety stop condition. 888 S. Please save your configuration to the controller and your computer. Figure 13a. Please note that any unsaved configuration can be lost during the power down and reboot process. Following faults can be reset and cleared through debug/Generators/Alarm Reset page. All non-latching alarms are cleared at stop or once the alarm condition is cleared. sales@leap-power. Saved9/5/2014 . 34 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Engine estop can be cleared by writing a value "0" on Debug/Alarm-Reset page.com GEN000231D www-leap-power.com. 1. administrator must clear the engine safety stop along with the system safety estop. Grenville Ave.Alarm-Reset (calibration Items) A bit value >3 indicates a warning and >7 sets a critical (latching) alarm for the following fault conditions: GenEngineEstop: An alarm "ECU Fault" indicates an engine fault.5. Tx 7081. due to safety concerns. However. latching alarms require Administrator to follow an alarm clearing and power reboot process.5 Debugging GenLeap allows clearing of latching alarms through debug page.

wrong shunt or disconnected LVBD may cause the system to start and shut down. 35 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Suite 302. Tx 7081. sales@leap-power.com GEN000231D www-leap-power. Saved9/5/2014 . In addition to the above latching alarms. fuel pump. GenOutFxOilPressure: Indicates a problem with high or low oil pressure. 888 S. A tripped breaker. A battery voltage too high or too low may create this alarm. Richardson. A value >7 on this page provides the source of the ECU Fault. USA +1-469-757-1787 (T). Grenville Ave. GenOutFxInOutVolts & Current: This latching alarm indicates an incorrect alternator or battery voltage or current. Figure 13b. ECU provides a list of alarms covered under system main alarm "ECU Fault" under Debug/Generator menu.com. GenOutFxFuelLvl: Indicates a problem with fuel inflow. stop solenoid and fuel filter lever position.Debug Items .

168. The username/password will be plg/plg.com.1. Suite 302. Make sure you can ping the Mini Controller to address 192.0. The software update bundles are located on our ftp server or may be requested by contacting technical support at info@leap- power.tar 36 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.230:(none)): *** Password:*** (see your invoice for assigned user ID and password.168. If your software is located on the c:\ drive.6. 1. User (192.1. Grenville Ave. Our software update releases for the eConLeap™ Mini Controller follows the naming convention of update_3. USA +1-469-757-1787 (T)..0. Richardson. Saved9/5/2014 .com. ftp> put update_3.17) ready.1 Upgrading eConLeap Mini 2440 Controller Please make sure that CAT5/6 LAN cable connection is properly secured. 220 FriendlyArm FTP server (Version 6.23. where X is a digit representing a specific version or release of the software. the latest software is update_3. Make sure that you transfer in binary mode. It will show extension release number followed by extension . 2) Connect your PC to the Mini Controller.1.4/OpenBSD/Linux-ftpd-0.230.tar.23.6 Software Upgrade GenLeap™ controllers software can be upgraded remotely or by changing flash memory in the controller.230 Connected to 192.1.230 C:\>ftp 192.X. This can be simply done by plugging your pc directly to the eConLeap™ router port 2 & 3 (not port 1).168. For example. Tx 7081.0. ftp> cd /sdcard 250 CWD command successful.230. Follow the instruction below: cd c:\ ftp 192. 1) Download a copy of the latest software to your PC. sales@leap-power. 1. For example. 888 S.0.168.168.0. 230 User plg logged in. 3) FTP the release to the eConLeap™ Mini Controller or transfer the file to the /sdcard folder for upgrading the eConLeap™Mini Controller.com GEN000231D www-leap-power.0.1. ftp> bin 200 Type set to I.

