GENERAL INFORMATION AuraGen Catalog - Aura …aurasystems.com/pdf/AuraCat_Sec 1_2-14.pdfGENERAL INFORMATION AURAGEN ... Inverter/Charger – 5,000 Watt 1-11 ... AuraGen Technical Specifications

GENERAL INFORMATION

AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 1

Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com

AuraGen Catalog

• Up to 8,000 watts of AC power from your vehicle’s engine.

• Eliminate the gensets in your fleet. • Improve operator productivity and

satisfaction.

EMERGENCY/HOMELAND SECURITY

UTILITY

MILITARY

MARINE

TRANSIT/RECREATIONAL

PICKUPS, VANS, SUV’s

FORD, GM, DODGE

GENERAL INFORMATION



TABLE OF CONTENTS PAGE

SECTION 1: GENERAL INFORMATION AuraGen System Description 1-6 General 1-6

AuraGen System Models 1-7 System Model Specifications 1-8

All-AC – 5,000 and 8,000 Watt 1-8 AC/DC – 6,000 and 7,000 Watt 1-9 All-DC – 6,000 Watt 1-10 Inverter/Charger – 5,000 Watt 1-11 Inverter/Charger – 8,000 Watt 1-12

Major Components Descriptions 1-13 Electronic Control Unit (ECU) 1-13 Optional ECU Features and Equipment 1-14 AuraGen Generator 1-15 Signal Cable Harness 1-16 DC Output Power Cable 1-16 AuraGen Power Cable 1-16 Control Panel 1-17 Vehicle Application Kits 1-17 Remote Power Strip 1-18 Cable Coupler Kit 1-18 Installation Equipment 1-19 Optional Equipment 1-20

SECTION 2: AURAGEN SYSTEM TABLES

How Do I Build My AuraGen System? 2-2 System Tables

All-AC System 5000 Watt 2-3 8000 Watt 2-4

AC/DC System 6000 Watt 2-5 7000 Watt 2-6

All-DC 6000 Watt 2-7

Inverter/Charger System (ICS) 5000 Watt 2-8 8000 Watt 2-9

GENERAL INFORMATION



TABLE OF CONTENTS Page

SECTION 3: VEHICLE APPLICATIONS Light-Duty Vehicles

Chevrolet / GMC - Trucks, Vans and SUV’ 3-2 Chrysler Van 3-4 Dodge Trucks 3-4 Ford - Truck, Vans and SUV’ 3-5

Medium Duty / Heavy-Duty International 3-7 Freightliner and GMC Chassis 3-7 AM General - Civilian 3-8

Military Applications 3-8 Recreational Vehicle, Bus Applications 3-8 Power Take Off (Shaft Driven) 3-9 Hydraulic (PTO Driven Pump) 3-9

SECTION 4: PTO AND HYDRAULIC APPLICATION GUIDE Power Take Off Application (Shaft Driven) 4-2 Hydraulic Application (PTO Driven Pump) 4-9

SECTION 5: AURAGEN PARTS CATALOG

Group 1 - Electronic Control Unit 5-2 Group 2 - AuraGen Generator 5-4 Group 3 - Signal Cable Harness 5-4 Group 4 - DC Output Power Cable 5-5 Group 5 - AuraGen and ECU Output Power Cable 5-6 Group 6 - System Control Panel 5-6 Group 7 - AuraGen Application Mounting 5-6 Group 8 - Remote Power Strip (Optional for AC Power Output) 5-9 Group 9 - Miscellaneous Parts (Spares, Etc.) 5-10 Group 10 - Installation and Test Equipment 5-10 Group 11 – Optional Equipment 5-11

SECTION 6: AURAGEN SYSTEM ORDERING AuraGen Technical Specifications Questionnaire 6-2 System Numbering for Ordering 6-3 Order Sheet 6-4 Sample Order Sheet 6-5

SECTION 7: AURAGEN PRICING SHEET 7-1

GENERAL INFORMATION



Section 1

GENERAL INFORMATION

STANDBY POWER (20 MINUTES)CONTINUOUS POWERAC POWER (CONTINUOUS)AC STANDBY (20 MINUTES)AC SURGE (2 SECONDS)AC VOLTAGE 120 VAC 240 VAC 120 VAC 240 VACAC CURRENT (CONTINUOUS) 42 AMPS 21 AMPS 2 X 33 AMPS 33 AMPS

