GenLeap Controller Manual v1.6 Rev

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.
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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
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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
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1.1 Introduction
This manual provides details of controller setup, configuration, monitoring and operation.
Customer may access GenLeap via ethernet interface using eConleap Mini controller or via
LCD touch screen display. Other optional interfaces like RS232, SNMP, dry contacts, wireless
access and mod bus interface are also available with GenLeap . Please reference the
GenLeap product manual for your configuration and associated functions and features.
1.2 Getting Started

1.2.1 Installation
To install the eConLeap web interface in GenLeap system, no application is required. The
web interface only requires Google Chrome or Firefox browser. A CAT5/6 LAN cable
connection is supplied at the front panel of your GenLeap system to connect to Ethernet. In
case the system is not equipped with the CAT5/6 Ethernet connection, 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.
Please note that a Basic Version o GenLeap is available without router for single port access to
the controller.
1.2.1.1 System Network Setup

a. Locate the router mounted inside control box from the front access door.
b. Port 2 or 3 connection is for the customer's monitoring device. An external CAT5/6
LAN cable (marked Ethernet) is supplied outside of the control box. The CAT5/6
LAN cable is included.
c. Port 2 and 3 accepts static IP address 192.168.1.0 subnet. Netmask is 255.255.255.0
and there should be no default gateway specified. (factory default). Addresses
192.168.1.230 and 192.168.99 are reserved and cannot be used.
d. Port 1 is provided for the customers access via intranet or internet. The port
accepts dynamic IP address via DHCP server (factory default). The user must
determine the actual address assigned by the customer
e. Port 5 is internally connected to eConLeap Mini Controller and Port 4 is to
uConLeap Generator controller.
Figure 1a- Installation
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Figure 1b- 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.
If using Google Chrome refer to the following URL.

http://support.google.com/chrome/bin/answer.py?hl=en&answer=95411
Windows requirements Mac requirements Linux requirements

Windows XP Service Ubuntu 10.04+
Operating Pack 2+ Mac OS X 10.5.6 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, RS-232 port (Recommended) or USB to RS-232 converter
If using Windows Internet Explorer refer to the following URL.

http://windows.microsoft.com/en-US/internet-explorer/products/ie-9/system-requirements
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1.2.2 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
1.2.3 Logging In
On startup, it is necessary to log in for security, tracking and data protection. 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. User login
settings can be change later by logging out on exit
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Figure 2- Login
Login username and password
Figure 3- Confirming Login or Logout
Successful login will show the

welcome bar below your web
page
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1.2.4 Connecting to eConLeap controller

To establish a link with the GenLeapcontroller, ensure that the controller is powered on and
that a Jack-45, an eight-wire connector used commonly to connect computers with local-area
networks (LAN), is properly connected. 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. Once connected to the controller, launch browser with IP
address 192.168.1.230 if you are connected to a static IP address (Port 2 & 3) or assigned IP
address if connected to dynamic IP address (Port 1).
Some customers may need to setup a RS-232 port to access the controller for higher
configuration and troubleshooting needs. Many factory default settings are accessible through
RS232 port and it's GUI application. Please reference GenLeap GUI application programming
and user manual for details.
1.2.5 Menu (left side bar)

Alarms: A table for critical, major, minor and warning alarms is supplied. Alarm logs can be
accessed and downloaded from this page.
Status: Status of key variables are shown on the status page. Status of system and each module
is shown under the horizontal bar menu.
Configuration: Allows threshold settings and system configurations.
Operation: System operations like start/stop and battery tests are available under Generator or
Battery operations menu.
Inventory: A static inventory allowing tracking of the site modules and capacities is available
under the inventory menu.
Setup: A system setup can be accessed from any module (horizontal bar) menu. The system
setup allows configuration of the mode of operation and battery charging method. Customer
can setup site information from this setup menu.
Debug: Allows items for debugging or troubleshooting. Debug/Alarm-Reset allows clearing of

latching alarms and monitoring of calibration items. A higher level access is required.
Logs: Alarm, Data and Event logs can be downloaded. Maximum storage capacity 4G is
available.
Dashboard: Dashboard, shown on the right side bar, provides a high level summary of the
system's operating parameters. The dash board can be placed anywhere on the computer
without having the full web pages turned on.
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1.2.6 Access levels