7. 888 S.0.com. SW2 switch allows the customer to select between the modes of remote and local operation of the unit. Richardson.0. (just for update_3.xml). 6) Reboot the controller. This could result in engine failure. A GUI application for advanced engineering & calibration is available to the customer needing such access to the controller. performance degradation and warranty cancellation. The ECU mode should be activated by trained technicians only. The system must be in Remote position when the customer is ready to start or operate the system via Ethernet connection. SW1 switch provides Remote (Web) and ECU (RS232) modes of operation. The customer can select between RUN. 4) Install the software. The DHCP connection on front of the Ebox should be always connected to the remote monitoring center and should not be removed during system maintenance.tar 5) Remove the current configuration.ksh update_3. The purpose of the switch is to avoid an unintended start of the generator from RS232 GUI or Web during installation and maintenance.168.com GEN000231D www-leap-power. Suite 302. It is recommended that the customer avoid changing factory default configuration without consulting Leap Power.tar release remove leapdb.23.0.1 Ebox Control Panel & Manual Switches A manual start and stop switch and operation mode selection switch are located at the front panel for manual activation of the system. sales@leap-power. AUTO mode 37 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. install the software as follows.23. Grenville Ave. The username is root (password is not required). USA +1-469-757-1787 (T).xml NOTE: By removing leapdb. Saved9/5/2014 .0. a) Telnet to the Mini Controller. a) cd /sdcard b) rm leapdb. You will have to re-configure the leapgen system.xml you are removing all configuration changes that you have made on the system. telnet 192. 1.230 b) cd /sdcard c) /swupdate. Once the download of the new release is completed on the mini-controller and it's in the /sdcard folder. A separate Ethernet connection is available for local configuration and provisioning during installation.1.7 Manual Connections & Controls GenLeap™ controllers software can be locally or remotely managed via RS232. AUTO and Remote positions. Tx 7081. 1.

4. Do not remove this CAT 5 connection for local access during installation & ON/OFF switch allows manual maintenance. Richardson. If SW2 is in Remote position. sales@leap-power. Tx 7081. Switch must be in ON position during system operation Use local Ethernet and OFF position connection for during installation provisioning and and maintenance. RS232 GUI shall be mainly used by experienced technicians or engineers for high level diagnosis and calibration. it is recommended that customer tests the system in manual RUN mode before working in AUTO or Web mode.1 and Figure 5 for more details.com GEN000231D www-leap-power. USA +1-469-757-1787 (T). Selecting RUN and AUTO mode allows the customer to disable Web interface and operate through RS232 GUI or manual mode. 888 S. It is always safe to switch the eBox ON/OFF Switch in OFF position. 38 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. the system cannot be operated in the manual local mode or via RS232 GUI. Saved9/5/2014 .Front panel and Ebox Use DHCP connection for remote control and management. SW1 in estop position and SW2 in Remote position when doing system installation or maintenance. WARRNING: System can start without notice if placed in RUN or AUTO positions via SW2. See section 1. disconnect for ebox. Grenville Ave. Figure 14. allows the customer to run the system in primary mode with voltage control method. configuration during installation and maintenance. During installation.com. Suite 302.

Customers may purchase an integrated DC distribution prewired with GenLeap™ cabinet or an external rack mount distribution that is normally integrated inside the battery cabinet. solar converters.com.7. sales@leap-power. Suite 302. parallel generator. rectifiers.2 DC Distribution Monitoring & Control GenLeap™ systems are sold in many configurations as a complete system with split distribution. batteries. 1. converters. GenLeap™ generators are also used in stand-alone or AC generator's retro fit applications with customer supplied DC distribution.com GEN000231D www-leap-power. 888 S. Richardson. USA +1-469-757-1787 (T). wind generator and other options. 39 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Tx 7081. Saved9/5/2014 . Complete system allows a unified system management and high efficiency energy management features via master controller (eConLeap™ Mini Controller). Grenville Ave.

External Leap Power's Supplied Distribution Wiring: Following wiring diagram is used with single or dual generator setup with Leap Power's supplied distribution.com GEN000231D www-leap-power. sales@leap-power. a. 888 S. 40 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Saved9/5/2014 . Grenville Ave. Tx 7081. Richardson.com. USA +1-469-757-1787 (T). Suite 302.

