Table of Contents
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MAIN INSTALLATION MANUAL
®
FOR AN AURAGEN
INDUCTION
POWER SOURCE
Vehicle Powered
Mobile Electric Power
Models G5000, G6000D, G6000X, G8500, G8500X
Aura Systems, Inc.
2335 Alaska Avenue, El Segundo, CA. 90245
Phone: (310) 643-5300 - Fax: (310) 643-7457 - Toll Free (800) 909-AURA
Web Site: www.aurasystems.com
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Table of Contents
Summary of Contents for auragen G5000
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Page 1: Power Source
FOR AN AURAGEN INDUCTION POWER SOURCE Vehicle Powered Mobile Electric Power Models G5000, G6000D, G6000X, G8500, G8500X Aura Systems, Inc. 2335 Alaska Avenue, El Segundo, CA. 90245 Phone: (310) 643-5300 - Fax: (310) 643-7457 - Toll Free (800) 909-AURA Web Site: www.aurasystems.com... -
Page 2: Table Of Contents
Estimated Installation Time..................Recommended Tools....................AuraGen System Components................Mounting Kit Contents....................Recommended Tools and Materials for AuraGen System Installation and Test..Required Additional Installation Materials..............How to Obtain Service..................... Returning AuraGen Components for Warranty or Service ........Section 2 - Warning and Safety Precautions Warnings and Precautions.................. - Page 3 Figure 1-1: AuraGen System Specification - AC-Only..........Figure 1-2: AuraGen System Specification - DC and AC/DC........Figure 1-3: AuraGen System Specification - G6000X Inverter Charger (ICS)..Figure 1-4: AuraGen System Specification - G8500X Inverter Charger (ICS)..Figure 3-1: Cable Routing - Fire wall................
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Page 4: Subject Page
Figure 3-50: Install Output Filter ................3-34 Figure 3-51: Install Wires on AC Output Power Board..........3-34 Figure 3-52: Install Wires on AuraGen Input Filter........... 3-35 Figure 3-53: Install Ferrite Filter on Signal Harness ..........3-35 Figure 3-54: AC Output Reference Colors............... -
Page 5: About This Manual
ANUAL ABOUT THIS MANUAL AuraGen Induction Power Source This manual provides detailed step-by-step The source of electrical power is the AuraGen Induction Power Source. This device resembles instructions for installing an AuraGen system an oversized vehicle alternator. It can be into a select series of vehicles. - Page 6 GAS ENGINES ENGINE SPEED 750 TO 3600 RPM 750 TO 3600 RPM DIESEL ENGINES AUTO START INTERFERENCE FILTER MODULE OPTIONAL FEATURES POWER STRIP TRANSFER SWITCH Figure 3-3: AuraGen System Specification - G6000X Inverter Charger (ICS) 020530E MAN-050-200, MAIN INSTALLATION MANUAL Page...
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Page 7: Auragen System Specifications
TOOLS AND MATERIALS FOR AURAGEN SYSTEM INSTALLATION Due to possible OEM midyear design varia- AND TEST tions, attempts to install an AuraGen kit on chas- sis models and engine configurations not de- fined in the AuraGen Induction Power Source Recommended: √... -
Page 8: Required Additional Installation Materials
AuraGen distributors, OEM’s, or deal- mended) ers. √ AuraEngr Interface Software The AuraGen and ECU are not designed to be field repairable. These components are in- tended to be removed and replaced as a whole. REQUIRED ADDITIONAL INSTAL- LATION MATERIALS... -
Page 9: Warnings And Precautions
This symbol is used to warn of an DEADLY! electrical hazard or unsafe practice which may result in personal injury, ♦ Do not test or operate the AuraGen System product damage or property dam- in an enclosed area. Always ensure there age. -
Page 10: General Safety Precautions
DEATH: GENERAL SAFETY PRECAUTIONS: ♦ Disconnect the vehicle battery before work- ing on or around the engine or AuraGen sys- ♦ Hot coolant under pressure can cause se- tem. vere personal injury. DO NOT open a radia- tor pressure cap while the engine running. -
Page 11: Cable Routing
UTOMOTIVE NSTALLATION ANUAL Cable Routing The AuraGen Signal Harness connects the ECU to the Throttle Control, Control Panel, and the AuraGen’s Temperature and RPM sensors. All of the system connectors are brought together into a common cable under the hood. The Power... - Page 12 ® UTOMOTIVE NSTALLATION ANUAL Figure 3-3: Drill a hole in the underside of the Figure 3-2: Route cables to rear area of vehicle near the place where the ECU is to be vehicle, keeping them clear of anything that located and route the Signal Harness and Power might subject them to damage by abrasion, Cable through it, as shown.
