- Generator Set:
- 3508 (S/N: 5PW1-UP)
- 3508B (S/N: CNB1-UP; BGX1-UP)
- 3512 (S/N: CMJ1-UP; 6WW1-UP)
- 3512B (S/N: CMC1-UP; BLF1-UP; BRK1-UP; 6GW1-UP)
- 3516 (S/N: CMD1-UP; 8TW1-UP)
- 3516B (S/N: CPA1-UP; BPJ1-UP; FDN1-UP; PPS1-UP; 8NW1-UP; FDX1-UP)
- 3508B (S/N: CNB1-UP; BGX1-UP)
- Power Module:
- PM3508 (S/N: BLM1-UP; BPY1-UP)
- PM3512 (S/N: BRF1-UP; BNR1-UP)
- PM3516 (S/N: CAC1-UP; BPD1-UP)
- PM3512 (S/N: BRF1-UP; BNR1-UP)
- Engine:
- 3508 (S/N: CAW1-UP; CTF1-UP; 1JZ1-UP)
- 3508B (S/N: CTC1-UP; 1FZ1-UP)
- 3512 (S/N: FDR1-UP; CTE1-UP; 1KZ1-UP)
- 3512B (S/N: FDE1-UP; CTB1-UP; CTH1-UP; 1GZ1-UP)
- 3516 (S/N: CAL1-UP; CTD1-UP; 1LZ1-UP)
- 3516B (S/N: BMB1-UP; CTA1-UP; CTG1-UP; CTJ1-UP; 1HZ1-UP)
- 3508B (S/N: CTC1-UP; 1FZ1-UP)
Introduction
This Special Instruction describes the retrofitting of jacket water heaters that utilize convection to circulate the jacket water to a jacket water heater that utilizes a pump in order to circulate the jacket water.
Theory of Operation
Illustration 1 | g01306992 |
Schematic of the coolant flow |
The new jacket water heater is mounted to the rail on the left side of the engine. The new heater consists of a pump and a heater. The heater contains two heating elements and a thermostat.
The heater is activated and deactivated by the generator set controller. When the generator set controller activates the contactor for the space heater, electrical power is supplied to the space heater (if equipped), to the pump, and to the thermostat.
The pump continuously draws coolant from the rear of the engine block into the heater. The contacts of the thermostat will close when the temperature of the coolant is below the set point. The closed contacts of the thermostat complete an electrical circuit that supplies power to the coil of the contactor for the water heater. The contactor for the water heater supplies electrical power to the heating elements. The heating elements heat the coolant and the coolant is returned to the engine block by the pump.
When the engine is running, the generator set controller deactivates the contactor for the space heater. This disables the pump, the thermostat, and the heating elements.
Electrical Requirements
The new jacket water heater receives electrical power from the generator's marshalling box.
For the pump and the thermostat, the customer must provide a source of 220 VAC at 50 Hz or 240 VAC at 60 Hz. This electrical source must be protected by a 10 amp circuit breaker.
For the jacket water heater, the customer must provide a source of 220 VAC at 50 Hz or 240 VAC at 60 Hz. This electrical source must be protected by two 25 amp circuit breakers.
Parts Lists
Order the jacket water heater that is appropriate for the application. Refer to Table 1.
Jacket Water Heater Groups     | |
50 Hz Generator Sets     | 60 Hz Generator Sets     |
237-2236 Jacket Water Heater Gp     | 235-1224 Jacket Water Heater Gp     |
Order the additional parts that are appropriate for your engine. Refer to Table 2.
Parts for Installation of Jacket Water Heaters on 3500 Generator Sets     | ||||
---|---|---|---|---|
Part     | Model of Generator Set and Quantity of Parts     | |||
3508 Generator Sets with Low Voltage Output or with Medium Voltage Output (4160 VAC Maximum) | 3508 Generator Sets with High Voltage Output (Above 4160 V)     | 3512 Generator Sets     | 3516 Generator Sets     | |
003-9163 Elbow     | 1     | 1     | 1     |     |
006-5707 Pipe Elbow     | 1     | 1     |     |     |
1L-4762 Pipe Elbow     | 1     | 1     |     |     |
235-1225 Bracket     | 1     | 1     | 1     | 1     |
235-1226 Hose As     |     | 1     |     |     |
235-1227 Hose As     |     | 1     |     | 1     |
235-1228 Hose As     |     |     |     | 1     |
235-1229 Hose As     |     |     | 1     |     |
235-1230 Hose As     | 2     |     | 1     |     |
237-0927 Bevel Washer     | 4     | 4     | 4     | 4     |
239-1324 Contactor     | 1     | 1     | 1     | 1     |
3H-9690 Elbow     | 1     | 1     | 2     | 2     |
4B-9029 Pipe Nipple     | 1     | 1     |     |     |
5P-1076 Hard Washer     | 10     | 10     | 8     | 8     |
5P-3413 Pipe Sealant     | 1     | 1     | 1     | 1     |
6V-8188 Nut     | 5     | 5     | 4     | 4     |
7D-4092 Clip     | 2     | 2     | 1     | 2     |
7X-0325 Bolt     | 4     | 4     | 4     | 4     |
7X-0326 Bolt     |     |     | 1     | 1     |
7X-0334 Bolt     | 1     | 1     |     |     |
8S-5107 Spacer     | 2     | 2     | 1     | 1     |
8T-4223 Hard Washer     | 1     | 1     | 1     | 1     |
Miscellaneous hardware is also required. Refer to Table 3.