5 P1-9 Distribution LVBD Coil -Ve. Saved9/5/2014 . Leap Power recommended parts are following: 1. A two wire battery current shunt connection to JCSB receptacle shall be maintained all the time. NC-2) with the eBox P1 connector. the following wiring must be connected with the distribution. Tx 7081. Bat 1 JCSB-1 mV Shunt +Ve Shunt 200A/50 Ext Dist. b. battery low voltage disconnect (LVBD). Please note that the battery shunt. PT100 Main Battery 12 Temperature P1-5 & 6 (supplied with GenLeap™) Temp +Ve POST Sensors Ethernet Connected to RJ45 connection on the eBox 13 Cat5e Cable Connection (supplied with GenLeap™) 41 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. LVBD: The DC contactor must be single pole double throw latching type with 24VDC coil voltage. The LVBD shall be connected to two 24Vdc control wires (+ve & -ve) and two communication wire (NC-1.com GEN000231D www-leap-power. Bat 2 JCSB-2 mV Shunt -Ve LVBD-NC-1. 2. Recommended From: DC TO: Front Panel of Ebox in GenLeap™ Parts (10kw) Distribution Shunt 200A/50 Ext Dist. 3 P1-8 Distribution LVBD-NC-2. 4 DC Contactor P1-7 Distribution 250A/24V- Latching Type LVBD Coil +Ve. Grenville Ave. Suite 302.DB9 Serial Female Front Panel 10 RS-232 JC1.com. sales@leap-power. Battery Current Shunt: A 50mv 100A to 300A shunt is recommended for 5KW to 10KW Genleap models. USA +1-469-757-1787 (T). 6 P1-10 Distribution Battery Voltage 7 Main 48VDC P1-3 Sense +Ve Battery Sense Battery Voltage 8 Wiring P1-4 Sense -Ve 9 RS232. and battery voltage sense leads MUST always be connected for battery charger plant to be operational. 888 S. battery temperature sensor (RTD).DB9 Serial Female System Output Generator Output Anderson output connector (gray) or two wires 11 48Vdc/200A +Ve & -Ve with lugs (supplied with GenLeap™) RTD. External Customer Supplied Distribution Wiring: In case the distribution was not a part of Leap's supplied system and the customer plans to use the generator for battery charging. The contactor rating shall be according to the DC generator rated voltage and current. Richardson.eBox RS-232 JC2.

Customers are only required to make the necassary connection with the DC distribution. Following are few examples of how RS232 GUI can be utilized by experienced technicians or engineers. All wiring to P1 connector with eBox is supplied with GenLeap™.8 Serial Connection with Engine Control Unit (ECU) GenLeap™ controllers software can be locally or remotely accessed via RS232 for engineering use. Tx 7081.com GEN000231D www-leap-power. This could result in engine failure. please see the system wiring schematic and model specific wiring. sales@leap-power. A GUI application for advanced monitoring & calibration is available to the customer needing such access to the controller. It is recommended that customer should avoid changing factory default configuration without consulting Leap Power. Please reference GUI Programming Manual for more details. performance degradation and warranty cancellation.8. For wiring other configuration and system rating. Custom cables can be ordered from Leap Power's factory.com. All wire lengths are based on a standard 5 feet distance between GenLeap™ eBox and DC distribution.RUN-STOP Command (Timer Mode) 42 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. 1. 1. A DB9 female connector is available at the front of the generator control box for serial connection. Suite 302. Saved9/5/2014 . Grenville Ave. USA +1-469-757-1787 (T). Richardson. Above list of recommended DC distribution's parts are based on 10KW (48Vdc/200A)DC Generator primary (off grid) power.1 Operating through RS232 GUI Figure 15. 888 S.