There are 2 user access levels User Name Description
used to filter and protect data
on GenLeap controllers.
These levels are divided as
follows: Level
Can monitor commonly used

3 User
data, view faults and logs.
Able to modify commonly

used settings and
configurations. Can monitor
2 Operator commonly used data, view
faults and logs. Many
functions may be disabled or
hidden.
Allowed to tune engine, and

change critical data items.
1 Admin
Can view and modify items
that may affect performance.
1.3 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. GenLeap
systems include the functions of a 48V DC power generation source replacing AC generators,
DC power rectifiers, ATS, battery charging, system controller, batteries, environment and fuel
supply management.
Customer may setup different operating modes based on the configurations purchased for on-
grid or off-grid systems. Customer can also select the battery charging modes (or generator
transition modes) to provide a seamless transition between multiple power sources.
Information such as site ID and locations may be assigned to each site by the administrator.
GenLeap system can be deployed in the following modes of operation:
1.3.1 Standby Power Mode

In this mode, the primary power is supplied by AC grid. A standby operation is where
customer requires a short battery backup and extended GenLeap backup when AC failure is
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detected. An integrated system with AC distribution, rectifiers, converters, and split DC

distribution from Leap Power maybe deployed and monitored as a unified system. The system
automatically allows switching from AC to battery to generator mode based on the thresholds
set by the customer. The transition between multiple source like rectifiers, batteries, solar or
generator may be programmed using voltage mode, timer mode or SOC modes. The battery
charging or cycling control is customer selectable based on the following methods:
1.3.1.1 Voltage control method

Battery discharge starts immediately upon the loss of AC. The DC Generator starts based on a
pre set voltage threshold. The DC Generator provides an extended backup subject to the
availability of the fuel. A typical setting involves battery discharge to 52Vdc after AC (or
rectifier) failure and DC Generator start at 47Vdc. The DC Generator operating (float) voltage is
normally set to 52 Vdc. 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. Other factors
like temperature and load variation will impact the duration and rate of discharge of the battery
backup.
1.3.1.2 Timer control method

Timer control method allows customers to decide how much (time) battery backup should be
available before DC Generator is turned on. 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, thereby, increasing the life of the DC Generator with lower start/stop cycles.
In the standby mode, 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. The system provides a timer function to enable this maintenance feature
automatically. A factory default 30 days exercise function and battery test is set in the system
for all Standby systems.
1.3.2 Primary Power Mode (Off-Grid)

In this mode, the primary power is supplied by GenLeap system and no AC grid power is
available. GenLeap system provides optional use of batteries in conjunction with the DC
Generator. GenLeap system allows the integration of an external DC source like solar power
(SunLeap) or Wind Turbine (WindLeap) for a hybrid system configuration. The transfer
between the different power sources will occur according to the configuration selected in the
battery charging control method.
1.3.2.1 Voltage control method
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The Generator starts based on a pre set voltage threshold. The DC Generator provides an
extended backup subject to the availability of the fuel. A typical setting involves battery
discharge at 52Vdc and DC Generator start at 47Vdc.
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.
Simultaneously, 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). GenLeap Voltage Mode operations allows 3 levels of Generator Start
and Two levels of Generator Stop conditions to maximize the system efficiency and utilization.
For example, if the system load is very small, customer may elect to deviate from the normal
CDC cycle and continue to discharge the batteries. On the other hand, if the load has suddenly
increased and additional power is required, customer may bring the generator on line before it
reaches the start threshold.
In the event of a complete failure of batteries, the DC Generator will continue to operate until
the fuel supply is exhausted. Similarly, in the event of DC Generator failure (or no gas supply),
the batteries will be discharged to Low Voltage Battery Disconnect (LVBD) set point. Normally,
the battery cut off voltage is set at 43 Vdc.
In the voltage control method, 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. Other factors like temperature and load variation will impact the duration and
the depth of discharge of the battery backup.
-54V
Battery
Discharge
-52V
-48V Battery
GenLeap ON Charge
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1.3.2.2 Timer control method
Time control method allows customers to decide how many hours each power/reserve source
should be operational. The total 24 hours operation can be divided between DC Generator,
batteries and an external power source like Solar (SunLeap). Timer mode allows customer to
adapt to its environment. A schedule such as charging of batteries at night under lower
temperature improves the battery life. While discharging them during day under higher
temperatures could provide higher capacity.
Timer mode also provides extensive scheduling capability with the Enhanced eConLeap
controller option. The scheduling capability permits the customer to select a specific time of the
day or calendar to start/stop the DC Generator operation. 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.
1.3.3 Battery Extension Mode

