Lesson4- 3500B series engines OPERATION.ppt
- 1. 3500 B series Engines
- 2. PRESENTATION ON CATERPILLAR 3500 SERIES ENGINES
- 3. Leadership does not just happen 1973 ??? OPEC... closed
- 4. Improve Exhaust emissions Fuel economy KW outputs Monitoring capabilities Reliability . Durability. 3500 "B" Objective
- 5. 3500 SERIES EVOLUTION Yr Product Max Rating 1980 Phase 0 100 kW/cyl. 1985 Phase 1 112.5 kW/cyl. 1988 Phase 2 125 kW/cyl. 1995 B Series 137.5 kW/cyl. 2000 B HD 150 kW/cyl.
- 6. Primary objectives of 3500 B development program. 1. Develop an electronic engine control platform. 2. Improved combustion system. 3. Improved specific output.
- 8. Introduction to 3500 series B engines 3500 SERIES B engines are controlled, monitored & serviced using a Microprocessor Higher Injection pressures Better combustion chamber design Best fuel efficiency in its class. Better response & block loading capability Larger and bigger Camshaft. Seperate circuit after cooling Very low emissions.
- 9. 3500B series engines We are now offering the engine in three versions 8 cylinder version - 3508 12 cylinder version - 3512. 16 cylinder version - 3516.
- 10. Ratings 1000 KVA - 3508 B - 1180 BHP 1500 KVA - 3512 B - 1756 BHP 2000 KVA - 3516 B - 2293 BHP
- 11. 3500 series B electronic architecture consists of 1. Engine control - ADEM II ( ECM) 2. Monitoring & Instrumentation - EIP 3. Engine servicing - ET 4. Information management - PRCM & CCM.
- 12. Advanced electronics PCB technology used in the engine control module has won mentor graphics award - eight times against some of the big names in computer and electronics industry.
- 13. Electronic Architecture ECM E I P ELECTRONIC UNIT INJECTORS ELECTRONIC SENSORS CCM PRCM CAT DATA LINK Optional
- 14. Engine control module ECM is a totally self contained computer. It has its own internal power. CPU has two motorola 68 HC- 11 microcontrollers and A1 - kb dual port ram chip, each of 2 MHz
- 15. EEPROM - Customer and factory programmable values. EPROM - Software programs. FLASH EEPROM - Field up load software program OPERATING ROM - Library software programs aboard micro controller. BATTERY BACK RAM - Logged events & data recording. ECM MEMORIES.
- 16. Electronic Injectors - Timing and metering done by the solenoid. Solenoid is controlled by the ECM. ECM monitors the engine real time. Frequency of monitoring is 1/4th of a second. ECM gives command for the FUEL SYSTEM OF 3500 B SERIES
- 17. ELECTRONIC UNIT INJECTORS Electronically controlled unit injector combines electronic actuator, pump assembly and nozzle into a single compact unit. The fuel can be injected into the cylinder at a very high pressure to the tune of 22000 psi. Fuel is metered by the
- 18. Timing control by ADEM II (ECM) • Timing is varied with respect to speed , load and after cooler temperature - 4 D timing map.. • Cold mode strategy adjusts fuel injection timing as a function of jacket water temperature, engine speed and injection
- 24. EUI - Injector Fill Without pressure from the rocker arm, a spring keeps the plunger retracted Fuel flows into the injector through the fill /
- 25. EUI - Mechanical Stroke As the cam rotates, it drives the plunger downward Until the ECM signals the start of injection, fuel goes out the
- 26. EUI - Injection On a signal from the ECM, the solenoid closes the poppet valve Pressure elevates at the tip to the 5,500 psi needed to unseat the
- 27. EUI - Injection Fuel continues to inject until the ECM signals the solenoid to open the valve Injection timing and duration is controlled by
- 29. Fuel Savings - 3500 B series Fuel savings - compared to the competetion 15 - 20 % !!! THE BEST in its class. THE RESULT -Customer laughs all the way to the BANK.