the engine will be commanded to stop for this number of minutes. If the “Remote Stop Time” variable is set to a nonzero number. Start / Stop / Running the machine: The system requires either the AUTO or RUN wired inputs to be activated before the engine will be allowed to run. A value of 255 will put engine in permanent STOP mode. Richardson.1 for further details. The system will run but will not enter charging mode ( runs at slow speed) if alarms are set that are configured to inhibit charging. Run Mode: If the SWI is in start position and SW2 is in RUN position. The RS-232 must change the number from 255 to another desired run time OR zero once it is desired to exit “run forever” mode.com GEN000231D www-leap-power. The RS-232 stop command will override any run command. SWI switch must be in start position and SW2 switch should be RUN or AUTO mode. There are similar settings for auto shutdown. The engine will automatically start when batteries are properly connected and battery voltage is below the start threshold for enough time.4. 43 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.7. Please see the section 1. Please reference section 1. the generator will be allowed to start and control voltage. Saved9/5/2014 . See calibration items in the area of “Strt Threshold Voltage 0” in section 1. If the timer reaches zero and something else is commanding it to run. If the counter exceeds the start time. the timer will not count down minutes. the system will be activated for RUN mode via RS-232 Run Command based on time selected by the operator. The system must be set to zero "Remote STOP Time" to allow it to operate in AUTO mode or WEB mode. RS-232 Run Command: User commands it to run for a number of minutes ( 1 to 254) or forever ( setting to 255 minutes) using the “Remote Run Time” variable. This command is in either AUTO or RUN mode. Tx 7081. 888 S. the system is commanded to start. If the number is 255. The machine will not start or continue running if alarms are configured or set to inhibit running. There are voltage & current thresholds below which timers start counting time below this voltage with a minimum of this current present.com.4. sales@leap-power. Suite 302. RS-232 Stop Command: The RS-232 interface will be allowed to command the machine to stop (or inhibit starting) for a number of minutes.3 for how to view the VirOutFns for fault status. Grenville Ave. Auto Mode: If the Auto input is activated.1. USA +1-469-757-1787 (T). it will initiate the start sequence.

Suite 302. The customer is allowed to change factory default maximum battery voltage. 888 S. USA +1-469-757-1787 (T). Richardson.com. discharge current and charging current limits. sales@leap-power.8.Max Voltage & Current Settings 44 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.com GEN000231D www-leap-power.2 Calibrating through RS232 GUI RS232 commands under Calibration/Charger Target allow customers to set maximum generator voltage and current limits. Figure 16. Tx 7081. Grenville Ave. Saved9/5/2014 . 1.

Suite 302.8. Saved9/5/2014 . It is recommended that web interface.com GEN000231D www-leap-power. 1. Items such as voltage. 888 S. not RS232 GUI is used as a tool for monitoring GenLeap™. USA +1-469-757-1787 (T). Tx 7081. Such an coolant temperature above threshold.Voltage & Current Monitoring RS232 GUI provides detailed overview of variables inhibiting engine operation for safety reasons or limiting its performance. 2 = warning set 4 = alarm1 set 8 = alarm2 set 16 = alarm3 set 32 = alarm4 set 64 = error bit set ( not implemented yet) 128 = E2 error / permanent error bit set ( not implemented yet) 45 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. batteries and load are shown in Figure 14 under Run Time/Gen Sensors Proc. Figure 17. The system faults with their sum of bits are shown in Figure 15 below under Run Time/VirOutFns. These are status bits for each comparison 1 = item is set. sales@leap-power. GUI allows extensive monitoring of the system.3 Monitoring through RS232 GUI During RS232 mode.com. Richardson. Grenville Ave. current for generator.

Grenville Ave.com GEN000231D www-leap-power. Saved9/5/2014 .) is simply the sum of the item's bits. Figure 18. .com. 15.. A value of 7 or greater would limit the generator RUN or AUTO and put the engine under emergency stop (estop) condition. One can choose what level of warning or alarm each input can set and clear. Suite 302. It can also be configured to clear any combination of its bits when the item is deactivated. USA +1-469-757-1787 (T).Fault's and Alarm's Status 46 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. Tx 7081. Each item has its own status bits and can be configured to set any combination of its bits. 888 S.. Richardson. The value (7. sales@leap-power.