AC POWERAC SURGE (2 SECONDS)AC VOLTAGEAC CURRENTENGINE ON-TO-OFF-TO-ON TRANSITIONBATTERY DRAW/AC ON/NO LOADBATTERY DRAW/AC OFFBATTERY DRAWDC POWER

DC VOLTAGEDC CURRENTTOTAL HARMONIC DISTORTIONFREQUENCY STABILITYVOLTAGE REGULATION

VEHICLE BATTERYENGINE BELTPOWER-TAKE-OFF

HYDRAULIC MOTORGENERATORECUGENERATORECU

GENERATOR

ECU

GAS ENGINES

DIESEL ENGINES

AUTO STARTEMI FILTER MODULEPOWER STRIPTRANSFER SWITCH

6000 WATTS5000 WATTS

DIMENSIONS12.16"DX6.4"W

DRIVE OPTIONS

9000 WATTS

ALL-AC SYSTEMS - 5000 AND 8000 WATT

AURAGEN MODELS

8500 WATTS8000 WATTS8000 WATTS8500 WATTS

G5000/G5000M (12 OR 24 VDC VEHICLE)


YES

YES

OPERATIONAL AMBIENT TEMPERATURE RANGE

-40 ºF TO 180 ºF

YES

5000 WATTS6000 WATTS7200 WATTS

-40 ºF TO 180 ºF

-40 ºF TO 120 ºF -40 ºF TO 120 ºF

YES YESYES

YES

TYPICAL OPERATIONAL ENGINE SPEED

1200 TO 6000 RPM 1200 TO 6000 RPM

750 TO 3600 RPM 750 TO 3600 RPM

YESYES YESYES

62 LBS. 65 LBS.50 LBS. 51 LBS.

YES YES

12 OR 24 VDC 12 OR 24 VDC

12.16"DX6.4"W19.27"LX13.5"WX8.52"H 19.27"LX13.5"WX8.52"H

LESS THAN 2.5%50/60 ± 0.15 HZ 50/60 ± 0.15 HZ

1.5% 1.5%

LESS THAN 2.5%

YES

DC OUTPUT NOT APPLICABLE NOT APPLICABLE

NOT APPLICABLE NOT APPLICABLE

SPECIFICATIONS

TOTAL POWER

AC OUTPUT IN GENERATOR MODE/ENGINE ON

AC OUTPUT IN BATTERY MODE / ENGINE OFF

AC POWER QUALITY

WEIGHT

OPTIONAL FEATURES

AURAGEN SYSTEM MODELS

AURAGEN MODEL SPECIFICATIONS MAJOR COMPONENT DESCRIPTIONS

GENERAL INFORMATION



AURAGEN® SYSTEM DESCRIPTION

General

The AuraGen® is a belt driven 8000 watt, maintenance-free, mobile generator that mounts under the vehicle hood, similar to an alternator. Mounted on the vehicle’s engine and belt driven by its crank drive, the AuraGen produces up to 8,000 watts of continuous clean AC power at 120 or 240 VAC. The variety of AuraGen models provide 24/7 access to AC, DC, or a combination of AC and DC electrical power, without the hassle and inconvenience of towing or carrying a utility generator. The AuraGen is a true mobile power solution since it produces full power at all engine speeds, from low to engine red line RPM. Moreover, when combined with auxiliary batteries, it produces power with the engine-off, like a high quality inverter, with seamless transition between engine-on and engine-off. The AuraGen’s uniquely clean power enables it to operate simultaneously through a full range of electrical loads from high surge compressors and A/C, to highly sensitive computer systems.

The AuraGen is supplied as a full turnkey system. It includes the generator, electronic controls, cabling and a complete vehicle-specific mounting kit. AuraGen applications include over ninety different vehicle/engine combinations for most popular light-duty, medium-duty and heavy-duty trucks, vans and SUV’s. In addition to engine-mounted belt-driven applications, the AuraGen is available for Power Take Off (PTO) and hydraulic motor driven systems. All mounting kits are listed in Section 3, Vehicle Applications. Necessary engineering and planning information for the hydraulic and PTO driven kits are found in Section 4, Guide to PTO Shaft Driven and Hydraulic AuraGens.