Miscellaneous Hardware     | |
---|---|
Item     | Purpose     |
16 Gauge Wire     | Connections between the marshalling box and the pump and the thermostat     |
10 Gauge Wire     | Connections between the marshalling box and the heating elements     |
Wire Nuts     | Electrical connections for the pump, for the thermostat, and for the heating elements     |
1/2 inch Electrical Conduit and Connectors for the Conduit     | Enclosure for the wiring between the pump and the heater     |
Miscellaneous Parts     | Grounding the pump and the heater     |
Ensure that all parts are available before you begin this procedure.
Mechanical Installation
Remove the Existing Jacket Water Heaters
Note: Some engines have convection heaters on the left side and on the right side. Both of the convection heaters must be removed from the engine.
- Disconnect the wiring from the existing jacket water heaters.
To avoid electric shock, disconnect all electrical power to the jacket water heaters and to the generator space heater prior to performing any maintenance. |
- If the existing heaters are equipped with shutoff valves, ensure that all of the shutoff valves are completely closed. This will reduce the loss of coolant.
Personal injury can result from hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. |
- Disconnect the coolant lines for the existing jacket water heaters. Drain the coolant from the lines into an appropriate container.
- Remove the coolant lines, the heaters, and the mounting brackets for each heater. If the engine is equipped with shutoff valves, do not remove the shutoff valves from the engine.
- If the engine is equipped with shutoff valves, install two 3/4 inch pipe plugs onto the outlets of the two shutoff valves on the right side of the engine. If the engine is not equipped with shutoff valves, install plugs into the openings for the coolant on the right side of the engine.
Install the New Jacket Water Heater
Modify the Rail
Note: The new jacket water heater is attached to a bracket. The bracket is attached to the rail on the left side of the engine. The rail must be modified by drilling four holes in the rail. Refer to Table 4 and Illustration 2 in order to determine the dimensions for the bracket's location.
Dimensions for the Location of the Mounting Bracket     | |||
---|---|---|---|
3508 Generator Sets with Low Voltage Output or with Medium Voltage Output (4160 V Maximum) 3512 3516     |
3508 Generator Sets with High Voltage Output (Above 4160 V)     | ||
X     | Y     | X     | Y     |
850 mm (33.5 inch)     | 27 mm (1.0 inch)     |
975 mm (38.5 inch)     |
128 mm (5.0 inch)     |
- Clamp the mounting bracket to the rail at the required location.
Illustration 2 | g01006203 |
Typical left side view and rear view |
- Drill four 14 mm (0.5625 inch) holes through the rail.
Prepare the Pump
- Remove two nuts (6) and two washers (5) from pump (7). Remove two bolts (1), two washers (2), flange (3), and seal (4). Retain all of the parts for the reinstallation of the flange.
Illustration 3 | g01005345 |
Jacket Water Heater (1) Bolt (2) Washer (3) Flange (4) Seal (5) Washer (6) Nut (7) Pump |
Note: Flange (3) must be removed from pump (7) in order to install a 3H-9690 Elbow onto the flange. The pump body may break if the flange is attached to the pump during installation of the elbow.
- Thread the elbow onto the flange and tighten the elbow securely.
- Reassemble the flange to the pump by using the original hardware. Be sure to install the gasket between the flange and the pump body.
Install the Heater
- Install the bracket to the rail with the hardware that is listed in Illustration 4. Be sure to install bevel washers (11) on the bottom side of the rail. The bevel washers provide the proper load for bracket (10) .
Illustration 4 | g01006572 |
Typical installation for the mounting bracket (8) 7X-0325 Bolt (4) (9) 5P-1076 Hard Washer (8) (10) 235-1225 Bracket (11) 237-0927 Bevel Washer (4) (12) 6V-8188 Nut (4) |
- Attach the heater to the bracket with the U-bolts and the nuts that are provided with the heater. Orient the heater according to Illustration 5. The outlet of the pump must be in a vertical position.