In this mode, the master controller external to GenLeap is in total control of the DC Generator
start and stop. Typical settings involve voltage mode control for the DC Generator start and
stop. The DC Generator provides an extension of the existing batteries (Battery Extender) and
replaces stand alone AC generator set. 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.
1.3.4 Manual Mode:

In this mode, the operator is in total control of the system operation unless safety features or
alarms are activated. 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. It is recommended that during initial setup, customer
should first exercise the manual RUN mode before starting the system in AUTO mode.
1.3.5 Redundant Operation with dual generator sets

GenLeap systems allow a parallel operation of multiple generators in a Timer Control and
Voltage Control Method. Two generators can be operated with independent distribution and
battery bank or shared Leap Power's split distribution with common battery bank. Common
methods for operation include:
a. 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. 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 . A failure of one unit is automatically backed up by the second unit.
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b. Load Share Mode: Multiple generators can be programmed to operate

simultaneously and share load. A load share option requires two units with a single DC
distribution bus. 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.
1.4 System Setup & Configuration
1.4.1 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.
The customer must choose between charging vs non-charging application at the time of the
order to allow proper system wiring and calibration. A battery charger plant cannot be operated
without 48Vdc main batteries, LVBD, distribution, shunts and other controls.
Setup menu allows administrator to setup GenLeap in fully programmed modes like Primary
Auto or Standby Modes. Generator & battery charge discharge cycles can be controlled with
voltage methods or timer control methods. Similarly, two generator cycle times can be defined
by selecting the period each generator will operate using a timer control method or voltage
control method.
Voltage
Control
Primary
Auto
Timer
Control
Setup Manual RUN
Standby
Power
Battery
Extension
a. An administration level access is required to operate the system in Manual RUN Mode.
b. When changing the operation mode or setup configuration, following steps 1.4.1.1 to 1.4.1.4
must be followed. Please note that during change of Operation Mode or Restart (Reset)
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Controller command, eConLeap controller will go through a self reboot. During the reboot,
customer connection will be lost until the reboot is complete. You may need to reload the web
page to return to the web GUI. The reboot process takes approximately one minute.
c. Dashboard provides the current mode of operation, status of batteries, and status of generator
cycle.
d. All alarms must be cleared prior to starting the system. The system will only start if the
alarms have been cleared.
e. If a communication failure occurs during setup, an invalid setup or configuration alarm will
be raised. It is recommended to resubmit the configuration and wait for confirmation on the
dash board.
Figure 4- 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), the following configuration details are required (Figure 5). In case customer
skips the following voltage method configuration setup, the default settings (recommended) in
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the example below will be activated. 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.
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Figure 5- Voltage Control Method
Allows voltage & time based charge discharge cycles:
Start Threshold Voltage Start Threshold Current Start Threshold Delay
Condition 1, 2, & 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
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Three different voltage mode settings are used for starting the generator.
Two settings are used for stopping the generator.
Start Generator if battery Voltage & Current meet one of the three (0, 1, & 2) Conditions:
First Condition:
Voltage0- Start generator If battery voltage is below 48 vdc
AND
Current0- If battery discharging current is above -99 Amps. A large negative number should be
used for current to make sure that the generator starts at this voltage regardless of the current.
AND
Delay for 60 Second to start after battery voltage reaches the threshold. Delay is used to
eliminate any transient or instantaneous change in the voltage or current.
OR
Second Condition:
AND
Current1- If battery discharging current is above 40 Amps. If below 40A load, the batteries will
continue to provide power.
AND
Delay for60 Second to start after battery voltage reaches the threshold OR
Third Condition:
AND
Current2- If battery discharging current is above ZERO Amps.
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.
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STOP Generator if battery Voltage & Current meet one of the two (1 & 2) Conditions:
First Condition:
Voltage0- Stop generator If battery voltage is above 54 vdc
AND
Current0- If battery charging current is above -6 Amps. If below -6A, the batteries will continue
to be charged. Charging current is always negative and a large negative number will always
stop the generator at 54Vdc
AND
OR
Second Condition:
Voltage1- Stop generator If battery voltage is above 53vdc
AND
Current1- If battery charging current is above -3 Amps. If below -10A, the batteries will
continue to be charged. Charging current is always negative.
AND
Enable Generator ON and OFF Delays
Voltage mode configuration allows customers to program a timer for ON/OFF Delay.
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.
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Causes:
Start Condition 0: Battery module requests start 50 seconds after shutdown. This time will be
enforced every time since V should always be < 100 and current > -999 regardless of charge or
discharge.
Start Condition 1: Battery module requests start 1 second after V < 44. Effectively starting every
time voltage falls below 44 volts.
Start Condition 2: Effectively, no impact.
Stop Condition 0: Battery module requests shut off 1800 seconds after startup provided a
voltage > 40 volts.
Stop Condition 1: Battery module requests shut off 20 seconds after voltage >56 amps AND
current < 4 amps.
Enable Delay- ON delay: Start 600 seconds after battery module requests startup.
Enable Delay- OFF delay: Stop 6000 seconds after battery module requests stop.
Primary Voltage method will utilize battery voltage and current as the key parameters for its
operation. However, time delays allow the user to configure a hybrid configuration that allows
a charging method based on voltage within a time window. In case of dual redundant or
backup generators, 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
GenLeapB ON
1.4.1.1 Selecting Setup Configuration:

Selecting your configuration (see Figure 4 & 5 for more details):
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Present control method

is Timer. New method
selected is Voltage
1.4.1.2 Confirming Setup Configuration:

Once the setup configuration is confirmed, system will reboot itself. Power to the eConLeap
master controller will be lost. You could lose any unsaved data or configuration at this point.
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1.4.1.3 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. It may take 10-20
seconds for controller to switch to the new configuration and show up on the dash board.
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New control method

Voltage and mode matches
now- ready to reboot.
1.4.1.4 Reconnecting after reboot:

During reboot, your connection to the controller (IP Address) will be lost. You will need to
refresh the page or re-enter the URL.It may take 20-30 seconds for controller to re-establish the
connection. Please note the system will continue to operate without interruption until te reboot
is completed.
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1.4.1.5 New setup:

Once the controller has completed a reboot process, you will see new setup configuration on
setup and dash board. Now your setup is complete.
1.4.2 Configuration
Customer shall not change any Generator, Battery or Environment menu configurations unless
recommended by Leap Power's application engineer or qualified service technician. Any
changes in these thresholds can result in failure of the engine or generator safety stop. 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. All maintenance items shall be
reset under Service thresholds by the customer to ensure service alarms work properly. Any
maintenance items like air filter change, oil change and fuel filter change should be logged by
resetting the counter. The tracking of service items allow system to generate service alarms on
time.
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Figure 5- Configuration of Generator Parameters
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Figure 6- Configuration of Environment Parameters
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Figure 7- Configuration of Battery Disconnect
1.4.3 Operations
Customer may test different voltage and current settings prior to changing their factory default
configuration. Generator operations (admin permission required) allows setting a new
generator target voltage, generator current, battery charge voltage, battery charging current
limit and discharge current limit. These values do not change customer configuration during
testing unless customer elects to permanently write to configuration file by electing "Persist". It
is always recommended to make a copy of the original configuration before overwriting your
configuration file.
Figure 8- Operations
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1.5 Monitoring & Control