MECHANICAL IDLE CONTROL

SIGNAL CABLE

POWER CABLE

REMOTE POWER STRIP (OPTIONAL)

AURAGEN GENERATOR

RECEPTACLE OUTLET PANEL

(OPTIONAL)

ELECTRONIC CONTROL UNIT (ECU)

CONTROL PANEL ON/OFF – STATUS LED’s (USUALLY UNDER DASH)

MOUNTING BRACKET (ENGINE AND VEHICLE SPECIFIC)

GENERAL INFORMATION



AURAGEN SYSTEM MODELS AuraGen System Models The AuraGen model numbers identify the generator and ECU combination required for the output performance of an All-AC, AC/DC, All-DC or Inverter/Charger system.

System model numbers suffixed with an “M” indicates that the ECU, generator, control panel, signal cable harness and Idle Control (if used) are comprised of heavy-duty components that are more suitable for use under harsh environmental conditions. Model numbers without the “M” suffix indicate that it is a “Standard” system for use under mild operating conditions. Example: A G8500XM model is a heavy-duty, 8,000 watt, Inverter/Charger system, suitable to operate in harsh environmental conditions.

System Models Output Description

G5000 or G5000M ALL-AC Up to 5,000 watts of continuous 120/240 volts AC

G8500 or G8500M ALL-AC Up to 8,000 watts of continuous 120/240 volts AC

G6000D or G6000DM AC/DC Up to 5,300 watts of continuous power in a simultaneous combination of 120 volts AC and 14 or 28 volts DC

G7000D or G7000DM AC/DC Up to 6,800 watts of continuous power in a simultaneous combination of 120 volts AC and 14 or 28 volts DC

G6000D or G6000DM ALL-DC Up to 5,600 watts of continuous power at 28 volts DC

G6000X orG6000XM

Inverter/Charger System (ICS)

AC/DC With the engine/drive running, produces up to 5,000 watts of continuous power in a simultaneous combination of 120/240 volts AC and 14 or 28 volts DC. In this mode the ICS manages power distribution to satisfy the AC load first, and if necessary, converts auxiliary battery power to AC to augment the demand. When the engine/drive is not running, AC power is provided by converting DC power from the auxiliary batteries to AC. Power transition from engine-on to engine-off to engine-on is seamless.

G8500X or G8500XM

Inverter/Charger System (ICS)

AC/DC With the engine/drive running, produces up to 8000 watts of continuous power in a simultaneous combination of 120/240 volts AC and 14 or 28 volts DC. In this mode the ICS manages power distribution to satisfy the AC load first, and if necessary, converts auxiliary battery power to AC to augment the demand. When the engine/drive is not running, AC power is provided by converting DC power from the auxiliary batteries to AC. Power transition from engine-on to engine-off to engine-on is seamless.

The following specification tables apply to “Standard” and “Heavy-Duty” system models for vehicle or auxiliary battery inputs of 12 or 24 volts DC. At the owner’s option, AC power produced at 120, 240 or 120 and 240 volts can be distributed to a remote power strip, vehicle mounted receptacles, dedicated equipment or a power distribution system. Systems producing 14 or 28 volts DC can be connected to the vehicle’s batteries, auxiliary batteries, dedicated equipment or a DC power distribution system.

