ApplicationNotes

APG2000/3000 ENGINATOR APPLICATION GUIDELINES

Note: The guidelines provided here have been established to assist a fabricator with the requirements of Waukesha APG2000/3000 Enginators. It is important that these guidelines be followed to receive satisfactory performance from APG2000/3000 Enginators. FUEL SYSTEM 1. The gas train is included in the standard scope of the Enginator and is shipped loose. The gas train regulates the gas pressure to a predetermined value based on the intake manifold pressure and is, along with the opening duration of the fuel injectors, used to control air fuel ratio. 2. The gas train consists of: fuel pressure regulator, coalescing lter with differential pressure switch gage, two blocking valves, ventilation system, temperature and pressure sensors and gauges.

INFORMATION FROM THE APPLICATION ENGINEERS AT WAUKESHA ENGINE No. WED1/07 Rev. 1

3. The gas pressure delivered to the gas train has to be 3.5 to 6 bar (51 to 87 PSI) at 0 to 50C (32 to 122F). 4. Compressed (control) air of 6 to 8 bar (87 - 116 PSI) is required. 5. A anged exible wire braid connection is required at the fuel pipe into the engine. This prevents breakage from fabrication misalignment and engine vibrations. 6. The maximum allowable distance between the gas train and the engine inlet is 5 m (16 ft). 7. Stainless steel piping is recommended between the gas train and the engine connection. 8. Manual and automatic fuel shutoff valves must be located as close as practical to the inlet of the fuel connection and within easy reach of the operator. This allows rapid shutoff of fuel automatically or manually in an emergency. A manual valve assures servicing personnel that the fuel line is closed during servicing. 9. The fuel line should be cleaned and free of dirt, dust, etc prior to start-up. This prevents start-up damage of the fuel system and internal engine components. 10. Waukeshas Engine System Manager (ESM) and the auxiliary systems interface, which are included in the standard scope of supply of the Enginator, provide the logic for the gas train. More information on fuel systems can be found in Waukeshas Installation of Waukesha Engines and Enginator Systems. AIR INDUCTION SYSTEM 1. The ltered air has to be delivered by the customer. The APG2000/3000 standard scope does not include intake air lters. Air lters must be supplied by the customer or can be ordered as an option from Waukesha. 2. Waukesha requires the customer to choose a Waukesha option for either a radial or the axial inlet air suction piece.

4 6

1. Gas inlet 2. Gas outlet 3. Gas regulator pilot (connected to engine intake manifold). 4. Compressor air connection 5. Gas vent 6. Electrical junction box Figure 1 Gas Train

ApplicationNotes
3. Waukesha offers optional equipment: air intake insulation on the turbo compressor and charge air cooler which is recommended for CHP applications. dry-panel type air lter with rain shields. heavy duty air lter with inertia separators and rain shields 4. The air lters should remove over 99.6% of coarse dust as described in SAE J726 Air Cleaner Test Code Standard. Reference S-9200-13 or most current version in Waukesha Technical Data for air ltration quality. 5. Air inlet piping between the lter and engine: a. must be permanently corrosion resistant (no rust, scale or akes should be pulled into the engine). This can be accomplished with PVC, aluminum or stainless steel piping, or with an adequate cleaning and treatment of steel. b. must be vacuum tight (gasketed). c. must be non-collapsible. d. must have a vacuum tight exible connection at the turbocharger inlet adapter. A rubber Hump Hose specically designed for internal combustion engines is preferred. This prevents turbocharger damage from piping strain and vibration. e. should have a restriction indicator located near each turbocharger inlet. 6. Air inlet piping restriction, including the maximum air lter restriction prior to renewing of the lter element, must not exceed 3 kPa (11.8 inch of H2O). 7. Turbocharger air inlets must be covered and sealed during fabrication, shipping and storage. 8. Air piping must be thoroughly cleaned prior to engine start-up and after extended periods of shutdown. 9. Air inlet piping must be sealed from water entrance during shipping and storage. 10. Air inlet piping must be supported such that no weight is carried by the turbocharger inlet adapter. 11. Induction air should be drawn from a cool location. More information on air induction systems can be found in Waukeshas Installation of Waukesha Engines and Enginator Systems. STARTING SYSTEM 1. The APG2000/3000 are standard equipped with one air starter (air only), a relay valve, a strainer and an air exhaust silencer. 2. The required regulated air pressure depending on engine type (12V or 18V for APG2000 or APG3000), driven equipment and engine temperature is 6.9 to 10.3 bar (100 to 150 PSI). Reference S-09200-12 or most current version in Waukesha Technical Data for more information. 3. The starting equipment provided with the engine must remain intact as assembled and piped by Waukesha. 4. Flexible connections must be used at the engine connections. This is to compensate for misaligned piping and engine vibration. 5. A manual valve must be installed upstream of the exible connection near the engine within easy reach of the operator. This provides a means of emergency shutdown and allows servicing personnel a guarantee that the starting air is off during servicing. More information on starting systems can be found in Waukeshas Installation of Waukesha Engines and Enginator Systems.

