3516 Engines Class

Ries Engineering Shares Company 1

3516 EnginesElectrical system- engine &

generator


Product Information Welding on engines with electronic controls.

1\ Turn Off the engine -ECS off 2\ Open disconnect switch or disconnect

the –ve battery terminal. 3\ Clamp the ground cable to the

component that will be welded. 4\ Protect the wiring harness from welding

debris.

Note: do not ground the welder to electrical components such as ECM or sensors


Product Description A complete self-contained unit for

generating electrical power. Transportable. Utilized for prime or standby power

generation.

SDLC


Power Module Components Engine :- -3500B genset engine. -Electronically controlled diesel

engine. -MEUI. -Equipped with jacket water after

cooling or SCAC. -Offered in 8,12,16 cylinder

engines. SDLC


Power Module Components Generator :- SR4B brushless generator. Used for mixed loads of motors and lights,

SCR controlled equipment, computer centers…etc.

SR4B are utilized in 3 phase full wave excitation and regulation.

4 pole of 6 pole design with 6 lead configuration or 12 depending on frame size.

50 HZ or 60 HZ.

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Power Module Enclosure

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Basic Container

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Load Cable Access Door

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Vertical Discharge PanelInstalled in PM equipped with vertical radiators.Directs hot air from radiator and exhaust through an opening in the roof.

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Fire Extinguishers & Louvers

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Fuel Storage /Delivery system1250 US gallon mounted in the front of the PM.Supply engine for 10 hrs at full continuous load.

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Fuel Transfer System & Fuel/Water separator

Option.Fill automatically the tank during operation.Pump driven by electric motor.

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Connected in parallel .Provide primary filtration.


Power Module Enclosure WiringBatteries :- -Mounted in racks. -24V for engine and interior lighting . -connected to a battery charger and to the alternator. -Disconnect switch.

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Auxiliary AC power distributionC.B available for 120/240.Interior lightening:- -24V. -Mounted on engine area & operator area. -Wired to a timer switch.Outlets:- -Option.

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Switchgear For proper control & protection of Genset.Include :- -EMCPII. -Paralleling switch. -C.B. -Load sharing module. -Transformers. -Voltage for auxiliary power. -Bus bar(3 phase fully rated).

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T1T1

T2T2T3T3

T4T4

T5T5T6T6

T7T7

T8T8

T9T9

T10T10T11T11

T12T12

Coil numbering


Electrical Measurements Measure the insulation resistance if the

generator was exposed to:- -Rapid change in temperature. -Freezing. -Wet climate during storage.

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Engine feature & controlsProgrammable system parameters.Configuration parameters.

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Parameter programmability

ECM serial number

No

Low idle speed

Yes

Engine cool-down duration

yes

Crank duration

yes


Caterpillar Monitoring system ECM monitors operating parameters of

the engine and initiate response if any parameter exceeds an acceptable range.

-Warning. -Derate. -Shutdown.

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Caterpillar Monitoring systemET is used to:-Select the available response.Program the level for monitoring.Program delay times for each response.

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Default setting for CAT monitoring system

Derate.Set point.Hysteresis.50 rpm below low idle, ECM check parameters.Failure of a sensor will result in active diagnostic code.

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Parameter Default setting

Warning setpoint

20V

Warning delay

10 sec

Hysteresis 2V

Voltage monitoring


Data link featuresCAT data link flash -Provide the capability to flash the software for the engine control with CAT data link.

Secondary CAT data link -Connect ECMs of the engine and of other engines (2-8 generators). -Used with switch gear , remote monitoring and control systems

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MACHINE INTERFACE CONNECTOR

120 Ohm TERMINATINGRESISTOR

120 Ohm TERMINATINGRESISTOR

5261

GEARBOXECM

Address 3

INSTRUMENT PANEL

Address 23

ENGINEECM

Address 0

HAND HELDSERVICE TOOL

Address 249 DATA BUS

NODE

NODE


Engine starting

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Before engine starting:- -Perform daily maintenance and other

periodic maintenance. -Walk around inspection -Leak Max service life.


Air inlet system Ensure that the air inlet piping and air

filters are in place. Ensure that all clamps and connections

are secure. Observe the air cleaner service

indicator.

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Cooling system Inspect the cooling system for leaks or

loose connections. Inspect the cooling system hoses for

cracks an loose clamps. Inspect the water pump for evidence of

leaks. Inspect the fan drive belts for cracks. Check the coolant level.

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Generator Perform any maintenance that is

required for generator. Ensure that the main C.B is open.

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Electrical system Inspect the wiring for the following:- -Loose connection. -Worn wire. Inspect the alternator belt. Ensure that the grounds are secured.

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Fuel system Inspect the fuel lines for loose fitting

and leaks. Ensure the fuel lines are properly

clamped. Ensure that the fuel is supplied to the

engine. Prime the fuel system – as required.