GENERAL INFORMATION



SYSTEM MODEL SPECIFICATIONS

STANDBY POWER (20 MINUTES)CONTINUOUS POWERAC POWER (CONTINUOUS)AC STANDBY (20 MINUTES)AC SURGE (2 SECONDS)AC VOLTAGE 120 VAC 240 VAC 120 VAC 240 VACAC CURRENT (CONTINUOUS) 42 AMPS 21 AMPS 2 X 33 AMPS 33 AMPSAC POWERAC SURGE (2 SECONDS)AC VOLTAGEAC CURRENTENGINE ON-TO-OFF-TO-ON TRANSITIONBATTERY DRAW/AC ON/NO LOADBATTERY DRAW/AC OFFBATTERY DRAWDC POWERDC VOLTAGEDC CURRENTTOTAL HARMONIC DISTORTIONFREQUENCY STABILITYVOLTAGE REGULATION

VEHICLE BATTERYENGINE BELTPOWER-TAKE-OFFHYDRAULIC MOTORGENERATORECUGENERATORECU

GENERATOR

ECU

GAS ENGINES

DIESEL ENGINES


SPECIFICATIONS

TOTAL POWER



AC POWER QUALITY

WEIGHT

OPTIONAL FEATURES

DC OUTPUT NOT APPLICABLE NOT APPLICABLE


LESS THAN 2.5%50/60 ± 0.15 HZ 50/60 ± 0.15 HZ

1.5% 1.5%

LESS THAN 2.5%

12 OR 24 VDC

12.16"DX6.4"W

62 LBS. 65 LBS.

YESYES

19.27"LX13.5"WX8.52"H

YESYES

12 OR 24 VDC

50 LBS. 51 LBS.

YES


1200 TO 6000 RPM 1200 TO 6000 RPM

750 TO 3600 RPM 750 TO 3600 RPM

YESYES YESYES YES


-40 ºF TO 180 ºF

-40 ºF TO 120 ºF -40 ºF TO 120 ºF

YES

YES

YES


-40 ºF TO 180 ºF

9000 WATTS

ALL-AC SYSTEMS - 5000 AND 8000 WATTAURAGEN MODELS





DIMENSIONS12.16"DX6.4"W

DRIVE OPTIONSYES

19.27"LX13.5"WX8.52"H

GENERAL INFORMATION




STANDBY POWER (20 MINUTES)CONTINUOUS POWERAC POWER (CONTINUOUS)AC STANDBY (20 MINUTES)AC SURGE (2 SECONDS)AC VOLTAGEAC CURRENT (CONTINUOUS)AC POWERAC SURGE (2 SECONDS)AC VOLTAGEAC CURRENTENGINE ON-TO-OFF-TO-ON TRANSITIONBATTERY DRAW/AC ON/NO LOADBATTERY DRAW/AC OFFBATTERY DRAWDC POWERDC VOLTAGE 14 VDC 28 VDC

DC CURRENT UP TO 200 AMPS

UP TO 100 AMPS

TOTAL HARMONIC DISTORTIONFREQUENCY STABILITYVOLTAGE REGULATION

VEHICLE BATTERY 12 VDC 24 VDCENGINE BELTPOWER-TAKE-OFFHYDRAULIC MOTORGENERATORECUGENERATORECU 65 LBS. 58 LBS.

GENERATOR

ECU

GAS ENGINES

DIESEL ENGINES

AUTO STARTINTERFERENCE FILTER MODULEPOWER STRIPTRANSFER SWITCH YES

YESYES YES

OPTIONAL FEATURES

YES

YES

1200 TO 6000 RPM

750 TO 3600 RPM 750 TO 3600 RPM


1200 TO 6000 RPM

YESYES

-40 ºF TO 180 ºF

-40 ºF TO 120 ºF -40 ºF TO 120 ºF


-40 ºF TO 180 ºF

WEIGHT65 LBS.58 LBS.

YES

DIMENSIONS12.16"DX6.4"W 12.16"DX6.4"W

19.27"LX16.8"WX8.52"H 19.27"LX16.8"WX8.52"H62 LBS.

YESYES YESDRIVE OPTIONSYES

YES

1.5%12 OR 24 VDC

LESS THAN 2.5%50/60 ± 0.15 HZ 50/60 ± 0.15 HZAC POWER QUALITY

LESS THAN 2.5%

1.5%

DC OUTPUT

2800 WATTS 2800 WATTS28 VDC

UP TO 100 AMPS

33 AMPS



SPECIFICATIONS

TOTAL POWER7000 WATTS6800 WATTS



AC/DC SYSTEMS - 6000 AND 7000 WATTAURAGEN MODELS

5800 WATTS

21 AMPS

4500 WATTS120 VAC

G6000D/G6000DM (12 OR 24 VDC VEHICLE)