- Page 13 (Yellow Wire) R e m o te S tart (Purple Wire) Pow er Strip (optional) Output Power • Hardware Control P anel • Power Strip (Optional) Figure 3-4: Interconnection Diagram of the AuraGen Systems 020530E MAN-050-200, MAIN INSTALLATION MANUAL Page...
- Page 14 OUTLET BOX CONTROL AND POWER CABLES ROUTED UNDER VEHICLE TO REAR-MOUNTED ELECTRONIC CONTROL UNIT REMOTE POWER STRIP (OPTIONAL) AURAGEN MOBILE AURAGEN INDUCTION POWER SOURCE GENERATOR Figure 3-5: Pictorial Wiring Diagram of a “Typical Installation” Page 3-4 020530E MAN-050-200, MAIN INSTALLATION MANUAL...
- Page 15 (with THNN or equivalent crimping tool. insulation) to connect the ECU to the AuraGen. 10. For the model G5000 and G6000 series, Solid wire will fatigue and eventually break. Do connect all four wire terminal lugs to termi-...
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Page 16: Electronic Control Unit Mounting - All
® UTOMOTIVE NSTALLATION ANUAL 13. For the G8500 model, connect all four wire Note: The ECU requires a minimum of 6 inches terminal lugs to terminal strip inside termi- of clearance on the air intake and exhaust. Many nal box according to the colors shown in Fig- mounting locations are possible, such as in the ure 3-8. - Page 17 ® UTOMOTIVE NSTALLATION ANUAL 11. Do not mount the exhaust fans facing the Ensure that the louvers are not positioned forward motion of the vehicle. This causes such that water/mud splash from the wheels backpressure of airflow. See Figures 3-9 would cause moisture to enter the compart- and 3-10.
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Page 18: Ecu Installation - Commercial
® UTOMOTIVE NSTALLATION ANUAL FORWARD DIRECTION AIR OUT AIR IN 120°F MAX. OPERATING AIR TEMPERATURE MEA- L.P.D. SURED AT ECU INLET Figure 3-10: ECU Compartment - Without Spash Water Environment ECU Installation - Commercial 2. Move the ECU out of the way, and using a scribe or sharp pencil, mark the locations (See the following section for of the two cable access holes (in the floor of... - Page 19 Figure 3-11: Drill hole for Rivnut™ Some ECU’s are supplied with 3/8" bolts, 3/8" washers, and Ny-lock nuts in place of Note: Proper function of the AuraGen sys- the Rivnuts and shoulder bolts. tem requires the ECU case to be grounded to the chassis.
- Page 20 ® UTOMOTIVE NSTALLATION ANUAL 12. Install the four rubber shock mounts ease of installation, move the straps to any (F/N 1) on the ECU. See Figure 3-14. of four attachment locations on the ECU 13. Place ECU over the mounting holes and case.