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Lubrication system Check the engine crank case oil level. Check for leaks; crank shaft seal,

crankcase, oil filters, plugs, sensors. Inspect the tubes, tee pieces and

clamps on the crank case breathers.

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Starting system Disconnect any battery charger that are

not protected against the high current drain that is created when the electric starting motor is engaged.

Inspect the battery cables. Inspect the gauges and the control

panel for good connection. Reset the shutoff and alarm

components.

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Engaging the Generator Ensure that gauges are in the normal

range. Increase the engine speed to rated rpm. Adjust voltage and frequency. Close C.B. Continue to check the gauges.

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Engine stoppingEmergency stop.Manual stop -Open main C.B. -Turn ECS to off/reset. -Or stop for engine with EMCP panel.

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Generator OperationLoading of the generator:- -Check for load total current/phase. -Share the load between phases.

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Block Loading Depends on:- Engine transient response. Voltage regulator response. Type of voltage regulator. Altitude of operation. Type of load. The amount of load that is already

present.

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Power Factor Represent the efficiency of the load. Ratio; apparent power : total power. KW=KVA x P.F. CAT genset p.f = 0.8 lag

Apparent power (2)

Real power (1)

Reactive power (3)

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Excitation system Self excited generators. Permanent Magnet pilot excited

generators (PMPE).

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Low Idle adjustment 900 rpm. 60 HZ 66% 50HZ 80% For electronic governor, no idle stop For mechanical governor, low idle is set

at the factory.

Of full load

speed

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Standby Gensets Most of them are automatic. Perform: start, pickup load, run and

stop.

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Parallel Operation

-1-

RequirementRequirement

I n order to operate alternators in parallel, I n order to operate alternators in parallel, several conditions MUST be metseveral conditions MUST be met

The 3 first fundamental conditions are :The 3 first fundamental conditions are :

* Same Frequency* Same Frequency* Same Voltage* Same Voltage* Same Phase Rotation* Same Phase Rotation

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Maintenance interval schedule To determine the maintenance interval

use the fuel consumption, service hours or calendar time…..which ever comes first.

Daily. Every week. Every 100 Hrs. Every 250Hrs. etc.

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Annunciator panel – inspect Lamp test.Alarm sound.Gauges condition.Frequently monitor:- -Fuel filter differential pressure. -Inlet air restriction. -Oil filter differential pressure.

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Electrical connections – check

Tightness and physical damage. Transformers. Fuses. Capacitors. Lightening arrestors.

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Starting motor – inspect Pinion & flywheel ring gear.Proper operation. -Listen for grinding.Problems of starter motor caused by:- -Solenoid malfunction. -Loose connections. -Corrosion or worn wires.

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Electronic control system

InputControlOutput

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Fuel system

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System operation ECM

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Temp. sensorsPressure sensorsSpeed sensorsECMWiring harnessSoftware

Electronic system components

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Cold cylinder cutout During cold start or extended period of

low idle. Activated when Programmed enable Engine speed equal to or below high

idle speed. Fuel rack is below 13 mm Jacket water temp below 63 degree c.

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Engine monitoring system ECM monitors parameters. Select an action (warning, derate,

shutdown). -Can be set by ET

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100 hour free configuration on engine start up

Provide the ability to change any configuration parameters via ET with out a password.

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Electronic control system operation

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52Web-Ex Presentation

















69

2004A Version,ECM test mode not availablePressure Sensor Calibration available

70

2004B Version,ECM test mode availablePressure Sensor Calibration no available


72

Test ECM Cheat Sheet• Flash the new ECM• Return to ET• Click Service, a window will appear. Click Test ECM mode• Click Activate in lower left corner• ET will give a warning that it will reconnect• Click OK• ET will connect, a window will appear and says ECM is in

test mode with how much time is left• Program all customer parameters. Including Engine

Serial Number• Always reactive a test mode when being used in another

engine

SUTRAC Development & learning centre


Electronic control circuit for the fuel system

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Testing & Adjusting Electronic control system Calibration -Calibration for electronic injection

timing with the electronic service tool Monitoring system parameters -ECM initiate an action if a specific

parameter exceeds an acceptable range -Log codes and events

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Engine speed/timing sensor remove and install

Inspect the sensor connector.Remove sensor from fly wheel.Examine the plastic end of the sensor.Pry the plastic sensor end to the fully extended position (appr.4.75 mm).Grasp the plastic end of the sensor. Wiggle the sensor from one side to the other to check for play.Gently push in on the plastic end of the sensor.Examine the O-ring seal at the base of the sensor thread.Install the sensor into the fly wheel housing.Connect the sensor connector.

SDLC

Documents

3516 Engines Class