Illustration 5 | g01005396 |
(3508, 3512) The jacket water heater is mounted on the outboard side of the bracket. (3516) The jacket water heater is mounted between the bracket and the engine. |
- Refer to Illustrations 6, 7, 8, and 9. Install the hoses and the associated hardware according to the appropriate Illustration. Apply 5P-3413 Pipe Sealant to the threads on the ends of each component that will carry coolant.
Illustration 6 | g01006976 |
Installation for 3508 Generator Sets with Low Voltage Output or with Medium Voltage Output (4160 V Maximum) (1) 235-1230 Hose As (2) 003-9163 Elbow (3) 8T-8917 Bolt (4) 5P-1076 Hard Washer (2) (5) 7D-4092 Clip (2) (6) 6V-8188 Nut (7) 7X-0334 Bolt (8) 8T-4223 Hard Washer (9) 8S-5107 Spacer (2) (10) 1L-4762 Pipe Elbow (11) 4B-9029 Pipe Nipple (12) 006-5707 Pipe Elbow |
Illustration 7 | g01006977 |
Installation for 3508 Generator Sets with High Voltage Output (Above 4160 V) (1) 235-1227 Hose As (2) 003-9163 Elbow (3) 8T-8917 Bolt (4) 5P-1076 Hard Washer (2) (5) 7D-4092 Clip (2) (6) 6V-8188 Nut (7) 235-1226 Hose As (8) 7X-0334 Bolt (9) 8T-4223 Hard Washer (10) 8S-5107 Spacer (2) (11) 1L-4762 Pipe Elbow (12) 4B-9029 Pipe Nipple (13) 006-5707 Pipe Elbow |
Illustration 8 | g01005887 |
Installation for 3512 Generator Sets (1) 235-1230 Hose As (2) 7X-0326 Bolt (3) 8T-4223 Hard Washer (4) 7D-4092 Clip (5) 8S-5107 Spacer (6) 003-9163 Elbow (7) 235-1229 Hose As (8) 3H-9690 Elbow |
Illustration 9 | g01006455 |
Installation for 3516 Generator Sets Use the existing hardware in order to install a 7D-4092 Clip to the support for the separate circuit's pump. (1) 235-1230 Hose As (2) 7D-4092 Clip (2) (3) 3H-9690 Elbow (4) 7X-0326 Bolt (5) 8T-4223 Hard Washer (6) 235-1227 Hose As |
- If the engine is equipped with shutoff valves for the jacket water heater, open the shutoff valves on the left side of the engine. Otherwise, fill the system with coolant.
- Check for any coolant leaks and correct any coolant leaks.
Electrical Installation
Ground the Pump and the Heater
- Remove covers (1) for the pump and for the heater.
Illustration 10 | g01006218 |
Pump and heater (1) Covers (2) 1/2 inch openings for the conduit |
- Install a length of flexible electrical conduit between the 1/2 inch openings (2) on the pump and on the heater.
- Inside the junction box for the pump, slide capacitor (3) from underneath clip (4). This will allow access to a green screw for the pump's ground.
Illustration 11 | g01006577 |
The inside of the junction box for the pump (3) Capacitor (4) Clip |
- Inside the junction box for the heater, remove four screws (5) that attach the thermostat to the housing.
Illustration 12 | g01006588 |
The inside of the junction box for the heater (3) Screws for the thermostat (4) Ground screw for the heater |
- Carefully remove the thermostat by pulling the thermostat straight out of the junction box. This will allow access to green screw (6) for the heater's ground.
Note: The sensing element for the thermostat is approximately 300 mm (12.0 inches) long.
- Fabricate a 16 gauge wire for a ground between the pump and the heater. The wire must be long enough to reach between the ground screws. Connect a ring terminal to each end of the wire.
- Thread the ground wire through the conduit between the junction boxes.
- Connect one ring terminal to the ground screw for the pump. Connect the other ring terminal to the ground screw for the heater.
- Fabricate a 10 gauge wire for a ground. The wire must be long enough to reach from the heater's ground screw to an external ground. Connect a ring terminal to each end of the wire.
- Connect one end of the 10 gauge wire to the heater's ground screw. Connect the other end of the wire to an external ground. Ground the heater according to the codes that are applicable to the site.
- Reinstall the pump's capacitor under the clip.
- Carefully slide the thermostat into the heater. Reinstall the four screws in order to attach the thermostat to the heater.
Install the Wiring Between the Marshalling Box and the Heating Elements
- Run wiring from the marshalling box to the heater. Mark each wire with a unique identification. Install the wiring according to the codes that are applicable to the site.
