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| Illustration 1 | g00275086 |
Contactor and transducer panel. | |
Setpoint - A setpoint is a critical limit of an operating parameter. A setpoint can be a temperature, a pressure, a level, a speed, etc. An alarm or a shutdown is activated if an operating parameter reaches a setpoint.
Contactor - A contactor is a switch that is controlled by temperature or pressure. The temperature or pressure that triggers the switch is set to a critical setpoint. If the setpoint is reached, an alarm or a shutdown will be activated.
Transducer - A transducer converts a mechanical stimulus into an electrical signal. An external power source is required.
Protective systems are mandatory on Caterpillar 3600 Series Fast Vessel Engines. Two types of protective systems are available. The Marine Monitoring System is controlled by a programmable logic control. The Electrical Engine Protective System is controlled through relay logic. Both systems are briefly described in this section.
Marine Monitoring System
The Marine Monitoring System uses a microprocessor to provide engine control and engine monitoring. The Marine Monitoring System enables an operator to use a display screen for controlling and monitoring engine operation.
When the package for annunciation is included, the operator is alerted to conditions that can cause alarms and shutdowns. The Marine Monitoring System can stop the engine if the engine operation reaches a setpoint that is programmed for shutdown.
Marine Engine Control Panel
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| Illustration 2 | g00270098 |
(1) Screen. (2) Switch. | |
Engine operation is monitored and controlled through the Marine Engine Control Panel. The Marine Engine Control Panel screen (1) is a touchscreen. The screen is used to configure the Marine Monitoring System for the particular engine. The configuration includes the following features:
- The optional gauges can be customized, enabled, or disabled.
- Metric units or English units can be selected for the display.
- The language that will be displayed can be selected. A keypad is required for this feature.
- The communication ports for external addresses can be selected and configured.
- The auxiliary gauges can be configured.
- Any auxiliary alarms can be configured.
An operator can choose from the following menu of monitoring features by using screen (1) :
Engine Overview - This window provides a general summary of the engine operation. This window graphically displays a top view of the engine. This window also displays operating parameters, including rpm, engine hours, operating temperatures and operating pressures.
Auxiliary Gauges and Status Outputs - This window displays the information that is provided by the auxiliary gauges. This window is also used to monitor the status of the communication of auxiliary parameters.
Alarm Annunciator - This window is used to display the precise cause of alarms that are active. This window can also display a history of all the alarms that have occurred. The operator can download the history to a floppy disk.
Air and Fuel - This window displays a set of gauges that show the air system and fuel system parameters.
Cooling System - This window graphically displays a diagram of the cooling circuit. The temperatures and pressures for the cooling system are also displayed. A window of the gauges and a trend chart for the cooling system can be accessed through this window.
Exhaust - This window displays a summary of the exhaust port temperatures. The exhaust port temperature deviation, the exhaust manifold temperature, and the exhaust stack temperatures can also be accessed through this window.
Lube Oil System - This window graphically displays a diagram of the lube oil system. The temperatures and pressures of the lube oil system are also displayed. A window of the gauges and a trend chart for the lube oil system can be accessed through this window.
Alarms
An optional beacon and a horn are required for annunciation of alarms. To test the annunciation, the operator can turn switch (2) to the "TEST" position.
If an alarm is activated, the "Alarms" icon at the top of the screen illuminates. An "Alarm Annunciator" window appears on screen (1). To acknowledge the alarm, turn switch (2) to the "ACKNowledge" position. To view a graphic display of the particular alarm, touch the "SUMMARY ALARM" button that is illuminated in the "Alarm Annunciator" window.
In addition to annunciation for undesirable engine operating conditions, an alarm will be displayed for the following conditions:
- A sensor output is out of specification.
- A wire from a contactor has failed.
- A wire from a contactor has been removed.
For example, the pressure sensor for lube oil is a 4 to 20 mA output. If the output from the pressure sensor is 22 mA, an alarm for the sensor will be displayed.
If a wire for a contactor is normally open, the closed side of the contactor is used in order to determine the continuity of the circuit. If the wire has failed or if the wire has been removed, an alarm for the sensor will be displayed.
A log of the events is recorded by the Marine Monitoring System. The log can be saved to a floppy disk. A report can be made from the record of the events.
Electrical Engine Protective System
Relay - A relay is an electromechanical device which uses a relatively small current to control an electromagnet. The electromagnet activates electrical contacts. The contacts open and the contacts close in order to switch larger electrical currents.
The electrical engine protective system provides contactors that have Marine Society approval. The control system consists of relays, contactors, timers, and other components.
The relay based system consists of the following main components:
- A control panel
- A contactor and transducer panel
- A mechanical gauge panel
- An optional annunciator panel
The components are installed at the shipyard.
The wiring for the engine can be installed at the factory in order to meet the Marine Society requirements. The wiring for the engine is attached to a junction box that is mounted on the engine. The mechanical sensors are routed to an interface bracket on the front of the engine.
The electrical connections between the junction box and the start/stop panel are made at the shipyard. The connections from the interface bracket to the contactor and transducer panel and the gauge panel are also made at the shipyard.
The contactors are configured as alarms and shutdowns in order to meet the requirements of the customer. The protective system can be customized with additional options. An optional annunciator panel can be added.
Annunciator Panel
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| Illustration 3 | g00270097 |
(1) Lamp. (2) Label. (3) "ALARM/FAULT CONTROL" switch. (4) Speaker. (5) "ANNUNCIATOR POWER" switch. | |
If an alarm condition occurs, the appropriate lamp (1) will illuminate and speaker (4) will annunciate. The operator can silence the speaker by turning "ALARM/FAULT CONTROL" switch (3) to the SILENCE position. The alarm can be identified by the appropriate label (2) over the illuminated lamp.
