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PowerTech Marine Power System Handleiding

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MARINE POWER SYSTEMS
SUPPLEMENTAL MANUAL
Power Technology Southeast, Inc.
634 State Road 44 Leesburg, FL 34748-8103
♦ (352) 365-2777 ♦ Fax (352) 787-5545 ♦
9/2004
POWER TECHNOLOGY S.E., INC.
MARINE POWER SYSTEMS
This supplement to your Owners Manual provides essential information pertaining to the
installation and maintenance of Marine Power Systems manufactured by Power Technology S.E., Inc.
The information contained within this supplement is relative to components designed specifically for
marine applications. Information pertaining to the Engine, Alternator and Control Box may be found
within the Owners Manual for your generator.
NOTE: Marine Power Systems manufactured by Power Technology S.E., Inc. ARE NOT “Ignition
Protected”. United States Coast Guard (USCG) regulation 33CFR183 requires a generator to be
“Ignition Protected” when used in a gasoline fueled environment.
Power Technology recommends all persons involved in the installation, operation, maintenance
and/or repairs of the generator carefully read this manual and all accompanying literature. Safety is of
the greatest concern; follow all Safety recommendations as outlined in your Owners Manual. Be sure to
read the Power Technology S.E., Inc. Limited Warranty as your rights as a Marine Power System owner
may vary from other applications. In the event you should experience a problem with your generator
please contact the sales dealer, one of our authorized service centers or Power Technology’s Customer
Service Department directly at 1-800-760-0027 from 8:00 a.m. to 5:00 p.m. EST. Please have the
generator model and serial numbers available when you call. This will help expedite service and parts to
you. Parts may be obtained directly through Power Technology S.E., Inc. and shipped the same day if
ordered by 3:00 p.m. EST.
Generator Model Number_____________________________
Generator Serial Number______________________________
POWER TECHNOLOGY SOUTHEAST, INC.
634 STATE ROAD 44
LEESBURG, FL 34748-8103
(352) 365-2777
FAX (352) 787-5545
www.PowerTech-Gen.com
INSTALLATION
GENERAL:
The installation of a Marine Power System may vary significantly from one craft design to
another. To ensure safe trouble free service Power Technology S.E., Inc. recommends that a boatyard or
installer who is knowledgeable and experienced in this type of marine application perform the
installation. Proper location of the Marine Power System in the vessel is of prime importance; therefore
it may be advisable to contact the vessel manufacturer with questions relating to location and
installation. It is also important for the owner/operator to become familiar with the details of the
installation. Periodic checks and routine maintenance will assure optimum performance and safe
operating conditions for all personnel on board.
Several key factors must be considered in the installation.
1. Location:
a) Size and accessibility of a hatchway.
b) Structurally sound to support the unit’s weight at all angles.
c) Above low-lying bilge water and vapor area.
d) Avoid water splash from above deck.
e) Accessible for maintenance and repairs.
f) Accessibility to a fire extinguisher. NFPA rating of ABC.
2. Ventilation:
a) Provide air for engine combustion.
b) Provide cooling air for the engine and generator end.
c) Expel hot air produced by the engine and generator end.
d) Prevent the accumulation of hazardous fumes.
3. Cooling Water Supply:
a) Properly located.
b) Sufficiently sized.
4. Fuel System:
a) Independent of other engine fuel supply and return lines.
b) Safely routed and secured.
5. Exhaust System:
a) Properly discharges cooling water (seawater).
b) Completely expel exhaust gases.
c) Sufficiently quiets exhaust noise.
d) Installation of Zinc Anode.
e) Safely routed and secured.
6. AC/DC Electrical Systems:
a) Proper voltage connections.
b) Electrically grounded.
c) Wiring safely harnessed and secure.
1
Depending upon the location of your Marine Power System; either above or below the water
line, some additional components may be required to complete the installation. See the following pages
for details on each system.
Cooling Water Supply Through-Hull Seacock Fitting (Flush Hull Type)
Shut OFF Valve
Seawater Strainer
Fuel System Primary Filter / Water Separator
Shut OFF Valve
Exhaust System Siphon Break
Hydro-Muffler
Zinc Anode
Shut OFF Valve or Cover
AC/DC Electrical Systems
Ship to Shore Transfer Switch
Remote Gauge Panel
INSPECTION of EQUIPMENT:
Prior to accepting your Marine Power System, check the unit for any shipping damage and be
sure all accessories ordered are present. Check the contents against the packing list and report any loss
or damage to the transportation company.
