3516 Engines

Electrical system- engine & generator

Ries Engineering Shares Company

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
Ries Engineering Shares Company 2

Product Description

A complete self-contained unit for generating electrical power. Transportable. Utilized for prime or standby power generation.

Ries Engineering Shares Company

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.
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Ries Engineering Shares Company

Power Module Components

Generator :SR4B brushless generator. Used for mixed loads of motors and lights, SCR controlled equipment, computer centersetc. 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. SDLC
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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 Panel

Installed 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 system

1250 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.

Connected in parallel . Provide primary filtration.

Ries Engineering Shares Company

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Power Module Enclosure Wiring

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

Ries Engineering Shares Company

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Auxiliary AC power distribution

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

Ries Engineering Shares Company

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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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Coil numbering
T1
T4

T7

T10 T11

T8
T12 T6 T9 T5

T3

T2

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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 & controls

Programmable system parameters. Configuration parameters.

programm ability ECM serial No number Low idle Yes speed Engine yes cool-down duration Crank yes duration
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Parameter

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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 system

ET 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.

Ries Engineering Shares Company

Voltage monitoring

Parameter
Warning setpoint Warning delay Hysteresis
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Default setting
20V 10 sec 2V

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Data link features

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

120 Ohm TERMINATING RESISTOR

HAND HELD SERVICE TOOL Address 249

NODE DATA BUS

120 Ohm TERMINATING RESISTOR

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

MACHINE INTERFACE CONNECTOR 52 61

ENGINE ECM Address 0

INSTRUMENT PANEL Address 23

GEARBOX ECM Address 3

NODE

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Engine starting

Before engine starting:-Perform daily maintenance and other periodic maintenance. -Walk around inspection -Leak Max service life.

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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.

Ries Engineering Shares Company

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

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Generator Operation
Loading 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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Ries Engineering Shares Company

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
Reactive power (3)

Real power (1)

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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

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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

Input Control Output

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Fuel system

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System operation

ECM

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Electronic system components

Temp. sensors Pressure sensors Speed sensors ECM Wiring harness Software

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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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Ries Engineering Shares Company

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.

Ries Engineering Shares Company

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Electronic control system operation

Ries Engineering Shares Company

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Web-Ex Presentation

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

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

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Web-Ex Presentation

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SUTRAC Development & learning centre

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

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Electronic control circuit for the fuel system

Ries Engineering Shares Company

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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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Ries Engineering Shares Company

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.

Ries Engineering Shares Company

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