Note: The existing wiring for the convection heaters may be usable for the new installation. In order to use the existing wiring, the wiring must reach from the marshalling box to the new jacket water heater. The wiring must be of the appropriate gauge. Each heating element requires two 10 gauge wires. The pump and the thermostat require 16 gauge wires.
Note: There are two options for wiring the pump and the thermostat. Refer to Illustrations 14 and 15. One option requires four wires. The other option requires three wires.
Illustration 13 | g01006245 |
There are two 3/4 inch knockouts. One of the knockouts is on each side of the junction box for the heater. |
Note: All of the wiring for the heating elements, for the thermostat, and for the pump must enter the heater through the 3/4 inch knockouts on the junction box. The wires for the pump will continue through the conduit between the heater and the pump.
Illustration 14 | g01006980 |
Two wires are used for the pump and two wires are used for the thermostat. |
Illustration 15 | g01006984 |
The thermostat and the pump share a wire. |
Connect the Wiring to the Pump and to the Thermostat.
- Connect two of the 16 gauge wires to the pump's wires. The polarity of the connections is not important.
Note: If four wires will be used to connect the pump and the thermostat, follow the directions in Step 1 and Step 2. If three wires will be used, follow the directions in Steps 3, 4, and 5.
- Connect the remaining two 16 gauge wires to the thermostat's wires. The polarity of the connections is not important.
Illustration 16 | g01006310 |
Wires for the thermostat |
- Connect a 16 gauge wire to a wire for the pump. Connect a 16 gauge wire to a wire for the thermostat.
- Fabricate a 16 gauge wire. Make the wire long enough to reach from the pump's wiring to the thermostat's wiring. Connect this wire to the remaining wire for the pump and the remaining wire for the thermostat.
- Connect the remaining 16 gauge wire from the marshalling box to the wire that runs between the pump and the thermostat. Refer to Illustration 17 for the wiring connections when three wires are used.
Illustration 17 | g01006987 |
The pump and the thermostat are sharing a wire. |
Connect the Wiring to the Heaters.
- Connect each 10 gauge wire to a wire for a heater. The polarity of the connections is not important.
Illustration 18 | g01006321 |
Connections for the heaters |
Space Heater Relay
Note: Although a generator space heater is not required for installation of the jacket water heater, a relay for a space heater is required.
- The relay for a space heater must be part number 221-0753. Replace the existing space heater relay, if necessary. Refer to Service Letter, PS41169.
- Refer to the schematic diagrams. If the space heater is not wired for 220 VAC or 240 VAC, perform the following procedure:
- Connect the L1 leg of the AC supply to HC-7.
- Connect the L2 leg of the AC supply to HC-9.
- Remove the wire that connects the HC-1 terminal to the H3 terminal.
- Remove the wire that connects the HC-3 terminal to the H2 terminal.
- Connect a 16 gauge jumper wire between terminals H-2 and H-3.
Note: The space heater must be wired for 220 VAC or 240 VAC.
Connect the Wiring at the Marshalling Box
- Refer to Illustration 19. Locate the rail for the AC components.
Illustration 19 | g01006607 |
There are two locations for the rail for the AC components. |
- Loosen the end stop on the left end of the rail. Slide the end stop from the left end of the rail.
Illustration 20 | g01006379 |
Rail with components |
- Slide the 239-1324 Contactor onto the left end of the rail.
Note: It may be necessary to shift the rail's existing components to the right in order to create enough space for the water heater contactor.
- Reinstall the end stop onto the left end of the rail.
Illustration 21 | g01006611 |
Location for the water heater contactor |
- Connect the wiring for the pump to terminals HC-1 and HC-3 on the relay for the space heater.
- Connect the wire for the thermostat to terminal WHC-A2 on the water heater contactor.
- The wires for each heating element are identified by a flag that is attached to each wire. Connect the wiring for the heaters according to the schematic diagram.
- Verify that all of the wiring connections have been made according to the schematic diagram. Also, refer to Illustrations 22 and 23.
Illustration 22 | g01006990 |
Connections for the water heater contactor |
Illustration 23 | g01007043 |
Connections for the space heater's relay |
- Reinstall the covers for the heater and the pump.
- Reconnect the electrical power to the space heater and to the jacket water heater.
- Verify that the pump is activated when the engine is not running. Verify that the pump shuts off when the engine is running.
- To adjust the setpoint of the thermostat, remove the cover for the heater and adjust the thermostat's dial to the desired temperature. Refer to Illustration 24. The recommended temperature for engine starting is 49 °C (120 °F). Replace the cover for the heater after you adjust the thermostat.
Illustration 24 | g01006994 |
Dial for adjusting the setpoint of the thermostat |