Figure 2 Waukesha 12V/18V220GL Air Starter System

ApplicationNotes
EXHAUST SYSTEM 1. The exhaust system must be designed in accordance with S-8242 or most current version in Waukesha Technical Data which addresses piping strength, thermal growth and piping support. a. Flexible connections are required to compensate for thermal growth of engine and exhaust pipe. b. Supports must direct thermal growth away from the engine. c. Symmetry of dual exhausts is required to create equal back pressure and ow on both banks allowing uniform operation. d. Back pressure must not exceed 5 kPa (19.7 inch H2O). e. Combined exhaust backpressure and air inlet restriction must not exceed 71 mbar (28 inch H2O). f. The exhaust system should be made from a minimum of Schedule 10 stainless steel pipe to withstand exhaust explosion occurrences. 2. Explosion relief valves prior to the silencer, catalytic converter or heat recovery equipment will help protect these devices in the event of an exhaust explosion. These valves must be vented to a safe area (reference local codes). 3. To prevent exhaust explosions and hazardous situations at start-up, a ventilation blower is required on the exhaust system. The blower should be located close to Legend: 1. Check Valve* 2. Restriction Valve* 3. Blower* 4. Drain** 5. Test Gauge** 6. Oil Separator* 2 requested for APG2000, 3 for APG3000 7. Flexible connection** 8. Rain Hood and Drip Collector** the engine exhaust using a valve to separate the blower from the engine during normal operation. A ow switch is to be installed to ensure that the blower is functioning. A temperature switch is to be installed to ensure that the valve is closed during engine operation, contact WED Application Engineering if recommendations are needed on equipment supply. It is advised to purge the exhaust with a volume of air at least three times the exhaust system volume after every shut-down and before every start-up. The auxiliary system interface provides the logic for the exhaust ventilation system. 4. Cover the engine exhaust outlets during fabrication to prevent dirt, slag and water from entering the turbochargers. Clean exhaust piping of slag and loose dirt prior to start-up. 5. Seal exhaust during storage and shipping to prevent water and dirt from entering the turbochargers and cylinders. 6. Exhaust must discharge away from the air induction system and cooling systems. 7. Exhaust systems must be designed to prevent water from entering the engine. More information on exhaust systems can be found in Waukeshas Installation of Waukesha Engines and Enginator Systems.