1.5.1 Alarms
Figure 9- Alarms & Logs
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Key Alarms (Severity: C=Critical, M= Major, 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)
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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)
1.5.2 Logs
Logs provide downloading option for Event, Data and Alarm logs in a tab separated format. A
log file may be copied to excel or access file by copy and paste.
Figure 10- Data & Event History Logs
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1.5.3 Status
Figure 11- Status
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1.5.4 Inventory
Inventory items shall be completed during installation of GenLeap and other modules.
Figure 12- Inventory
Inventory items shall be completed during installation of GenLeap and other modules.
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1.5.5 Debugging
GenLeap allows clearing of latching alarms through debug page. All non-latching alarms are
cleared at stop or once the alarm condition is cleared. However, due to safety concerns, latching
alarms require Administrator to follow an alarm clearing and power reboot process. Please note
that any unsaved configuration can be lost during the power down and reboot process. Please
save your configuration to the controller and your computer. Following faults can be reset and
cleared through debug/Generators/Alarm Reset page.
Figure 13a- 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. If a safety stop condition is
generated from Engine Control Unit (ECU), administrator must clear the engine safety stop
along with the system safety estop. Engine estop can be cleared by writing a value "0" on
Debug/Alarm-Reset page. All alarms initiating estop condition must be cleared before clearing
an eStop. 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.
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GenOutFxInOutVolts & Current: This latching alarm indicates an incorrect alternator or battery
voltage or current. A battery voltage too high or too low may create this alarm. A tripped
breaker, wrong shunt or disconnected LVBD may cause the system to start and shut down.
GenOutFxFuelLvl: Indicates a problem with fuel inflow, fuel pump, stop solenoid and fuel filter
lever position.
GenOutFxOilPressure: Indicates a problem with high or low oil pressure.
In addition to the above latching alarms, ECU provides a list of alarms covered under system
main alarm "ECU Fault" under Debug/Generator menu. A value >7 on this page provides the
source of the ECU Fault.
Figure 13b- Debug Items
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1.6 Software Upgrade

GenLeap controllers software can be upgraded remotely or by changing flash memory in the
controller.
1.6.1 Upgrading eConLeap Mini 2440 Controller
Please make sure that CAT5/6 LAN cable connection is properly secured.
1) Download a copy of the latest software to your PC. It will show extension release number
followed by extension .tar.
Our software update releases for the eConLeap Mini Controller follows the naming
convention of update_3.0.0.X, where X is a digit representing a specific version or release of the
software. For example, the latest software is update_3.0.0.23. The software update bundles are
located on our ftp server or may be requested by contacting technical support at info@leap-
power.com.
2) Connect your PC to the Mini Controller.
Make sure you can ping the Mini Controller to address 192.168.1.230. This can be simply done
by plugging your pc directly to the eConLeap router port 2 & 3 (not port 1).
3) FTP the release to the eConLeap Mini Controller or transfer the file to the /sdcard folder
for upgrading the eConLeapMini Controller..
The username/password will be plg/plg. Make sure that you transfer in binary mode.
For example, If your software is located on the c:\ drive.
Follow the instruction below:
cd c:\
ftp 192.168.1.230
C:\>ftp 192.168.1.230
Connected to 192.168.1.230.
220 FriendlyArm FTP server (Version 6.4/OpenBSD/Linux-ftpd-0.17) ready.
User (192.168.1.230:(none)): ***
Password:***
(see your invoice for assigned user ID and password.

230 User plg logged in.
ftp> bin
200 Type set to I.
ftp> cd /sdcard
250 CWD command successful.
ftp> put update_3.0.0.23.tar
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4) Install the software.
Once the download of the new release is completed on the mini-controller and it's in the /sdcard folder,
install the software as follows;
a) Telnet to the Mini Controller. The username is root (password is not required).
telnet 192.168.1.230
b) cd /sdcard
c) /swupdate.ksh update_3.0.0.23.tar
5) Remove the current configuration. (just for update_3.0.0.23.tar release remove leapdb.xml).
a) cd /sdcard
b) rm leapdb.xml
NOTE: By removing leapdb.xml you are removing all configuration changes that you have made on the
system. You will have to re-configure the leapgen system.
6) Reboot the controller.
1.7 Manual Connections & Controls

