Section 2

DESCRIPTION

2.1         GENERAL SAFETY NOTICES

The Carrier Transicold model 69UG15 under−mounted diesel−driven generator sets provide electrical power for all−electric refrigeration units.

The generator set (see Figure 2.1, Figure 2.2 and Fig­ure 2.3) consists of a diesel engine direct−connected to an alternating current generator and mounted in a structural steel frame. The engine is a vertical in−line, four cylinder diesel manufactured by Kubota, while the generator is a 15 kW, brushless, dual bearing type. Generator sets will start at 50Hz. Once the unit is run­ning, the voltage controller will read the voltage output of the generator and adjust accordingly, to keep the voltage within ISO limits. As the Container becomes loaded, voltage drops and current increases, the gen­erator set will switch windings or speed based on power demand and ambient conditions. The unit will typically run at 50Hz and will vary generator output via winding selection. The speed change to 60 Hz will typi­cally occur when the ambient temperature is high and the unit is heavily loaded.

Electrical controls are mounted in a control box with operating controls and gauges mounted on a control panel, which also serves as the control box cover. The control panel components are protected by a deflector assembly and a windowed control box door.

Auxiliary engine equipment consists of the battery, solid state battery charging system, “spin−on” lube oil filter, fuel filter and other necessary components for proper unit operation. The water pump and the radiator cooling fan are belt−driven from the engine crankshaft. All references to engine are as viewed from the fly wheel end.

The 69UG15 is available as a standard configuration, with an Auto Restart option or with Auto Restart and Low Coolant Sensor. The Auto Restart option automat­ically restarts the unit in the event of a unit shutdown. Auto Restart also offers built−in indicators that signal low oil pressure, high water temperature, overspeed, and other overcrank conditions.

Carrier Transicold’s Ecodriven dual speed option pro­vides an energy saving alternative to the practice of continuously running the generator at full speed. This speed reduction results in increased fuel economy, reduced carbon footprint, and lowers operating costs.

2.2         CONFIGURATION IDENTIFICATION

Generator set identification information is provided on a label located below the left mounting pad to the left of the access service door (front facing). The label pro­vides the generator set model number, serial number, and parts identification number (PID). The model num­ber identifies the overall configuration while the PID provides information on specific optional equipment and differences in detailed parts.

The model number, serial number and PID number must be included when ordering parts and inquiring about your unit.

Separately bound manuals covering the diesel engine are also available (see the following chart).

Manual /Form Number	Equipment Covered	Type of Manual
62-11335	V2203-DI	Engine Part List
62-11362	V2203-DI	Workshop

Figure 2.1  Unit View, UniDrive (Line Drawing)

 

Figure 2.2  Unit View, Front

 

Figure 2.3  Unit View, Top

 

2.3         ENGINE

The engine is a vertical, in−line four cylinder diesel engine, which is directly connected to the alternating current generator. Information on the major engine sys­tems is provided in the following sub-paragraphs.

2.3.1              Electronic Governor Module

The electronic governor module (EG) is a solid state control module pre−programmed for 1800 RPM high speed and 1500 RPM low speed operation.

The EG unit has an LED which may be used to diag­nose failures within the electronic speed control sys­tem, refer to Section 4.5 for additional troubleshooting information on diagnosing failures.

Figure 2.4  Electronic Governor Module

 

2.3.2              Engine Air System

The air cleaner (see Figure 2.2) is designed to prolong engine life and performance by preventing dirt and grit from entering the engine and causing excessive wear on all operating parts. In order for the air filter to oper­ate properly, the operator must regularly maintain the air cleaner equipment in accordance with the instruc­tions provided within this document.

2.3.3              Fuel System

The fuel system is fitted with an in−line fuel strainer and a fuel filter, which also acts as a water separator. The fuel system is shown in Figure 2.5.

The fuel heater system is located in the fuel filter and uses a 12 volt heater to heat fuel as it passes through the fuel filter, see Figure 2.5.

Figure 2.5  Fuel System Diagram

 

2.3.4              Lube Oil Filter Arrangement

The engine lubricating oil filter is mounted in a horizon­tal arrangement and shown in Figure 2.6.

Figure 2.6  Lube Oil

 

2.3.5              Engine Screw Threads

All threads used on the engine are metric except for the oil drain plug, which is American Standard Pipe Thread (NPT).

2.4         ALTERNATING CURRENT GENERATOR

The generator is directly bolted to the engine and sup­plies nominal 50/60Hz power depending on the load requirement.

2.5         BATTERY CHARGING SYSTEM

The solid state battery charger (see Figure 2.1) is located in front of the battery. The battery charger is powered by the generator, and this input is protected by fuses located in the receptacle box. The battery charger produces a tapered charge (40 amps maxi­mum) and is designed not to overcharge the battery.