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Page 21: Ecu Hookup Hardware
® UTOMOTIVE NSTALLATION ANUAL ECU Hookup Hardware 2. Slide the nut (B) of the liquid tight connector over the four wires and onto the flexible con- duit. Note: Refer to Figures 3-16 and 3-17 for 3. Slide seal ring (C) of the liquid tight connec- the following steps. -
Page 22: Auragen And Ecu Wiring Hookup
® UTOMOTIVE NSTALLATION ANUAL AuraGen and ECU Wiring Hookup 11. Cut each wire coming out of the conduit to 6” to allow a service loop for connection to the terminal block or EMI/RFI filter terminals. 12. Strip one-fourth inch (1/4”) of insulation from ends of all four wires and crimp a #6 spade terminal (Thomas &... -
Page 23: Signal Harness Connection At Ecu
Connect the red wire from labeled Temperature Sensor and RPM Sen- the Signal Harness Cable labeled 12 VDC sor to the AuraGen area and enclose in 1/ to the “Key On” +12 VDC fuse panel con- 2” automotive loom. Connect Temperature... -
Page 24: Installation Of The Control Panel
® UTOMOTIVE NSTALLATION ANUAL Seal Ring Nutplate ECU Wall Gasket Plate #4 Screw Figure 3-20: ECU Signal Cable Installation Figure 3-21: ECU Signal Cable Connector Figure 3-22: Secure Signal Cable to ECU Installation of the Control Panel 5. Secure the Signal Harness to the ECU using the #4 hardware or nutplate removed in Step The Control Panel plugs into the Signal Harness 1. -
Page 25: Remote Power Strip Connector Installation
® UTOMOTIVE NSTALLATION ANUAL Remote Power Strip Connector 2. Insert the Remote Power Strip connector into the ECU as shown in Figure 3-23 and Installation 3-24. 3. Visually take note of the color of each of The output power can be configured a few dif- the existing wires connected to the termi- ferent ways: a.) Optional remote Power Strip nal block or EMI/RFI filter terminal block. -
Page 26: Output Power Wiring For Ac Only - 120/240
Wiring for the 20 amp service is not sup- bly and secure the conduit to the coupler plied as part of the AuraGen mounting kit assembly by screwing nut (B) to the bot- and must be purchased from local vendors. - Page 27 ® UTOMOTIVE NSTALLATION ANUAL 9. Secure the rubber gasket and butt plate to the ends of each wire using a wire crimping the inside wall of the ECU using the #4 hard- tool. Ensure each terminal is tight on wire. ware packaged with the coupler kit.
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Page 28: Hard Wired Output Power - 120/240 Vac, 40 Amp Service
5. Thread the steel nipple in to the coupler until Note: Wiring for the 40 amp service is not it is fully tightened against the coupler. supplied as part of the AuraGen mounting 6. Thread the steel coupler adapter onto the kit and must be purchased from local ven- 90 degree coupler and firmly tighten. - Page 29 ® UTOMOTIVE NSTALLATION ANUAL 11. Secure the nipple to the butt plate with a 15. Connect the three wires from the conduit to lock nut. Use a small hammer and screw- the same color wire located on the terminal driver to ensure lock nut is fully tightened. block or EMI filter terminal block.
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Page 30: Output Power Wiring For Inverter/Charger System
AC power output cables should be compliant to authoritative documentation provided to the 5. Thread the steel nipple into the coupler until AuraGen system installer. it is fully tightened against the coupler. 6. Thread the steel coupler adapter onto the Note: Refer to Figures 3-43and 3-44 for the 90 degree coupler. - Page 31 ® UTOMOTIVE NSTALLATION ANUAL Note: Ensure the wires connected to the ter- 8. Remove the access cover from top of the minal block or EMI/RFI filter match, RED to ECU. RED, BLACK to BLACK, WHITE to WHITE 9. Strip one-fourth inch (1/4”) of insulation from and GREEN to GREEN.
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Page 32: Dc Power And Ground For Inverter/Charger System
(+) to the ECU first and be compliant to documentation provided to then to the auxiliary battery’s positive (+) ter- the AuraGen system installer. minal. 7. Using the nuts provided, attach the black DC ground cable (-) to the ECU first and then to the battery’s negative (-) terminal. - Page 33 1. Faulty wiring - R&R bad wiring. H/W, Power, IGBT Fail, or 177, 178, 179 2. Faulty ECU - R&R ECU. H/W Inverter Overload 3. Faulty AuraGen - R&R AuraGen. Slow Flash Self-test Failure 1. Faulty ECU - R&R ECU. 1. Idle Control mechanical linkage not adjusted properly - adjust properly.
- Page 34 1. Faulty temp sensor - R&R AuraGen. Fast Flash Slow Flash Wiring Failure 117, 118 2. Internal AuraGen wiring incorrect - R&R AuraGen. 1. Faulty ECU - R&R ECU. Fast Flash Fast Flash Inverter 0 or 180 Overload 49, 50 2.
- Page 35 1. Temp sense connector not connected - Yellow AuraGen Temp Sense ECU=145 connect. Slow Flash Open 2. Temp sensor open - R&R AuraGen. 1. AuraGen not getting sufficient Yellow AuraGen Over- ECU=113 ventilation - provide additional ventilation. Fast Flash temperature 2.
- Page 36 ICS. Yellow ICS=564 Over-temp 2. Cooling fan(s) failure - R&R ICS. 3. Cooling fins clogged - remove debris. 1. Battery, AC or AuraGen wiring Low or High Voltage ICS=504 problem correct wiring. Driver Fault 2. ICS internal problem - R&R ICS.
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