Ensure that "ALARM/FAULT CONTROL" switch (3) is reset after repairs have been made. Turn "ALARM/FAULT CONTROL" switch (3) to the LAMP RESET position.
To test the annunciator panel, turn "ANNUNCIATOR POWER" switch (5) to the LAMP TEST position.
Sensor Locations
The illustrations of the sensor locations are for the Marine Monitoring System. For information about sensors for the Electrical Engine Protection System, consult your Caterpillar dealer.
Air Restriction
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| Illustration 4 | g00274778 |
Air restriction is monitored by sensor (1) that measures the pressure of the air that enters the turbocharger air inlet.
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| Illustration 5 | g00281990 |
Air restriction gauges are mounted on the engine. | |
Two air restriction gauges are mounted on the engine. Air restriction is an indication of the cleanliness of the air filter element. Air restriction increases as the air filter element becomes plugged. A high air restriction will activate an alarm.
Aftercooler and Oil Cooler Water Temperature
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| Illustration 6 | g00281988 |
Aftercooler and oil cooler water temperature is monitored by sensor (2) that is located at the outlet for the aftercooler and oil cooler water pump. A high aftercooler and oil cooler water temperature can activate an alarm.
Crankcase Pressure
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| Illustration 7 | g00281977 |
Crankcase pressure is monitored by sensor (3) that is inside of the crankcase.
Rapid changes in crankcase pressure can indicate problems with the pistons, piston rings, and cylinder liners. High crankcase pressure can activate an alarm or a shutdown.
Cylinder Head Exhaust Port Temperature
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| Illustration 8 | g00281998 |
The exhaust temperature of each cylinder is monitored by sensors (4). If the exhaust temperature of any cylinder has a difference of more than 50°C (122°F) from the average exhaust temperature of all of the cylinders, an alarm is activated.
Fuel Pressure
A fuel pressure sensor is located at a tee fitting that is on a fuel line after the fuel filters. The tee fitting is between the rear of the fuel filters and the fuel manifold. A decrease in fuel pressure can indicate a high fuel filter differential pressure. A low fuel pressure will activate an alarm.
Fuel Filter Differential Pressure
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| Illustration 9 | g00281974 |
The sensors for fuel filter differential pressure are located at the rear of the fuel filters. Sensor (5) monitors the pressure of the fuel after the fuel has circulated through the fuel filters. Sensor (6) monitors the pressure of the fuel before the fuel has circulated through the fuel filters.
The difference of the two pressures is the fuel filter differential pressure. The fuel filter differential pressure increases as the fuel filters become plugged. A high fuel filter differential pressure will activate an alarm.
Fuel Temperature
The sensor for fuel temperature is located at a fuel line on the engine side of the primary filter/water separator.
A loss of power will occur if the fuel temperature exceeds 29°C (85°F). A high fuel temperature can activate an alarm or a shutdown.
Inlet Manifold Air Pressure
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| Illustration 10 | g00282008 |
The sensor for inlet manifold air pressure (7) is located in the air plenum. A high inlet manifold air pressure will activate an alarm.
Inlet Manifold Air Temperature
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| Illustration 11 | g00281991 |
The sensor for inlet manifold air temperature (8) is located in the air plenum. An excessive inlet manifold air temperature can indicate a problem with the aftercooler or the jacket water cooling system. A high inlet manifold air temperature can activate an alarm or a shutdown.
Jacket Water Pressure
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| Illustration 12 | g00281987 |
The sensor for jacket water pressure (9) is located at the outlet of the jacket water pump. Low jacket water pressure will activate an alarm or a shutdown.
Jacket Water Temperature
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| Illustration 13 | g00281985 |
Top view | |
Jacket water temperature is monitored by sensors (10) that are located in coolant lines near the water temperature regulator housing. A low jacket water temperature can activate an alarm. A high jacket water temperature can activate an alarm or a shutdown.
Oil Filter Differential Pressure and Low Oil Pressure
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| Illustration 14 | g00281975 |
Sensor (11) monitors the pressure of the oil before the oil has circulated through the engine oil filters. Sensor (12) monitors the pressure of the oil after the oil has circulated through the engine oil filters. The difference of the two oil pressures is the oil filter differential pressure. The oil filter differential pressure increases as the oil filters become plugged. A high oil filter differential pressure will activate an alarm or a shutdown.
Sensor (13) monitors the engine oil pressure. Low oil pressure can activate an alarm or a shutdown. The setpoints for the alarm and the shutdown depend on the engine rpm.
Oil Mist Detector
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| Illustration 15 | g00282004 |
Oil mist detector (14) monitors the concentration of oil mist in the crankcase. If the concentration of oil mist exceeds the setpoint, an alarm is activated.
For more information, refer to the literature that is provided by the OEM of the oil mist detector.
Oil Temperature
The sensor for oil temperature is located in the oil temperature regulator housing. High oil temperature can activate an alarm or a shutdown.
Overspeed
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| Illustration 16 | g00281999 |
Engine rpm is monitored by a magnetic pickup (15) that senses the passage of the ring gear teeth on the flywheel (16). If the engine rpm exceeds 113 percent of the rated rpm, both the fuel and the inlet air to the engine are shut off immediately.
Sea Water Pressure
A sensor that monitors sea water pressure is located at the outlet for the auxiliary water pump. Low sea water pressure will activate an alarm.
Starting Air Pressure
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| Illustration 17 | g00282002 |
Pressure sensor (17) monitors the air pressure that is available for starting the engine. If the air pressure is insufficient, an alarm is activated.