Notes: Breather piping should slope upward from the engine connection to the blower (i.e. no low spots to trap oil) Adjust restriction valve to maintain required crankcase pressure per engine specication All connections must be exible ----- Indicates customer piping * Component supplied as a loose part Figure 3 Waukesha APG2000/3000 Breather System Schematic

ApplicationNotes
BREATHER SYSTEM 1. Waukesha offers an optional crankcase breather. The optional crankcase breather is shipped loose and consists of a crankcase ventilation blower with 50 or 60 Hz motor, crankcase emission absorbers (oil separators), restrictor valve and check valve. 2. Breather piping should slope upwards from the engine connection to the blower (i.e. no low spots to trap oil). 3. The typical crankcase volume ow for new engines is 41 m/h (24 cfm) for the APG2000 and 62 m/h (32 cfm) for the APG3000. Just before engine overhaul this will be higher. A factor of two or higher can be expected. A crankcase vacuum pressure of 0 to 5 mbar (0 to 2 inches of H2O) is required. 4. Figure 3 shows the schematic for the breather system. 5. Blower operating logic should be as follows: a. Blower start on engine start. b. Blower stop at engine shutdown. 6. The breather connection must be sealed during fabrication, shipping and storage. 7. A crankcase pressure switch should be used to detect positive crankcase pressure. The engine should not be allowed to operate with positive crankcase pressure. High positive crankcase pressure can also indicate engine damage. At crankcase pressure over 13 mbar (5 inches H2O) the engine has to be stopped as this can result in engine damage. Reference S-Sheet S-09200-9 or most current version in Waukesha Technical Data for more detailed information. General information on breather systems can be found in Waukeshas Installation of Waukesha Engines and Enginator Systems COOLING SYSTEM 1. The APG2000/3000 cooling system standard consists of 2 or 3 circuits. The HT circuit consists of the (high temperature) rst stage intercooler and the jacket water. The LT circuit consists of the (low temperature) second stage intercooler and the optional Waukesha lube oil cooler. When the customer chooses the customer supplied lube oil cooler, this becomes the third cooling circuit. 2. HT and LT twin water pump and thermostat and jacket water pre-heater with circulating pump are standard equipment. 3. A Jacket Water heater is included in the standard scope of the Enginator to maintain a temperature above 40C. 4. The LT circuit can be selected at either 45C (113F) for high efciency or 55C (131F) for hot climate applications. 5. The optional internal lube oil cooler is available for applications where 45C or 55C LT coolant will be used for the oil circuit. A customer supplied external oil cooler is required when the lube oil heat is to be reclaimed at a higher temperature. More information is available in Application Note WED10/06 APG2000/3000 Enginator Lube Oil Cooling. 6. The APG2000/3000 comes standard with a 100C (212F) thermostat for the HT circuit. The inlet head to both the HT and LT water pump should be within 1.6 and 2 bar (23 to 29 PSI). To safely and continuously meet this requirement a bladder style pressurization system with degassing tank and relief valve is strongly recommended. 7. One expansion tank can pressurize both cooling systems. As the pressure difference between the inlet of the two pumps has to be below 0.3 bar (4.4 PSI) a balance line between the inlet of both pumps is required. As shown in Figure 4 the expansion tank can be connected to this balance line thus reducing the costs. This balance line should be installed preferably within 2 meters (6.6) of the inlet locations to the engine and be a minimum DN25 (1) pipe.

Figure 4 APG Bladder Style Pressurization System With Degassing Tank

8. The degassing tank is to be connected to the highest points of the engine. For the APG2000 and APG3000 this is the port between the front two cylinders on the A bank. 9. Venting of the LT system is required when lling the system during the lling checks and immediately after. Reference the O&M manual for the correct lling, venting and draining procedure.