- 30. SENSOR S Sensors used on the engine are Electrical - either Digital or Analog Power Supply is distributed by ADEM II. All Electronic Items undergo Failure Mode and Effects Analysis to ensure very high reliability
- 31. Crankcase pressure sensor. Coolant temperature sensor. Filtered fuel pressure sensor. Unfiltered fuel pressure sensor. Filtered oil pressure sensor. Unfiltered oil pressure sensor. Speed /timing sensor. Left turbocharger inlet pressure sensor Right turbocharger inlet pressure sensor. Turbocharger outlet pressure sensor. Atmospheric pressure sensor. Aftercooler temperature sensor. Right exhaust temperature sensor. Left exhaust temperature sensor. SENSORS
- 32. 3500 B series Engine Monitoring
- 33. ELECTRONIC INSTRUMENT PANEL EIP consists of the following for the monitoring of the engine continuously. 1. Gauge clusters 2. Smart electronic monitoring system. 3. Engine control switch 4. Scroll switch 5. Mode selector toggle switch 6. Horn & horn silencer. Most importantly this panel can be kept even 100 ft away from the engine using extension cables and mounting hard ware.
- 34. GUAGE CLUSTERS There will be two guage clusters as standard in the engine Each guage cluster will have four guages for monitoring the following. 1. Oil pressure 2. Coolant temperature 3. System voltage 4. Fuel pressure. Oil Pressure System Voltage Coolant Temp Fuel Pressure
- 35. 5. RH exhaust temperature. 6. LH exhaust temperature. 7. RH air inlet pressure 8. LH air inlet pressure. 9. Fuel filter pressure differential 10. Oil filter pressure differential. Exhaust Temp Fuel Filter Restriction Air Inlet Restriction Oil Filter Restriction GUAGE CLUSTERS
- 36. SEMS panel has ten LED s with alaram to alert the operator of the condition of the engine : System shutdown . System voltage. Overspeed Overcrank Not in auto. Low oil pressure. High coolant temperature Low coolant temperature Engine coolant level SEMS PANEL
- 37. SEMS Panel has a Liquid Crystal Display or LCD which can give read out of engine parameters MODE -0: Engine speed and hours of operation MODE - 1 : Fuel consumption /hr and individual values being displayed by guage modules. MODE - 2 : Diagonostic codes MODE - 3 : Displays the worst case & Tattle tale. MODE - 4 : Toggles between SEMS Panel
- 38. ENGINE CONTROL SWITCH ENGINE CONTROL SWITCH HAS THE FOLLOWING SELECTIONS. OFF/ RESET AUTO MAUAL START COOL DOWN / STOP AUTO MANUAL START STOP OFF - RESET
- 39. Emergency Stop Button and Alarm/Alarm Silence
- 40. Start-up Testing
- 41. CAT DATA LINK The cat data link is a proprietory high speed electronic communication. Using this link ECM can share information EMCP II, PRCM, CCM and ADEM related service tool. Maximum total distance from one end of the link to the other is 1500 ft (457 m)
- 42. ENGINE PROTECTION STRATEGIES PARAMETERS ALARM DERATE SHUT OFF ECM VOLTAGE YES ENGINE OIL PRESSURE YES YES YES JW TEMPERATURE HIGH YES YES YES JW TEMPERATURE LOW YES OVERSPEED YES YES AIR INLET RESTRICTION YES YES ALTITUDE DERATION YES EXH. TEMPERATURE YES YES OIL FILTER DIFFERENTIAL YES FUEL FILTER DIFFERENTIAL YES CRANK CASE PRESSURE YES YES YES AFTER COOLER TEMP HIGH YES YES
- 43. CAT Electronic Technician By using this computer based service tool the 3500 series B electronics can be easily accessed. CAT ET provides real time access ET can also capture the engine operating conditions just before the fault condition. ET is also self diagnosing, it is able to detect the correctness
- 44. Customer Programmable Functions Accelaration delay on start up. Accelaration ramp time. Cooldown /shut down Auto crank cycle time Crank terminate. Here the customer can alter the default settings of the engine to suit his convenience with a service tool only. No password required.
