Power Ignition and Controls

a division of Spartan Controls

24VDC Generator and Battery System Manual

Power Ignition and Controls

a division of Spartan Controls

“Engine and Compressor Control Specialists”

www.powerignition.com

Calgary Edmonton Fort McMurray Grande Prairie Regina Saskatoon Fort St John Surrey
403-207-0700 780-468-5463 780-790-0440 780-539-1161 306-721-6925 306-934-3484 250-785-0285 604-539-7250
305 - 27 St SE 8403 - 51 Av 300B MacKenzie Blvd 11419 - 98 Av 475 Maxwell Cres 206B-2750 Faithful Av 9603 -112 St 104-19329 Enterprise Way
 Power Ignition and Controls
a division of Spartan Controls

Electrodyne 24VDC Industrial Generator

This high output unit provides 24 VDC power to operate
most engine control systems. In remote applications, the
generator will provide power for engine ignition systems,
electronic governors, control panels, communication
systems, and intermittent plant lighting. The unit is belt
driven from the engine drive pulley and is provided with
a standard mounting bracket and tension adjustment.
The unit provides designed output at a speed range
between 2000 and 3600 RPM.
• Class 1 Div 2 Groups C & D
• 40 Amps Usable Output
• Regulated 24 VDC

Division 2 Battery Box

PIC has designed a Class 1 Div 2 battery box for use
with the ELECTRODYNE Generator to meet the rigors of our climate and environment. Two 12
VDC flooded deep cycle batteries provide exceptional characteristics for output and recharging.
The battery box comes complete with enclosure, batteries, vent, and fuses necessary to complete
the installation of the generator to plant equipment. The optional undervoltage shutdown includes a
pushbutton bypass for startup.
• 100 & 227 Amp-Hr of 24 VDC Power
• Fused Inputs and Outputs
• Optional Undervoltage Shutdown
• Approved for Class 1, Div 2 locations
www.powerignition.com

Calgary Edmonton Fort McMurray Grande Prairie Regina Saskatoon Fort St John Surrey
403-207-0700 780-468-5463 780-790-0440 780-539-1161 306-721-6925 306-934-3484 250-785-0285 604-539-7250
305 - 27 St SE 8403 - 51 Av 300B MacKenzie Blvd 11419 - 98 Av 475 Maxwell Cres 206B-2750 Faithful Av 9603 -112 St 104-19329 Enterprise Way
Basic Components

1 10-080-678, Electrodyne 24VDC Industrial Generator

2 BB2-CB-xxx-z, Control box
xxx options are standard (Base) & Undervoltage (UVGD)
3 BB2-BATTENCL-Z, Battery Enclosure
Z options are standard (A) & Cranking (C)

How To Order

Electrodyne Industrial 24VDC Generator

Part Number: 10-080-678 – 60 amp 24VDC Generator

Generator Mounting Brackets

Part Number: 10-080-678/MB4 – 4” tall adjustable generator support bracket
Part Number: 10-080-678/MB9 – 9” tall adjustable generator support bracket (Standard)

Undervoltage / Gas Detection Battery System

Part Number: BB2-UVGD-A-BE-A - undervoltage/gas detection battery enclosure

Standard Battery System / Gas Detection

Part Number: BB2-BASE-A-BE-A – Standard battery enclosure w/ gas detection interface

Additional Battery Capacity

Part Number: BB2-BATTENCL-A – 105 Amp/Hr battery enclosure (Standard)
Part Number: BB2-BATTENCL-C – 227 Amp/Hr battery enclosure for electric starters

Additional Parts
Part Number: H014 – Generator hub
Part Number: 77606103 – ‘B’ type link belt - per foot
Part Number: BKxxH – Generator sheave – xx size to be determined at time of order

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Electrodyne 24VDC Industrial Generator

Part Number: 10-080-678

This generator is designed specifically for
industrial applications. Rated at 24 VDC with 60
ampere capability this unit will provide power for
multiple control systems and auxiliary equipment
such as FIRE EYEs and area lighting. There are
no brushes or springs to wear or fail and with
only one moving part, a unitized non-electrical
rotor shaft. This generator is covered by a one
(1) year warranty to provide hours of trouble free
operation. The one piece bearing housing, which
also serves as an oversize grease reservoir,
assures permanent bearing alignment.
Heavy duty, extra long life roller and ball bearings
are used to handle high belt load and end
loads. Large diameter stator wire decreases IR
winding losses for more power output with lower
horsepower input. Dual mounting ears in one piece steel casting. This is a unit that you can
depend on for extended operational life and service.
CSA certified for operation in Class 1, Div. 2 environments.