G7000D/G7000DM (12 OR 24 VDC VEHICLE)


120 VAC

GENERAL INFORMATION




AURAGEN MODELG6000D/G6000DM 24 VDC VEHICLE

STANDBY POWER (20 MINUTES) -CONTINUOUS POWER 5600 WATTSAC POWER (CONTINUOUS)AC STANDBY (20 MINUTES)AC SURGE (2 SECONDS)AC VOLTAGEAC CURRENT (CONTINUOUS)AC POWERAC SURGE (2 SECONDS)AC VOLTAGEAC CURRENTENGINE ON-TO-OFF-TO-ON TRANSITIONBATTERY DRAW/AC ON/NO LOADBATTERY DRAW/AC OFFBATTERY DRAWDC POWER 5600 WATTSDC VOLTAGE 28 VDCDC CURRENT 200 AMPSTOTAL HARMONIC DISTORTION NOT APPLICABLEFREQUENCY STABILITY NOT APPLICABLEVOLTAGE REGULATION NOT APPLICABLE

VEHICLE BATTERY 24 VDCENGINE BELT YESPOWER-TAKE-OFF YESHYDRAULIC MOTOR YESGENERATOR 12.16"DX6.4"WECU 19.27"LX16.8"WX8.52"HGENERATOR 62 LBS.ECU 66 LBS.

GENERATOR -40 ºF TO 180 ºF

ECU -40 ºF TO 120 ºF

GAS ENGINES 1200 TO 6000 RPM

DIESEL ENGINES 750 TO 3600 RPM

AUTO START YESINTERFERENCE FILTER MODULE YESPOWER STRIP N/ATRANSFER SWITCH N/A


NOT APPLICABLE

OPTIONAL FEATURES


DIMENSIONS

DRIVE OPTIONS

ALL-DC SYSTEM - 6000 WATT

SPECIFICATIONS

TOTAL POWER



WEIGHT

AC POWER QUALITY

DC OUTPUT

NOT APPLICABLE

GENERAL INFORMATION




STANDBY POWER (20 MINUTES)CONTINUOUS POWERAC POWER (CONTINUOUS)AC STANDBY (20 MINUTES)AC SURGE (2 SECONDS)AC VOLTAGE 120 VAC 240 VAC 120 VAC 240 VACAC CURRENT (CONTINUOUS) 42 AMPS 21 AMPS 42 AMPS 21 AMPSAC POWERAC SURGE (2 SECONDS)AC VOLTAGE 120 VAC 240 VAC 120 VAC 240 VACAC CURRENT 21 AMPS 11 AMPS 33 AMPS 16 AMPSENGINE ON-TO-OFF-TO-ON TRANSITIONBATTERY DRAW/AC ON/NO LOADBATTERY DRAW/AC OFF

BATTERY DRAW

DC POWERDC VOLTAGEDC CURRENTTOTAL HARMONIC DISTORTIONFREQUENCY STABILITYVOLTAGE REGULATION


GENERATOR

ECU

GAS ENGINES

DIESEL ENGINES


SPECIFICATIONS

TOTAL POWER



DC OUTPUT

AC POWER QUALITY

DRIVE OPTIONS

DIMENSIONS

WEIGHT


LESS THAN 2.5% LESS THAN 2.5%50/60 ± 0.15 HZ 50/60 ± 0.15 HZ

3000 WATTS

UP TO 1750 WATTS UP TO 3500 WATTS

SEAMLESS SEAMLESS10 AMPS NOMINAL 8 AMPS NOMINAL

LESS THAN .01 AMPS LESS THAN .01 AMPS

APPROX. 100 AMPS PER KW APPROX. 50 AMPS PER KW

2500 WATTS

14 VDC 28 VDC125 AMPS 125 AMPS

1.5% 1.5%12 VDC 24 VDC

YES YESYES YESYES YES

12.16"DX6.4"W 12.16"DX6.4"W20.75"LX13.5"WX8.52"H 20.75"LX13.5"WX8.52"H

65 LBS. 65 LBS.64 LBS. 64 LBS.

-40 ºF TO 180 ºF -40 ºF TO 180 ºF

YES

-40 ºF TO 120 ºF -40 ºF TO 120 ºF


1200 TO 6000 RPM 1200 TO 6000 RPM

750 TO 3600 RPM 750 TO 3600 RPM

INVERTER CHARGER (ICS) - 5000 WATT

6000 WATTS

OPTIONAL FEATURES

N/A N/A

YES YESYES YES

YES

AURAGEN MODELSG6000X/G6000XM (12 VDC VEHICLE)