GenLeap controllers software can be locally or remotely managed via RS232. A GUI
application for advanced engineering & calibration is available to the customer needing such
access to the controller. It is recommended that the customer avoid changing factory default
configuration without consulting Leap Power. This could result in engine failure, performance
degradation and warranty cancellation.
1.7.1 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. The purpose of the switch is to avoid an unintended
start of the generator from RS232 GUI or Web during installation and maintenance.
SW1 switch provides Remote (Web) and ECU (RS232) modes of operation. 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. 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. A separate Ethernet connection is
available for local configuration and provisioning during installation.
SW2 switch allows the customer to select between the modes of remote and local operation of
the unit. The customer can select between RUN, AUTO and Remote positions. AUTO mode
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allows the customer to run the system in primary mode with voltage control method. See
section 1.4.1 and Figure 5 for more details. If SW2 is in Remote position, the system cannot be
operated in the manual local mode or via RS232 GUI.
WARRNING: System can start without notice if placed in RUN or AUTO positions via SW2.
Selecting RUN and AUTO mode allows the customer to disable Web interface and operate
through RS232 GUI or manual mode. RS232 GUI shall be mainly used by experienced
technicians or engineers for high level diagnosis and calibration.
It is always safe to switch the eBox ON/OFF Switch in OFF position, SW1 in estop position and
SW2 in Remote position when doing system installation or maintenance. During installation, it
is recommended that customer tests the system in manual RUN mode before working in AUTO
or Web mode.
Figure 14- Front panel and Ebox
Use DHCP connection for

remote control and
management. Do not
remove this CAT 5
connection for local access
during installation &
ON/OFF switch
allows manual
maintenance.
disconnect for ebox.
Switch must be in
ON position during
system operation Use local Ethernet
and OFF position connection for
during installation provisioning and
and maintenance. configuration during
installation and
maintenance.
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1.7.2 DC Distribution Monitoring & Control

GenLeap systems are sold in many configurations as a complete system with split
distribution, batteries, solar converters, parallel generator, rectifiers, converters, wind generator
and other options. Complete system allows a unified system management and high efficiency
energy management features via master controller (eConLeap Mini Controller). 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. GenLeap
generators are also used in stand-alone or AC generator's retro fit applications with customer
supplied DC distribution.
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a. External Leap Power's Supplied Distribution Wiring:
Following wiring diagram is used with single or dual generator setup with Leap Power's
supplied distribution.
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b. 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 following wiring must be connected with the
distribution. Please note that the battery shunt, battery low voltage disconnect (LVBD), battery
temperature sensor (RTD), and battery voltage sense leads MUST always be connected for
battery charger plant to be operational. Leap Power recommended parts are following:
1. 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, NC-2) with the eBox P1 connector. The contactor rating shall be
according to the DC generator rated voltage and current.
2. Battery Current Shunt: A 50mv 100A to 300A shunt is recommended for 5KW to 10KW
Genleap models. A two wire battery current shunt connection to JCSB receptacle shall be
maintained all the time.
Recommended From: DC
TO: Front Panel of Ebox in GenLeap
Parts (10kw) Distribution
Shunt 200A/50 Ext Dist, Bat
1 JCSB-1
mV Shunt +Ve
Shunt 200A/50 Ext Dist, Bat
2 JCSB-2
mV Shunt -Ve
LVBD-NC-1,
3 P1-8
Distribution
LVBD-NC-2,
4 DC Contactor P1-7
Distribution
250A/24V-
Latching Type LVBD Coil +Ve,
5 P1-9
Distribution
LVBD Coil -Ve,
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- eBox RS-232 JC2- DB9 Serial Female
Front Panel
10 RS-232 JC1- 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, 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)
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All wiring to P1 connector with eBox is supplied with GenLeap. Customers are only required to
make the necassary connection with the DC distribution. All wire lengths are based on a standard 5 feet
distance between GenLeap eBox and DC distribution. Custom cables can be ordered from Leap
Power's factory.
Above list of recommended DC distribution's parts are based on 10KW (48Vdc/200A)DC