Net Rated Amperes

60 (CSA Approved @ 40Amps)
Preset Voltage
27.6 VDC (set at factory)
Preset Voltage Range
25.5 – 30.0 VDC
Voltage Regulator
Integral, Adjustable, Self Excited
Full Load Voltage
27.3 VDC
Full Load Field Coil Amps
4.5
Grounding
ISOLATED
Diode Capacity
225 AMP
Rotation
Bi-directional
Shaft Diam. (Pulley I.D.)
7/8”
Maximum RPM
3000 continuous, 3500 peak
AMPS VOLTS GENERATOR RPM
30.0 25.5 1,600
60.0 27.6 3,000

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Basic Operation

Low Voltage Operating Instructions

The Undervoltage Shutdown (LVD) provides a method of disconnecting load supply when the
battery voltage falls below an unacceptable voltage. The pushbutton bypass is provided to allow
for provision of load supply when the battery voltage is below the low-voltage disconnect and the
LVD has disabled regular battery power.

GREEN LED
Typically the green light is not applicable with the PIC BB2 applications.
If a solar panel (PV array) or DC power is connected to terminals 3 & 4, The green LED indicator
will light as long as there is power available. (Daytime for solar applications).

RED LED Indicator

Whenever the battery charge state falls below the LVD set point (23 volts, Reconnect @ 25.2
volts), the load will be disconnected and the red LED will light. This indicates that the controller
has disconnected the load to protect the battery from further discharge and possible damage.

Gas Detection Operating Instructions

The GAS DETECTION option allows for the operator to remove control power to relay R1 (item
16), by opening the contact between terminals TB15 and TB16. The supplied jumper must be
removed to enable this function. This will disconnect 24VDC power to terminal TB12. A diode
block (item 11) isolates battery power from the generator. A 3 amp un-switched fuse (item 10) is
installed for connection to the gas detector, so that the detector remains powered up in this state.

Generator Failure/ Blown Fuse Alarm

The BB2-CB-UVGD-A provides a signal to the panel indicating the generator and control fuse
are operating properly. The relay state is connected to the panel to indicate generator power is
available. If either of the fuses blow, or the generator fails (failure or broken belt), the relay will
turn off and signal the panel of a fault. A class B alarm should be used for the panel input. The
relay is suitable for non-incendive use provided suitable wiring methods are used to maintain this
protection method.

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Battery Box Maintenance & Troubleshooting

General Maintenance
• Please check the battery box terminals for tightness on a regular basis. This helps to ensure
that no potential ignition sources are present in the battery box.
• Visually inspect the batteries on a periodic basis. Look for possible corrosion, battery bulging
(sign of overcharging), and other irregularities. If the batteries appear to be damaged or not
operating properly, please contact a PIC office for battery replacement.
• Inspect the “T” vent for obstructions and the vent’s ability to pass any gas out of the box.
Always check the vent for obstructions before opening the enclosure.
• With a volt meter, periodically check the output voltage of the generator by measuring the
voltage at the battery terminals while the engine is running. The preferred voltage should be
between 26.5 and 29.0 volts. If the voltage is outside this range, please contact a PIC office
for assistance.

Troubleshooting
Cautions:
• Troubleshooting should be done by qualified personnel only.
• Remember that a battery can cause serious damage if shorted.
• There are no user serviceable parts, fuses or circuit breakers inside the LVD.
• Observe all normal precautions when working with energized circuitry.

Battery is not Charging

• Check the green LED indicator. The green charging LED should be on if the engine /
generator are running
• Check that the proper battery type (Sealed or Flooded) has been selected. PIC uses flooded
batteries (Jumper Removed)
• Check that all wire connections in the system are correct and tight. Check the polarity (+/-) of
the connections.
• Check that the load is not drawing more energy than the Generator can provide.

Load Not Operating Properly

• Check that the load is turned on. Check that no system fuses are defective. Check that no
system circuit breakers are tripped. Remember that there are no fuses or circuit breakers
inside the LVD.
• Check connections to the load, and other controller and battery connections.
• Check for proper LED indications on the LVD. If the red load disconnect LED is on, the load
has been disconnected due to low battery voltage.
• Measure the voltage at the controller battery terminals. If this voltage is above the LVD, the
load should have power. Then measure the voltage at the controller load terminals, and if
there is no voltage present, the controller may be defective.

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Transmission or Process Facility
Sec. 12(2) (a) (b)
12(4) (c) (e)
Hazardous Area Classification

Additional when heavier-than-air vapours may be present

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Drawing Number - BB2-CB-BASE-A-01-SD Rev.1

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Drawing Number - BB2-CB-BASE-A-02-SD Rev.1

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Drawing Number – BB2-CB-UVGD-A-01-SD Rev.1

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Drawing Number – BB2-CB-UVGD-A-02-SD Rev.1

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Drawing Number – BB2-BATTENCL-A-01-SD Rev.1

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Drawing Number – BB2-BATTENCL-C-01-SD Rev.1

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Drawing Number – 10-080-678.dwg Rev.C

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Drawing Number – 10-080-678-MB4-SD.dwg Rev.B

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Drawing Number – 10-080-678-MB9-SD.dwg Rev.C

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