230. See GenLeap controller manual section 1. 888 S.. 7. Continue with the next step. USA +1-469-757-1787 (T).4. Calculate the battery discharge time and charge time based on its capacity. this function can be performed by our support engineer. 2. Follow instructions to download upgrade software for eConLeap and uConLeap controllers if you have an older release. Please reference RS232 GUI programming manual.230. Saved9/5/2014 . 5.168. Charge crank battery to minimum 12 vdc.2 for more details. DoD% and battery limit selection. Check generator/distribution output circuit breaker 1-3. sales@leap-power. 3. Unit will not start if CBs are open.2. Unit could not be started due to a fault that will need to be cleared prior to starting the configuration process.7. If RUN is successful. 4. 9. recheck all wiring and battery connections. See section 1.com. Suite 302.9 Quick Guide To Starting GenLeap™ First Time 1. 8. Grenville Ave. Connect DC distribution wiring to the Generator. 6. Ensure adequate fuel flow and fuel level.1. If remote access via TeamViewer7 is available. 14. Exercise RUN mode (Remote RUN Time/ Remote Stop Time) by manually starting the generator. Launch your web browser with IP address 192. A project file with configuration for your system is included with GUI program. Make sure that the batteries are equalized and not below low voltage disconnect settings. 10. You are now ready to configure the system per your application. 11. If the unit does not start during manual RUN. Allow pre heating the oil and engine in cold weather. Battery capacity and current limit selection must meet the intended duration of cycle at peak load. Install RS232 GUI software to your computer. Make sure ON/OFF switch is in ON position. 12. Read carefully GenLeap Controller manual & product manual. 48Vdc battery connection and load connection are also required for GenLeap system to start. Tx 7081.168. Follow steps to log in using Chrome WEB browser. Position SW1 switch in ECU position and SW2 in RUN position. 13.1. Connect 48Vdc battery bank. Green bar below dash board on the web must be moving to validate the connection with GenLeap controller. Connect Ethernet cable supplied with the unit to your computer. See section 1. Richardson.7. New releases are available on Leap Power ftp sites. 47 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. exit switch SW1 and SW2 to Remote positions. Check engine oil and coolant level. 15.com GEN000231D www-leap-power.1. Check the communication by connecting with IP address 192. 1. Connect CAT5 cable supplied with GenLeap to your computer.

com.10 System Layout & Trouble Shooting To Power Distribution/DC Distribution GenLeap™ Harness Layout with power distribution SYSTEM OUTPUT (Gray Connector) DC Distribution/Power Distribution ECU Harness Assembly Generator A & B Output Connection Regulators & Output Filter (C5) Ebox Assembly JT (P) JT (S) DB9 Female JC1 JW1 (S) JW1 (P) 8 Position Aux Sense Wires JW2 (S) JW2 (P) 8 Position Aux Sense Wires Generator B ECU PD-2BP Generator B Crank Battery PD2-BS J1 (18 Pos) JSCB (P) JSCB (S) 48V Bat Shunt J1P J1S 48V BAT Sense J8P J8S STC-1B JE1P (mag) JE1S (mag) Mag Pickup sensor J1EP J1ES Coolant Temp Sensor J4S J4P ( Actuator) CHB PB RB STC-1A J1S ON/ J1P SW1 SW2 OFF Ebox Assembly Ring Term Router 8 Position Aux Sense wires 8 Position Aux Sense wires PLC Oil PSI J2 (30 Pos) Generator A Generator A Mini STC-106 PD2-AP PD2-AS J3S J3P STC-1 Stop Solenoid Stop Solenoid P1 Relay 2 J2S Fuel Pump Relay 4 STARTER Relay 5 Battery V Sense Alternator & Engine MAIN Relay 6 Glow Plug 48 Vdc Fuses F1-3 Batteries Revision A4.com GEN000231D www-leap-power. Follow system configuration menu. Grenville Ave. 17. 18. Make sure you save your configurations on your computer and in the controller. 16. Tx 7081.1 & Figure 4. 12-29-12 Leap Power Confidential 48 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information. 888 S. you may want to use small batteries to keep the charge/discharge cycles short.4. A complete 12V power down may be required. During initial test. If batteries below threshold. sales@leap-power. USA +1-469-757-1787 (T). 19. 1. Follow trouble shooting guide to clear all the alarms. Richardson. Apply load to the system and start discharging batteries. Saved9/5/2014 . the generator will start automatically. Review section under Alarms. Suite 302. Position SW1 and SW2 switch in Remote position. Check voltage mode configuration in section 1. Reset the system thru controller reboot or reset.

Grenville Ave. Tx 7081. 888 S. USA +1-469-757-1787 (T). 49 of 49 CONFIDENTIAL Date 10/28/11 This document contains proprietary information.com. Saved9/5/2014 . sales@leap-power. Richardson.com GEN000231D www-leap-power. Suite 302.