Observe proper polarity when installing the battery or connecting a battery char­ger. The negative battery terminal must be grounded. Reverse polarity may dam­age the charging system. When charging the battery in unit, isolate the battery by disconnecting the negative battery termi­nal first, then the positive. Once the bat­tery has been charged, connect the positive battery terminal first, then the negative.

2.6         VOLTAGE CONTROLLER

Voltage Controller maintains ISO voltage via two−speed and dual winding control. It is used to regu­late voltage in order to keep the generator output within ISO limits:

50Hz − 1500 RPM, 360 − 460 VAC

60Hz − 1800 RPM, 400 − 500 VAC

2.7         OPERATING CONTROLS & INSTRUMENTS

2.7.1              Introduction

Components required for monitoring and controlling the Genset unit are located in the control box, on the con­trol panel and on the receptacle box.

2.7.2              Control Panel and Related Components

1.     Gauges and Senders

a.     Oil Pressure Gauge (see Figure 2.7)

The purpose of this gauge is to observe nor­mal operating engine oil pressure. Normal oil pressure is 35 to 60 psig (3.3 to 5.2 kg/cm2).

b.        Oil Pressure Sender (see Figure 2.6)

This device senses engine lube oil pressure and transmits a signal to the oil pressure gauge. The oil pressure sender is located on the oil filter housing.

c.     Water Temperature Gauge (see Figure 2.7)

The function of this gauge is to observe water operating temperature. The gauge is con­nected to the water temperature sensor.

d.     Water Temperature Sensor (see Figure 2.3)

This device senses engine water tempera­ture and transmits a signal to the water tem­perature gauge.

e.     Low Coolant Sensor (see Figure 2.3)

This device senses the coolant level inside the radiator and will complete a conductive circuit as long as the probes remain immersed in coolant. When coolant level falls below the probes, a signal is sent to the auto restart module, shutting down the engine & all 12−volt circuitry.

f.       Auto Restart Module

Auto start/restart is provided to simplify the start−up process and provide an automatic restart feature that will automatically attempt to restart the unit in the event of shutdown. Four LEDs are used to indicate shutdown from overcrank, overspeed, low oil pressure, and high water temperature. A fifth LED is used to indicate the unit is running (see Fig­ure 2.9). Refer to Table 2–2 for system pre­set values.

The auto restart function will perform a series of six attempts to restart the unit and make three attempts within each series. Once the function has completed all 18 attempts, the unit will automatically lock out future crank attempts. Refer to Table 2–2 for detailed information on auto restart sequencing.

2.     Meters

a.     Ammeter (A)

The ammeter (see Figure 2.7) is an indicator of the charging system and unit electrical draw. It indicates the rate of discharge or charge of the battery. During start up, the intake heater draws approximately 42 amps.

b.     Total Time Meter (TT)

The total time meter (see Figure 2.7) calcu­lates the total hours and provides an accu­rate readout of accumulated engine running time. This data can be used to establish proper maintenance schedules (refer to Sec­tion 4.1).

3.     Manual Switches

a.     Intake Heater Switch (HS) (see Figure 2.7)

The intake heater switch is a momentary switch. When held in the PREHEAT position, the switch allows approximately 42 amps of battery current to flow into the intake heater, which preheats the air within the intake mani­fold and allows the engine to start. After start­ing the engine, the intake heater switch should continue to be held in the ON position for approximately 5 seconds until the engine has developed enough oil pressure to close the oil pressure safety switch.

b.     Ignition Switch (IGN) (see Figure 2.7)

The ignition switch is a momentary switch that has OFF/ON/START positions. When held in the START

(ignition) position, it energizes the starter motor solenoid, which in turn allows the starter motor to crank the engine. The switch is released to the RUN position once the engine has started.

c.     Ignition Switch (IGN)(Auto Restart) (see Fig­ure 2.7)

The ignition switch is a maintained contact switch that has the RUN/OFF positions. When switched to the RUN position, it ener­gizes the control module, which in turn con­trols all functions of the Genset.

4.     Timers

a.     Intake Heater Timer (IHT)

The Intake Heater Timer continues to supply power to the intake heater for 3 minutes after initial start−up.

b.     Starter Timer (SST)

The Starter Timer limits the amount of time that the starter can be engaged to 15 sec­onds. If the starter is manually engaged for more than 15 seconds, power will be cut to the starter. Once power has been removed, the starter can again be engaged for up to 15 seconds.