ApplicationNotes
10. Waukesha Engine strongly recommends the use of the optionally offered bladder style pressurization system for the APG2000 and APG3000. This system includes a degassing tank, a pressure relief valve and an air compressor for the pressure in the bladder all specially designed for the APG2000 and APG3000. 11. Flexible connections must be used at the engine cooling system connections to compensate for misaligned piping and vibrations. 12. The piping must be cleaned and free of dirt, rust, scale, tools and rags prior to engine start-up. 13. Coolant quality and treatment must meet specications as outlined in Waukeshas Water Treatment for Engine Cooling Systems S-7610-3 or most recent version. 14. Reference S-6699-7, Cooling Systems Guidelines for Waukesha Engines, or most current version for more information. More information on cooling systems can be found in Waukeshas Installation of Waukesha Engines and Enginator Systems. LUBRICATION SYSTEM 1. The APG2000/3000 lubrication system comes standard with a wet oil sump, an oil pump, pre-lube pump, lube oil module with berglass lter cartridges, and a centrifugal lter for the removal of ne particles. 2. Waukesha offers an optional internal lube oil cooler with lube oil thermostats for applications where the coolant temperature is 45C (113F) or 55C (131F). For other coolant temperatures, as in CHP applications that have a demand for heat at higher temperatures, a customer supplied oil cooler with lube oil thermostats is required. Reference Application Note WED10/06 APG2000/3000 Enginator Lube Oil Cooling for more information. 3. At low ambient temperatures use oil which will provide proper lubrication when the engine is hot and working. 4. Flex connections must be used at all lube oil connections to the engine to compensate for misaligned piping and vibrations. 5. The piping must be cleaned and free of dirt, rust, scale, tools and rags prior to engine start-up. 6. Check that the elements have been installed in the main lube oil lter. 7. The engine must be prelubed by the auxiliary system interface logic prior to each start. Prelubrication purges the lubrication system of air and ensures all moving parts subjected to friction are properly lubricated before the engine starts. This protects the engine from starvation or extreme wear at start-up. 8. The engine will be postlubed by the auxiliary systems interface logic, in non emergency shutdown conditions, to cool down components and protect the oil from overheating at hot spots. 9. Reference S-1015-30, Lubrication Oil Recommendations for Waukesha Engines, or most current version for more information, lube oil recommendations and change intervals. More information on lubricating systems can be found in Waukeshas Installation of Waukesha Engines and Enginator Systems. CONTROLS 1. Waukesha Engine System Manager (ESM) integrates the controls of the engine. This includes: fuel injection, spark timing control, speed governing, detonation protection, start-stop control, diagnostic tools, fault logging and engine safeties. 2. The auxiliary systems interface is located on the engine, communicates to the ESM, and provides the logic to operate prelube and postlube, HT heating and circulation, gas train and exhaust ventilation system. 3. The APG2000/3000 have factory mounted and wired sensors for lube oil pressure and temperature, intake manifold temperature and pressure, overspeed, knock, speed and jacket water temperature all accessible through ESM. ESM also controls the performance and safety of the engine through these sensors and ignition timing, fuel injection and waste gate. 4. ESM provides predictive spark plug diagnostics, advanced diagnostics of engine and sensors, and logs any faults. 5. Customer connections are required to the local control panel through the Waukesha supplied customer interface harness, the gas train, the AC junction box (400V for 50 Hz and 480V for 60 Hz) and for 24V DC power supply.

ApplicationNotes
MOUNTING The Enginator base is designed to be rigidly mounted to a foundation or installed on vibration isolators. Waukesha supplies isolators as an option. Information on mounting can be found in Waukeshas Installation of Waukesha Engines and Enginator Systems. SERVICE 1. Overhead cranes with a minimum 1 ton capacity must be available to position individual cylinders, turbochargers and the ywheel. A larger crane is required for lifting the crankcase or complete generator. 2. To allow sufcient space for all servicing functions, spacing between engines should be a minimum of 1.60 meter (63 inches) and 1.35 meter to the wall (53 inches). Overhead clearance should be at least 1.62 meter (64 inches). 3. Crankcase pressure relief valves must not be blocked. SHIPPING In most cases the Engine mounted to the base will be shipped in one container while the generator (on wood skid) along with any loose items (gas train, pressure tank, etc) will be in another. The engine is to be picked by the base.
Consult your local Waukesha Distributor for system application assistance. The manufacturer reserves the right to change or modify without notice, the design or equipment specication as herein set forth without incurring any obligation either with respect to equipment previously sold or in the process of construction except where otherwise specically guaranteed by the manufacturer.

WAUKESHA ENGINE DRESSER, INC. 1101 West St. Paul Ave. Waukesha, WI 53188 262.547.3311 www.waukeshaengine.dresser.com