RIGGING and LIFTING:
Because of the size and weight of the unit, careful planning for rigging and lifting must be
considered. Each unit is equipped with lifting eyes that are designed to carry the full weight of the
generator. These lifting eyes are located on the upper engine section of the unit and allow the unit to be
hoisted horizontally. In some situations the hatchway may not be large enough to accommodate the unit
in the horizontal position. Therefore hoisting the unit in a vertical position will be necessary and
specialized rigging may be needed to accomplish vertical hoisting. Be especially careful that the rigging
does not interfere with or damage components on the unit. Never attach rigging to components or
accessories, remove these parts if necessary and re-attach after the unit is in place. Special rigging work
is best done by competent and experienced personnel working with proper equipment. Avoid short cuts.
GENERATOR LOCATION and MOUNTING:
As previously mentioned the location of the Marine Power System in the vessel is extremely
important. Follow the vessel manufacturer recommendations should they apply to your installation. All
key factors must be considered when choosing the mounting location for the unit. The engine and
generator end are mounted to a heavy gauge sheet metal base pan by 4 flexible isolators that help
prevent the transfer of vibrations from the generator to the mounting location. The unit must be
orientated on a level and structurally sound mounting platform, and securely bolted into place. Once the
unit mounting is completed the installer may begin attaching the component systems.
VENTILATION:
Most vessels are equipped with an ambient air ventilation system. If your vessel is not equipped
or insufficiently equipped to support the extra demand of a Marine Power System, provisions must be
made to install or increase the volume of ambient air into the area while providing for expulsion of hot
air and hazardous fumes.
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COOLING WATER SYSTEM:
The Marine Power Systems engine is cooled by a fresh water/anti-freeze system employing a
heat exchanger to dissipate engine heat. The engine fresh water-cooling system is a closed loop system
similar to non-marine units, with the exception being a heat exchanger instead of a radiator. Seawater is
used as the heat exchanger’s cooling medium. This system operates by pumping cool seawater into the
heat exchanger, which absorbs heat from the fresh water system; it then exits through the engines
exhaust manifold, also removing exhaust heat and gases as well. The seawater cooling system
incorporates components specifically designed for marine applications. Attention to component
selection and mounting location is an important consideration.
CAUTION: DO NOT use a scoop-type through-hull fitting for the seawater supply. This type of fitting
will cause excessive pressure on the seawater pump, actually forcing seawater pass the impeller into the
engine exhaust manifold and cylinders. Engine damage resulting from this is not a warrantable issue.
The seawater is supplied through a flush-type hull seacock fitting located in an area of the hull
which must remain submerged at all times during operation. From the seacock fitting a positive shut
OFF valve should be placed ahead of the seawater strainer. A visual-type seawater strainer should be
used and mounted at or below the water line to be assured the supply line remains primed. The use of
high quality wire reinforced hose is recommended to prevent the hose from collapsing during operation.
Non-reinforced hose may collapse from the seawater pumps’ suction. All hoses and fittings must be of
adequate size to prevent any restrictions in the flow of seawater throughout the system. Machined
fittings with true inside diameters are preferred over standard pipefittings.
FUEL SYSTEM:
The diesel fuel system for a Marine Power System must be designed to operate independently
from the vessels main engine. In most installations both engines operate from a common fuel tank with
separate pick-up and return lines for each engine.
NOTE: Never use a simple Tee fitting to supply both engines from a common fuel line. This practice
may cause a fuel starvation situation to either or both engines. Additionally, excessive pressure may
build up in the main supply line and possibly cause a fuel line or connector failure resulting in a
hazardous fuel leak.
The unit comes equipped with a spin-on type fuel filter installed between the fuel pump and the
injector pump. It is recommended however; that a positive shut OFF valve and marine approved primary
filter/water separator be installed between the fuel tank and fuel pump. Mount these components in an
area that is readily accessible for service. Use only high quality ¼” ID fuel line and fittings suitable for
marine applications throughout the system. Carefully plan and route the fuel supply and return lines,
secure them with the proper clamping devices to prevent vibration and chaffing. Routine inspections and
service of all fuel system components will assure safe trouble free operation.
IMPORTANT: A fire extinguisher with the NFPA rating of ABC should be in close proximity to the
unit and easily accessible. Maintain it in good working order and be familiar with its use.
3
EXHAUST SYSTEM:
When connecting the exhaust system to your Marine Power System special consideration must
be taken in its design, components used and Safety issues encountered with the installation. The design
and components used are relative to the location of the unit. That is, above or below the water line. In all
cases Safety is of prime importance. A well-designed leak free exhaust system is essential to the
operation and performance of the generator and to the Safety of the vessel and its occupants.
WARNING: Carbon Monoxide gas is present in exhaust gases produced by diesel engines. Carbon
Monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal. Prevent the
acumination of exhaust gases in closed areas or from being drawn into such areas. Avoid still/calm
conditions, always exhaust downwind and away from others.