G6000X/G6000XM (24 VDC VEHICLE)

6000 WATTS

7200 WATTS




GENERAL INFORMATION




STANDBY POWER (20 MINUTES)CONTINUOUS POWERAC POWER (CONTINUOUS)AC STANDBY (20 MINUTES)AC SURGE (2 SECONDS)AC VOLTAGE 120 VAC 240 VAC 120 VAC 240 VACAC CURRENT (CONTINUOUS) 2 X 33 AMPS 33 AMPS 2 X 33 AMPS 33 AMPSAC POWERAC SURGE (2 SECONDS)AC VOLTAGE 120 VAC 240 VAC 120 VAC 240 VACAC CURRENT 21 AMPS 11 AMPS 33 AMPS 16 AMPSENGINE ON-TO-OFF-TO-ON TRANSITIONBATTERY DRAW/AC ON/NO LOADBATTERY DRAW/AC OFF

BATTERY DRAW

DC POWERDC VOLTAGEDC CURRENTTOTAL HARMONIC DISTORTIONFREQUENCY STABILITYVOLTAGE REGULATION


GENERATOR

ECU

GAS ENGINES

DIESEL ENGINES

AUTO STARTEMI FILTER MODULEPOWER STRIPTRANSFER SWITCH YES

N/AYES YES

OPTIONAL FEATURES

N/A

YES

1200 TO 6000 RPM

750 TO 3600 RPM 750 TO 3600 RPM


1200 TO 6000 RPM

YESYES

64 LBS.65 LBS. 65 LBS.

-40 ºF TO 120 ºF -40 ºF TO 120 ºF

-40 ºF TO 180 ºF -40 ºF TO 180 ºF

YESYES YES

20.75"LX13.5"WX8.52"H 20.75"LX13.5"WX8.52"H12.16"DX6.4"W 12.16"DX6.4"W

1.5%50/60 ± 0.15 HZ 50/60 ± 0.15 HZ

YES YES12 VDC 24 VDC

28 VDCUP TO 1750 WATTS UP TO 3500 WATTS

LESS THAN 2.5% LESS THAN 2.5%125 AMPS 125 AMPS

8 AMPS NOMINALSEAMLESS SEAMLESS

APPROX. 100 AMPS PER KW APPROX. 50 AMPS PER KW

LESS THAN .01 AMPS LESS THAN .01 AMPS


10 AMPS NOMINAL

14 VDC

1.5%

YES

64 LBS.

AC POWER QUALITY

DRIVE OPTIONS

DIMENSIONS

WEIGHT

TOTAL POWER



DC OUTPUT


INVERTER CHARGER (ICS) - 8000 WATTAURAGEN MODELS

8500 WATTS



SPECIFICATIONS


8500 WATTS8000 WATTS8000 WATTS8500 WATTS9000 WATTS


8000 WATTS

GENERAL INFORMATION



MAJOR COMPONENT DESCRIPTIONS

The following generally describes the major AuraGen components. Section 2, “AuraGen System Tables”, and Section 5, “AuraGen Parts Catalog”, lists these components by specific product group, description and part number.

GROUP 1: ELECTRONIC CONTROL UNIT

Group 1: Electronic Control Unit (ECU)

The ECU regulates the electrical signal to provide a stable AC and/or DC output while supplying optimal system efficiency throughout the AuraGen RPM range. The ECU provides the optimal voltage and frequency stability (less than 2.5% THD) at all power load levels up to the rated output. The frequency output is software selectable between 60 and 50 Hertz (Hz). The ECU chassis envelope shown below is common to all ECU configurations, but the overall dimensions can vary depending upon the type of AuraGen system it is configured for.

