Auxiliaries and Startup

When the module is not in operation (generator cb is open) the auxiliaries have to be supplied by a safe

Power supply to ensure

- Preheating

- loading of batteries

After the generator cb of the module is closed, the supply of the auxiliaries may be switched to the bus bar.

 Equipments

 Starting Equipment:

Starter batteries: lead/acid

24 V, 200 Ah per module.

Battery Charger:

24 V, 40 A:

With integrated control system power supply 24 V =, 18 Ah. Used for module controller.

Control System Power Supply:

24 V=, min. 22 - max. 30 V (inclusive of ripple) at terminal. Max ripple Uss = 2,4 V.

 Control voltage for module control cabinet from starter batteries

(Diode encoupled).

Control voltage for common cubicles (interlock panel ...)

Provided by starting batteries, connected via diodes.

 Jacket Water Preheating:

3x 400 V, 50 Hz, 6 kW

Thermostatically controlled between 55 – 60°C.

Jacket water preheating ON when Engine in OFF position.

Jacket Water Circulating Pump:

231 V, 50 Hz, 245 W:

Pump operates during engine shutdown and auxiliary cool down phase.

Technical specification of the control

 Intercooling Water Pump:

3x 400 V, 50 Hz, 1550 W:

Pump operates during module operation and during 5 minutes cool down run.

 Pre-Lube and Cool Down Oil Pump:

1x 24 VDC, 180 W:

Controlled by module PLC.

Operating time > 1 minute before engine start. Once engine speed exceeds 800 rpm, the pumps is switched off.

After module stop, the pump continues to operate for 40 minutes in order to cool down the turbocharger.

Additionally, the pumps can be manually controlled in order to preheat the lube oil.

Solenoid valve SOV 13: 1x 24 VDC, 22 W

At engine start with a jacket water temperature < 86°C the valve is open

At engine operation and jacket water temperature > 86°C the valve is closed. If the temperature decreases below 84°C the valve is open

During the 20 minutes auxiliary cool down run the valve is open.

 Start up procedure for Generator Sets

1. Check all electrical connections in generator and panel.

2. Check fuel system and bleed out any air. Make sure supply and return lines are open.

3. Check exhaust system for proper installation

a. Dry exhaust

b. Wet exhaust

4. Check engine ventilation system.

a. Industrial application

b. Marine application

5. Check for proper fluid levels.

a. Heat exchanged units, seawater is at pump.

b. Keel cooled units.

Most keel cooled units will overheat on start up, because of air in the system. This will be indicated by a rise above 200 degrees on the engine temperature. Water pump inlet will be hot and the expansion tank discharge will be cold.

Method to correct this:

a. On a cold engine, fill coolant system slowly. Using vent on side of thermostat housing, vent air out until water flows through vent. Also bleed air from vent on turbo, on turbocharged units.

b. On a hot engine, with engine running, carefully keep adding coolant with the thermostat vent open until engine temperature drops to normal and unit stops taking coolant. Close vent. Be careful of engine burping coolant and air out the filler opening. Also double check turbo vent for air.

c. Radiator units, coolant should be approximately 1 inch below top of radiator.

6. On some installations, keel coolers are installed in such a manner that the cooler slopes upwards away from the inlet and outlet. In this case it is the responsibility of the boatbuilder to install a bleed screw at the high point of the cooler.

7. Start unit at no load.

8. Check AC output voltage at the generator, for proper output. And make sure the generator output is the proper voltage and phase that is needed by the boat or building.

9. Check AC voltage regulator field voltage. a. 10 to 18 volts DC approximately – with no load.

10. If voltage regulator fuse or breaker blows, check wiring and make sure generator is not connected to the load source.

11. If 8, 9, and 10 are okay then check panel meters for proper operation.

12. Then apply load and note operation of equipment for normal events.

13. Fill out paperwork.

Paralleling Procedure

 Preliminary steps

Step 1. Start unit no. 1 and record no load AC voltage, hertz, and DC field voltage. Close line circuit breaker to the buss and load. Then record again the load AC voltage, hertz, and voltage regulator DC field voltage in steps of 25% load if possible.

Step 2. Start unit no. 2 and record no load AC voltage, hertz, and DC field voltage then check phase rotation to match the buss. Remove unit no. 1 from the buss and put unit no. 2 on the buss, recording loaded AC voltage, hertz, and voltage regulator DC field voltage. In the same load steps as on first unit.

The purpose of doing the above is to match AC voltage between the units. So when you are done with the settings both units should have the same no load voltage and they should droop the same amount of voltage under the same load conditions. And the same goes for the speed droop. The AC voltage stability on all units should be about the same to minimize cross current at no or light load conditions.

A word on cross current, the voltage regulator should have the paralleling option to provide regulator droop under load conditions, if one units voltage goes up and the other units voltage goes down, reverse the “ct” leads at the regulator to match.

 Paralleling procedure manual, lights or scope

Generator paralleling

After preliminary adjustments are made you should not have to do them again, unless for some reason the values change. Always record readings and keep, in maintenance log.

Synchronization steps

Step 1. With one unit on the buss and carrying the load, start the second unit.

Step 2. Turn on the sync. Lights or scope.

Step 3. Observing lights adjust speed of second unit to be slightly faster than the unit on the buss. The lights will go on and off slowly (bright to dark).

Step 3a. With the sync. scope adjust the off line unit’s speed so that the scope rotates clockwise slowly.

Step 4. At the instant the lights go darkest, close the second unit’s circuit breaker to the buss.

Step 4a. With the sync. scope, as it rotates between the 11:00 and 1:00 position instantly close the second units circuit breaker to the buss.

Step 5. At this point you can balance loads by adjusting engine speed. Load imbalance is a function of engine speeds up or down.

NEVER ADJUST VOLTAGE AFTER UNITS ARE IN PARALLEL!!!!!!!!!!