The Marine Power System comes equipped with the seawater pump, heat exchanger, exhaust
manifold and exhaust elbow already mounted to the engine and connected with the appropriate hoses.
The installer is responsible for attaching the remainder of the exhaust components in order to complete
the installation.
IMPORTANT: For installations where the Marine Power System is located below the water line
provisions MUST be made to install a siphon-break in the seawater supply hose connected to the water
injected exhaust elbow. The siphon-break will prevent the siphoning of seawater through the cooling
system. Without the siphon-break seawater will fill the exhaust system to a point that the exhaust
manifold and engine cylinders will be flooded. The siphon-break MUST be located at least 12”above the
water line at all angles of operation. Engine damage resulting from an un-installed or improperly
installed siphon-break is not a warrantable issue.
When installing the hydro muffler follow the manufacturers instructions regarding hose size and
location. It is generally recommended to locate the hydro muffler as close to the unit as practical.
Always exhaust in a downward direction and never loop the exhaust hose between the exhaust elbow
and hydro muffler. Avoid restrictions and unnecessary bends in the exhaust hose as they may cause
excessive backpressure and poor performance. It is advisable to check the backpressure with a Mercury
Manometer or similar gauge. Backpressure should not exceed 3” of Mercury (0.104 kg/cm²). Only use
exhaust hose and clamps that are appropriate for marine applications. For a leak free exhaust system,
securely mount and tighten all connections.
When the generator is not in operation it is important to prevent seawater from entering the
exhaust system. If the vessel experiences healing/backing down or like conditions, seawater could fill
the exhaust system and engine cylinders. To avoid such a situation a closure or valve should be installed
near the exhaust seacock fitting. Engine damage resulting from these conditions is not warrantable issue.
Your best protection against exhaust gas leakage is a daily inspection of the complete exhaust
system. Check for leaks around all components and junctions. Check surrounding areas for signs of
excessive heating. Listen for sound changes in the system. If any of the signs of exhaust leakage are
observed immediately shut down the unit and have a qualified mechanic inspect and repair the problem.
IMPORTANT: Circumstances may arise in which the engine will not start. Excessive cranking of the
engine creates a situation in which the seawater pump will fill the exhaust manifold and flood the engine
cylinders. To prevent this from happening, close the valve on the seawater supply line, drain off
accumulated seawater in the exhaust system and correct the starting problem. It is important the
owner/operator keeps this in mind. Engine damage under these circumstances is not a warrantable issue.
4
ELECTRICAL SYSTEMS:
The Marine Power System incorporates two separate electrical systems. DC Voltage is used to
start the engine and supply current to engine components such as switches, gauges, and battery charging
circuit. The engines DC wiring harness and control box is factory installed, all that is necessary for
operation is to connect to a 12V DC battery and connect the wiring to the optional remote gauge panel.
The generator end of the unit produces the AC Voltage used throughout the vessel. Follow the vessel
manufacturers’ recommendations for wiring your generator into the AC circuits of the vessel. Ensure the
proper voltage and ground connections are made and all wiring is safely harnessed and secured. A Ship
to Shore transfer switch will enable your vessel to operate on generator output power or connect to
utility shore power when available. The Ship to Shore transfer switch also prevents the simultaneous
connection between utility shore power and the generators output.
IMPORTANT: A hazardous situation may occur if utility shore power and generator output power are
connected simultaneously. Dangerous back feeding of AC Voltage can cause serious damage and/or
injury. Damages resulting from back feeding, improper wiring or faulty components are the
responsibility of the installer and are not warrantable issues.
OTHER IMPORTANT CONSIDERATIONS:
A few components of the seawater cooling system that need regular attention are the seawater
pump impeller and the Zinc Anode. The seawater pump impeller is made of neoprene and should never
be run dry. Impeller failure may occur due to lack of water or age. It is advisable to have on hand a spare
impeller and gasket should a failure occur. If the impeller breaks apart, be sure to locate and remove all
fragments from the system.
The heat exchanger in the seawater cooling system has provisions for a Zinc Anode. The purpose
of this Zinc Anode is to sacrifice itself to electrolysis action within the system thereby reducing the
effects of electrolysis on the other components in the system. The Zinc Anode should be inspected on a
monthly basis, cleaned and/or replaced as required. Be sure to clean any anode debris from the area
inside the heat exchanger. It is advisable to have a few spare Zinc Anodes on hand.
Maintain the 12V DC charging system in good working order. Make sure the battery is securely
mounted and well ventilated. Regularly check the battery and terminal connections. Clean and tighten as
required. Maintain the recommended electrolyte level.
WARNING: Take all necessary precautions when handling and servicing batteries. Protect your eyes
and skin from acid splash. Never smoke or allow an open flame near batteries since they emit highly
explosive gas.
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