Generator primary (off grid) power. For wiring other configuration and system rating, please
see the system wiring schematic and model specific wiring.
1.8 Serial Connection with Engine Control Unit (ECU)

GenLeap controllers software can be locally or remotely accessed via RS232 for engineering
use. 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. This could result in engine
failure, performance degradation and warranty cancellation. A DB9 female connector is
available at the front of the generator control box for serial connection. Following are few
examples of how RS232 GUI can be utilized by experienced technicians or engineers. Please
reference GUI Programming Manual for more details.
1.8.1 Operating through RS232 GUI

Figure 15- RUN-STOP Command (Timer Mode)
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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. SWI switch must be in start position and SW2 switch should be RUN or
AUTO mode. The machine will not start or continue running if alarms are configured or set to
inhibit running. The system will run but will not enter charging mode ( runs at slow speed) if
alarms are set that are configured to inhibit charging. Please see the section 1.7.3 for how to
view the VirOutFns for fault status.
Auto Mode:
If the Auto input is activated, the generator will be allowed to start and control voltage. The
engine will automatically start when batteries are properly connected and battery voltage is
below the start threshold for enough time. See calibration items in the area of Strt Threshold
Voltage 0 in section 1.4.1. There are voltage & current thresholds below which timers start
counting time below this voltage with a minimum of this current present. If the counter
exceeds the start time, the system is commanded to start. There are similar settings for auto
shutdown. Please reference section 1.4.1 for further details.
Run Mode:
If the SWI is in start position and SW2 is in RUN position, the system will be activated for RUN
mode via RS-232 Run Command based on time selected by the operator.
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. 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.
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. This command is in either AUTO or RUN mode. If
the Remote Stop Time variable is set to a nonzero number, the engine will be
commanded to stop for this number of minutes. If the number is 255, the timer will not
count down minutes. If the timer reaches zero and something else is commanding it to
run, it will initiate the start sequence. The RS-232 stop command will override any run
command. The system must be set to zero "Remote STOP Time" to allow it to operate in
AUTO mode or WEB mode. A value of 255 will put engine in permanent STOP mode.
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1.8.2 Calibrating through RS232 GUI

RS232 commands under Calibration/Charger Target allow customers to set maximum
generator voltage and current limits. The customer is allowed to change factory default
maximum battery voltage, discharge current and charging current limits.
Figure 16- Max Voltage & Current Settings
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1.8.3 Monitoring through RS232 GUI

During RS232 mode, GUI allows extensive monitoring of the system. Items such as voltage,
current for generator, batteries and load are shown in Figure 14 under Run Time/Gen Sensors
Proc. It is recommended that web interface, not RS232 GUI is used as a tool for monitoring
GenLeap.
Figure 17- Voltage & Current Monitoring
RS232 GUI provides detailed overview of variables inhibiting engine operation for safety
reasons or limiting its performance. 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. Such an coolant temperature above threshold.

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)
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The value (7, 15, ...) is simply the sum of the item's bits. A value of 7 or greater would limit the
generator RUN or AUTO and put the engine under emergency stop (estop) condition. Each
item has its own status bits and can be configured to set any combination of its bits. It can also
be configured to clear any combination of its bits when the item is deactivated. One can choose
what level of warning or alarm each input can set and clear.
Figure 18- Fault's and Alarm's Status
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1.9 Quick Guide To Starting GenLeap First Time
1. Read carefully GenLeap Controller manual & product manual.