• Length 19.27 in. (ICS is 20.25 in.) • Width 13.50 in. (AC/DC and All-DC is up to 18.50 in.) • Height 8.52 in. • Weight (G5000 / G8500X /G6000D) 50 / 64 / 65 lbs. • Environmental Temperature Range -40°F to +120°F • Environmental Conditions - Weatherproof, can be

mounted in or under vehicle

GENERAL INFORMATION




Group 1: Electronic Control Unit

Optional ECU Features and Equipment

• Auto Start: With this option, power from the AuraGen system is available automatically when the vehicle engine is started. Auto Start is factory installed and is available for most ECU models.

• Electromagnetic Interference/Radio Frequency Interference (EMI/RFI) Filters: The EMI/RFI filter pack is available for all ECU models. The filters reduce the radiated noise generated by the AuraGen and ECU’s output power cabling. This option is factory installed.

• ECU Shock Mount Kit: Special shock mounts are recommended for vehicles that travel off-road or experience high impact loads. For example, this kit is used on all military HMMWV’s.

ECU Shock Mount Kit

GENERAL INFORMATION




Group 2: Generator

Group 2: AuraGen Generator The AuraGen generator is a brushless, AC axial gap, 3-phase electrical induction machine. The picture below shows a heavy-duty version with an output power connector.

• Diameter 12.16 in • Width 6.40 in • Weight (G5000 / G8500) 62 / 65 lbs • Environmental Temperature Range -40°F to +180°F • Environmental Conditions Under Hood/Chassis • AuraGen Maximum Speed 12,000 RPM • Typical Engine RPM Range (Ref only) 1200 to Red Line (Gasoline)

950 to Red Line (Diesel pick-up trucks) 650 to Red Line (Diesel mid-sized vehicles)

GENERAL INFORMATION




Group 3: Signal Cable

Group 3: Signal Cable

The signal cable provides communications between the ECU, system control panel, idle control, AuraGen’s temperature and speed sensors, the vehicle or auxiliary batteries, and the vehicle’s ignition-on and parking brake switches. The signal cables are available in a variety of lengths and differ depending on the ECU type.

Group 4: DC Power Cable

Group 4: DC Power Cable

DC power cable kits are provided in various lengths and gauges for the AC/DC, All-DC and ICS systems. These kits include all necessary components and hardware required to install and secure the DC output power cables.

Group 5: Power Cable Group 5: Power Cable Generator-to-ECU and ECU-AC-output power cables are available in bulk lengths of 100-foot (roll), or in a variety of pre-cut lengths (with and without connectors). The cables consist of a flexible, grounded armor sheath with a plastic overcoat for resistance to water penetration.

Heavy-Duty Power Cable Standard Power Cable

GENERAL INFORMATION




Group 6: Control Panel

Group 6: Control Panel – All-AC, AC/DC, All-DC

The standard Control Panel is typically located under the dashboard. It has a push button switch to turn the AuraGen system ON or OFF, and to reset the system if required. The panel has a red and green LED light that indicate system and component status.

Group 6: Control Panel – Inverter/Charger System (ICS)

The ICS Control Panel is typically located under the dashboard. It has a two-position switch to turn the AC power ON and OFF, with the engine running or not. The panel has four LED monitoring lights labeled:

BAT State of auxiliary battery(s) charge

GEN State of AuraGen generator operation

CHG State of battery charging operation

AC AC power output power on or off

All LED’s are system-active dependent and combine to indicate ICS and component operational status.

Group 7: Vehicle Application Kits Group 7: Vehicle Application Kits

Vehicle application kits provide a full set of brackets, pulleys and hardware necessary for mounting the AuraGen generator on each specific vehicle type.

Some kits include an Idle Control (mechanical or electrical) to set the minimum required engine speed as necessary.

Most application kits are packaged in a single box under a single part number. Some kits are packaged in a Base Kit and a Supplemental kit. The application kits are listed in section 3, “Vehicle Applications”.

