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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
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 2
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 3
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 4
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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)
G8500/G8500M (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® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 5
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 6
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 7
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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
AUTO STARTEMI FILTER MODULEPOWER STRIPTRANSFER SWITCH
SPECIFICATIONS
TOTAL POWER
AC OUTPUT IN GENERATOR MODE/ENGINE ON
AC OUTPUT IN BATTERY MODE / ENGINE OFF
AC POWER QUALITY
WEIGHT
OPTIONAL FEATURES
DC OUTPUT NOT APPLICABLE NOT APPLICABLE
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
TYPICAL OPERATIONAL ENGINE SPEED
1200 TO 6000 RPM 1200 TO 6000 RPM
750 TO 3600 RPM 750 TO 3600 RPM
YESYES YESYES YES
5000 WATTS6000 WATTS7200 WATTS
-40 ºF TO 180 ºF
-40 ºF TO 120 ºF -40 ºF TO 120 ºF
YES
YES
YES
OPERATIONAL AMBIENT TEMPERATURE RANGE
-40 ºF TO 180 ºF
9000 WATTS
ALL-AC SYSTEMS - 5000 AND 8000 WATTAURAGEN MODELS
8500 WATTS8000 WATTS8000 WATTS8500 WATTS
G5000/G5000M (12 OR 24 VDC VEHICLE)
G8500/G8500M (12 OR 24 VDC VEHICLE)
6000 WATTS5000 WATTS
DIMENSIONS12.16"DX6.4"W
DRIVE OPTIONSYES
19.27"LX13.5"WX8.52"H
GENERAL INFORMATION
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 8
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
SYSTEM MODEL SPECIFICATIONS
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
TYPICAL OPERATIONAL ENGINE SPEED
1200 TO 6000 RPM
YESYES
-40 ºF TO 180 ºF
-40 ºF TO 120 ºF -40 ºF TO 120 ºF
OPERATIONAL AMBIENT TEMPERATURE RANGE
-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
AC OUTPUT IN BATTERY MODE / ENGINE OFF
NOT APPLICABLE NOT APPLICABLE
SPECIFICATIONS
TOTAL POWER7000 WATTS6800 WATTS
AC OUTPUT IN GENERATOR MODE/ENGINE ON
4000 WATTS4250 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)
5300 WATTS2500 WATTS3000 WATTS3600 WATTS
120 VAC
GENERAL INFORMATION
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 9
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
SYSTEM MODEL SPECIFICATIONS
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
AC OUTPUT IN GENERATOR MODE/ENGINE ON
NOT APPLICABLE
OPTIONAL FEATURES
TYPICAL OPERATIONAL ENGINE SPEED
DIMENSIONS
DRIVE OPTIONS
ALL-DC SYSTEM - 6000 WATT
SPECIFICATIONS
TOTAL POWER
AC OUTPUT IN BATTERY MODE / ENGINE OFF
OPERATIONAL AMBIENT TEMPERATURE RANGE
WEIGHT
AC POWER QUALITY
DC OUTPUT
NOT APPLICABLE
GENERAL INFORMATION
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 10
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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 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
VEHICLE BATTERYENGINE BELTPOWER-TAKE-OFFHYDRAULIC MOTORGENERATORECUGENERATORECU
GENERATOR
ECU
GAS ENGINES
DIESEL ENGINES
AUTO STARTEMI FILTER MODULEPOWER STRIPTRANSFER SWITCH
SPECIFICATIONS
TOTAL POWER
AC OUTPUT IN GENERATOR MODE/ENGINE ON
AC OUTPUT IN BATTERY MODE / ENGINE OFF
DC OUTPUT
AC POWER QUALITY
DRIVE OPTIONS
DIMENSIONS
WEIGHT
OPERATIONAL AMBIENT TEMPERATURE RANGE
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
TYPICAL OPERATIONAL ENGINE SPEED
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
4000 WATTS6000 WATTS
5000 WATTS5000 WATTS6000 WATTS7200 WATTS
5000 WATTS5000 WATTS6000 WATTS
GENERAL INFORMATION
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 11
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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) 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
VEHICLE BATTERYENGINE BELTPOWER-TAKE-OFFHYDRAULIC MOTORGENERATORECUGENERATORECU
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
TYPICAL OPERATIONAL ENGINE SPEED
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
OPERATIONAL AMBIENT TEMPERATURE RANGE
10 AMPS NOMINAL
14 VDC
1.5%
YES
64 LBS.
AC POWER QUALITY
DRIVE OPTIONS
DIMENSIONS
WEIGHT
TOTAL POWER
AC OUTPUT IN GENERATOR MODE/ENGINE ON
AC OUTPUT IN BATTERY MODE / ENGINE OFF
DC OUTPUT
8000 WATTS8500 WATTS9000 WATTS
INVERTER CHARGER (ICS) - 8000 WATTAURAGEN MODELS
8500 WATTS
G8500X/G8500XM (12 VDC VEHICLE)
G8500X/G8500XM (24 VDC VEHICLE)
SPECIFICATIONS
2500 WATTS3000 WATTS
8500 WATTS8000 WATTS8000 WATTS8500 WATTS9000 WATTS
4000 WATTS6000 WATTS
8000 WATTS
GENERAL INFORMATION
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 12
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
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
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 13
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
MAJOR COMPONENT DESCRIPTIONS
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
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 14
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
MAJOR COMPONENT DESCRIPTIONS
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
AURAGEN® CATALOG, SECTION 1 PAGE 1- FS-100, JANUARY, 2005 15
Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
MAJOR COMPONENT DESCRIPTIONS
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
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Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
MAJOR COMPONENT DESCRIPTIONS
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
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Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
MAJOR COMPONENT DESCRIPTIONS
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
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Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
MAJOR COMPONENT DESCRIPTIONS
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
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Aura Systems, Inc. (800) 909-AURA (310) 643-5300 www.aurasystems.com
MAJOR COMPONENT DESCRIPTIONS
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