2. Charge crank battery to minimum 12 vdc.
3. Check engine oil and coolant level. Allow pre heating the oil and engine in cold weather.
4. Ensure adequate fuel flow and fuel level.
5. Connect DC distribution wiring to the Generator. See GenLeap controller manual section
1.7.2 for more details.
Check generator/distribution output circuit breaker 1-3. Unit will not start if CBs are open.
48Vdc battery connection and load connection are also required for GenLeap system to start.
6. Connect 48Vdc battery bank. Make sure that the batteries are equalized and not below low
voltage disconnect settings. Calculate the battery discharge time and charge time based on its
capacity, DoD% and battery limit selection. Battery capacity and current limit selection must
meet the intended duration of cycle at peak load.
7. Connect Ethernet cable supplied with the unit to your computer. Check the communication
by connecting with IP address 192.168.1.230. Green bar below dash board on the web must be
moving to validate the connection with GenLeap controller..
8. Install RS232 GUI software to your computer. A project file with configuration for your
system is included with GUI program. Please reference RS232 GUI programming manual.
9. Connect CAT5 cable supplied with GenLeap to your computer.
10. Follow steps to log in using Chrome WEB browser.
11. Follow instructions to download upgrade software for eConLeap and uConLeap controllers
if you have an older release. New releases are available on Leap Power ftp sites.
If remote access via TeamViewer7 is available, this function can be performed by our support
engineer.
12. Position SW1 switch in ECU position and SW2 in RUN position. Make sure ON/OFF switch
is in ON position. See section 1.7.1.
13. Exercise RUN mode (Remote RUN Time/ Remote Stop Time) by manually starting the
generator.
14. If RUN is successful, exit switch SW1 and SW2 to Remote positions. You are now ready to
configure the system per your application. If the unit does not start during manual RUN,
recheck all wiring and battery connections. Unit could not be started due to a fault that will
need to be cleared prior to starting the configuration process. Continue with the next step.
15. Launch your web browser with IP address 192.168.1.230. See section 1.2.4.
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16. Review section under Alarms. Follow trouble shooting guide to clear all the alarms. Reset
the system thru controller reboot or reset. A complete 12V power down may be required.
17. Position SW1 and SW2 switch in Remote position. Follow system configuration menu.
18. Check voltage mode configuration in section 1.4.1 & Figure 4. Apply load to the system and
start discharging batteries. If batteries below threshold, the generator will start automatically.
During initial test, you may want to use small batteries to keep the charge/discharge cycles
short.
19. Make sure you save your configurations on your computer and in the controller.
1.10 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, 12-29-12
Leap Power Confidential
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888 S.

Grenville Ave, Suite 302,

7/8/2010 Saved 9/5/2014

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

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1.7.2 DC Distribution Monitoring & Control ....................................................................... 39

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

1.2 Getting Started

1.2.1.1 System Network Setup

Figure 1a- Installation

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Figure 1b- Installation

Router connections to the customer's Internal connection between Router and

Recommended PC minimum requirements:

eConLeap Mini Controller

If using Google Chrome refer to the following URL.

Windows requirements Mac requirements Linux requirements

In addition, RS-232 port (Recommended) or USB to RS-232 converter

If using Windows Internet Explorer refer to the following URL.

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

1.2.2 First Startup

Name Password Access Level

admin ********** 1 (High)

operator ********** 2 (Medium)

user ********** 3 (Low)

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

Login username and password

Figure 3- Confirming Login or Logout

Successful login will show the

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

1.2.4 Connecting to eConLeap controller

1.2.5 Menu (left side bar)

Configuration: Allows threshold settings and system configurations.

Debug: Allows items for debugging or troubleshooting. Debug/Alarm-Reset allows clearing of

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

1.2.6 Access levels

Can monitor commonly used

Able to modify commonly

Allowed to tune engine, and

1.3 System Operating Modes & Control Methods

1.3.1 Standby Power Mode

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

detected. An integrated system with AC distribution, rectifiers, converters, and split DC

1.3.1.1 Voltage control method

1.3.1.2 Timer control method

1.3.2 Primary Power Mode (Off-Grid)

1.3.2.1 Voltage control method

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

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

1.3.2.2 Timer control method

1.3.3 Battery Extension Mode

1.3.4 Manual Mode:

1.3.5 Redundant Operation with dual generator sets

a. Redundant Cycle Mode: Allows units to operate in consecutive cycle mode

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

b. Load Share Mode: Multiple generators can be programmed to operate

1.4 System Setup & Configuration

Setup Manual RUN

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

Figure 4- Timer Control Method

Allows setting of time based charge discharge cycles:

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

Figure 5- Voltage Control Method