GENERAL INFORMATION




Group 8: Remote Power Strip Group 8: Remote Power Strip

An optional remote power strip allows power users to unreal up to 20 feet of flexible cable to take AC power to the required location. All configurations have water-resistant cover plates and can be physically coupled to or removed from the ECU. The kit part numbers have been included for clarity.

The reel enclosure comes in five different configurations as describe below.

• M900-020, G5000 systems only: Two 120 AC – 20 amp, GFCI, duplex receptacles and a single 240 volt AC - 20 amp, flanged, "Twist-lock" outlet (Arrow Hart P/N 6216). Requires a Hubbel, HBL2321 plug.

• M900-021, G5000 systems only: Two 120 AC – 20 amp, GFCI, duplex receptacles connected to the output from one leg of a 240 AC - 50 amp "Dryer" receptacle (NEMA-10-50R). Requires a Hubbell, HBL7513C (NEMA 10-50P) plug.

• M900-022, G5000 and G8500 systems: Two 120 AC – 20 amp, GFCI, duplex receptacles and one 240 AC – 50 amp receptacle (NEMA 6-50R). Requires an Arrow Hart, (P/N 2P3W) plug (NEMA 6-50P).

Group 9: Miscellaneous Parts

Group 9: Miscellaneous Parts Cable Coupler Kit: This kit contains all necessary hardware to route and secure the cabling for any system, and for the standard systems, to connect the hard-wired components. The adjacent picture exhibits only a sample of what this kit contains.

GENERAL INFORMATION




Group 10: Installation Equipment

Group 10: Installation Equipment

M800-100, ECU Interface Box: The interface box is required to install software into, test and diagnose symptoms with all non-ICS AuraGen systems. The interface box attaches between the ECU and the installer’s laptop via the serial port. M800-110, ICS Interface Cable: The ICS interface cable connects to the system’s control panel via an RS232 port. It is required for upgrading software, and to test and diagnose the ICS. The opposite end of the cable attaches to the installer’s laptop at the serial port. M800-200, AC Load Bank: The load bank is required to properly test the output power of the AuraGen system. The load bank can also be used as a diagnostic tool on existing installations. The load bank is a capable of testing 120 volt or 240 volt AC power loads up to 10,000 watts. The loads can be applied via seven toggle switches in 500, 1000 and 2000 watt increments. There are three analog meters: AC voltage, AC current and frequency. A six (6) foot input cord with a 240 volt –20 amp twist-lock receptacle and a separate ground cable with an alligator clamp is provided.

M800-011, Belt Tension Gauge: Single click type belt tension gauge provides a method measuring the AuraGen belt tension on manual belt tensioner type AuraGen installations.

M800-701, AuraEngr Service Pack CD: This compact disk contains the following.

• Required ECU installation interface software • Adobe Acrobat to view and print out the vehicle specific installation and service manuals • The AuraGen Main Manual for ECU and electrical wiring installation instructions • Service, maintenance and technical bulletins • AuraGen Catalog • The AuraGen RMA and Warranty Policy and Procedures • The Customer Concern/Field Problem Report (CCFPR) form

The Service Pack CD is updated on a periodic basis and distributed to the service and sales managers of certified AuraGen installation facilities free of charge. Additional copies are available for a nominal fee.

TO ECU DIAGNOSTICS CABLE

TO INSTALLER PC

TO CONTROL PANEL

TO INSTALLER PC

TO ECU POWER OUT

GENERAL INFORMATION




Group 11: Optional Equipment

Group 11: Manual Transfer Switch

The optional manual transfer switch allows the AuraGen System power to be integrated into any facility (office or business building, house, etc.) that needs AC power. This transfer switch provides a method to safely and easily disconnect from the utility/primary power grid and use the AuraGen as an alternative power source.

Power is switched from grid-to-AuraGen-to-grid via a manual switch on the control panel.

Warning! This switch should only be installed by a licensed electrician.

CONNECTED TO ECU’S POWER OUTPUT CONECTOR

Documents

GENERAL INFORMATION AuraGen Catalog - Aura …aurasystems.com/pdf/AuraCat_Sec 1_2-14.pdfGENERAL INFORMATION AURAGEN ... Inverter/Charger – 5,000 Watt 1-11 ... AuraGen Technical Specifications