- 45. Low emission diesel 30% average improvement 5-8 g/bhp-hr depending on SCAC strategy Improved fuel economy Improved transient response Less transient smoke Emissions
- 46. New Emission Draft Laws Smoke Limit Nox HC CO PM 1.7.2003 9.2 1.3 5 0.6 0.7 1.7.2004 9.2 1.3 3.5 0.3 0.7 1.7.2003 9.2 1.3 5 0.5 0.7 1.7.2004 9.2 1.3 3.5 0.3 0.7 >50kwupto 260 kw 1.7.2003 9.2 1.3 3.5 0.3 0.7 >260kw upto 800kw 1.7.2004 9.2 1.3 3.5 0.3 0.7 >19kw upto 50kw Rating Date of Impleme ntation Emission limits(g/kw- hr) for upto 19kw
- 48. PROGRAMMABLE RELAY CONTRO MODULE.(OPTIONAL) By using PRCM, information through CAT data link can be used to activate standard relay contacts. This has seven standard relays and it can be expanded upto total 25 relay contacts. Since it is programmable, operator can select from over 53 functions, which to annunciate. PRCM SEVEN RELAYS LEDS
- 49. ECM PRCM CAT DATA LINK DIGITAL SIGNALS RELAY OUTPUTS RELAY RELAY DATA LINKS UPTO 1000 FT OR 305 M 9 DRY CONTACTS 9 DRY CONTACTS PROGRAMMABLE RELAY CONTROL MODULE (OPTIONAL)
- 50. CAT DATA LINK DATA LINKS UPTO 1000 FT OR 305 M CCM MODEM SATELLITE PERSONAL COMPUTER PERSONAL COMPUTER Module(Optional) ECM
- 51. Genset Data Links CAM CIM Alarm Modules (six options) CCM ADEM Remote RDM Note: Maximum of 3 Modules on Serial Data Link Serial Data Link (two conductor, 1000 feet max. from GSC) Generator Fault Relay Output to Breaker Shunt trip Over current/ Over Voltage Relays RS 232 Interface (40 feet max.) Cat Data Link (two conductor, 1500 feet max.)
- 52. CYLINDER BLOCK High Tensile strength block - better strength & Rigidity. Top Deck Cooling Shelf - Optimized heat transfer & Cool operation and long Engine life Access covers on block with out board split
- 53. Articulated Pistons These engines uses two piece articulated piston consisting of forged steel crown and a cast aluminium skirt. This two part design provides excellent piston strength and reduced weight while allowing for closer fit to the cylinder liner and reducing noise from piston slap. These pistons also
- 54. Larger Camshafts Cam shaft major bearing diameter from 85.9 mm to 91.9 mm to allow for more aggressive lift ramp on injector lobe. Cam base circle and un machined core diameters are increased to the maximum diameter possible. To accomadate higher valve train loads , all lifters feature a larger diameter roller pressure lubricated . helper spring provided for better stability.
- 55. R A D I A T O R Lower fuel consumption and low emissions, controlling the after cooler temperature either to 30 deg C or 60 deg C or 90 deg C, irrespective of ambient temperature. Seperate Circuit After Cooling (SCAC) ENGINE AFTER COOLER P P A C R A D
- 56. 3500 B - Transient Response Transient Response 30 35 40 45 50 55 1 2 3 4 5 6 7 8 9 10 11 Time(secs) Freq.(Hz) (secs) 3516 B 3516 Transient response is excellent due to : Higher injection pressures Improved combustion chamber design. Better atomisation. Variable timing. Dual turbo - low inertia matched turbos
- 57. Service is the Difference
- 58. Partners in Power Power Partners should have complimentary capabilities and organizations. Choosing the correct partner is the key to the long term success