Figure 2.7  Control Panel and Box, Standard

 

Figure 2.8  Control Panel and Box & Auto Restart

 

Figure 2.9  Control Panel and box, Auto Restart & Low Coolant Sensor

 

Table 2–1  Auto Restart Preset Values

Indicator	Preset Value	Description
Overspeed	2100 RPM	Overspeed is the point at which the unit will signal for shut­down
Crank Disconnect	700 RPM	Crank Disconnect is the point at which the auto restart module senses the engine has started and will disengage the starter
Shutdown Lockout Delay	15 seconds	The oil pressure and water temperature inputs are ignored during this 15 second delay (after start up)
Intake Heater Delay	30 seconds preheat 3 minutes postheat	The delay is used during start up. The intake heater delay begins timing after the auto restart module signal is re­ceived. During the entire delay, the intake heater circuit will be energized, an indicator light will be illuminated, and an alarm will sound. When the delay expires, the unit will crank.
Crank Attempts	18 attempts	A series of six attempts with three attempts in each series (total of 18 attempts)

Figure 2.10  Receptacle Box

 

Table 2–2  Auto Restart Sequencing

*Engine crank and rest is repeated three times each series unless the engine starts.
Series Attempt Number	1	Engine Status: If the engine starts: 1.      Run sequence begins 2.      Intake heater remains energized for 3 minutes If the engine fails to start: 1.      Intake heater will de-energize. 2.      Fuel solenoid will de-energize. 3.      Crank output will de-energize. 4.      Overcrank LED will flash once. Wait two seconds and repeat. 5.      Unit will rest 30 minutes and proceed to the next series.
Intake Heater Energized in Seconds	30
Fuel Solenoid Engaged	Yes
Engine Crank Duration (Seconds)	Up to 15
Engine Rest Duration (Seconds)	25
Series Attempt Number	2	Engine Status: If the engine starts: 1.      Run sequence begins 2.      Intake heater remains energized for 3 minutes If the engine fails to start: 1.      Intake heater will de-energize. 2.      Fuel solenoid will de-energize. 3.      Crank output will de-energize. 4.      Overcrank LED will flash twice. Wait two seconds and repeat. 5.      Unit will rest 30 minutes and proceed to the next series.
Intake Heater Energized in Seconds	30
Fuel Solenoid Engaged	Yes
Engine Crank Duration (Seconds)	Up to 15
Engine Rest Duration (Seconds)	25
Series Attempt Number	3	Engine Status: If the engine starts: 1.      Run sequence begins. If the engine fails to start: 1.      Intake heater will de-energize. 2.      Fuel solenoid will de-energize. 3.      Crank output will de-energize. 4.      Overcrank LED will flash three times. Wait two seconds and repeat. 5.      Unit will rest five hours and proceed to the next series.
Intake Heater Energized in Seconds	30
Fuel Solenoid Engaged	Yes
Engine Crank Duration (Seconds)	Up to 15
Engine Rest Duration (Seconds)	25
Series Attempt Number	4	Engine Status: If the engine starts: 1.      Run sequence begins. If the engine fails to start: 1.      Intake heater will de-energize. 2.      Fuel solenoid will de-energize. 3.      Crank output will de-energize. 4.      Overcrank LED will flash four times. Wait two seconds and repeat. 5.      Unit will rest five hours and proceed to the next series.
Intake Heater Energized in Seconds	30
Fuel Solenoid Engaged	Yes
Engine Crank Duration (Seconds)	Up to 15
Engine Rest Duration (Seconds)	25
Series Attempt Number	5	Engine Status: If the engine starts: 1.      Run sequence begins. If the engine fails to start: 1.      Intake heater will de-energize. 2.      Fuel solenoid will de-energize. 3.      Crank output will de-energize. 4.      Overcrank LED will flash five times. Wait two seconds and repeat. 5.      Unit will rest five hours and proceed to the next series.
Intake Heater Energized in Seconds	30
Fuel Solenoid Engaged	Yes
Engine Crank Duration (Seconds)	Up to 15
Engine Rest Duration (Seconds)	25
Series Attempt Number	6	Engine Status: If the engine starts: 1.      Run sequence begins. If the engine fails to start: 1.      Intake heater will de-energize. 2.      Fuel solenoid will de-energize. 3.      Crank output will de-energize. 4.      Overcrank LED will illuminate solid and lock out future crank attempts. 5.      To reset, turn unit power switch OFF and back ON..
Intake Heater Energized in Seconds	30
Fuel Solenoid Engaged	Yes
Engine Crank Duration (Seconds)	Up to 15
Engine Rest Duration (Seconds)	25

2.8         SAFETY DEVICES

Safety devices, such as circuit breakers, fuses, and safety switches protect system components from dam­age.

The AC generator, solid state battery charger, fuel heater, high water temperature, safety relay, total time meter and intake heater are protected by circuit break­ers. If a safety device opens and there is an interrup­tion of electrical current, the electronic governor module will be de−energized, which will also de−ener­gize the fuel solenoid, interrupt the fuel flow to the engine and stop the engine.

In units with auto restart, the engine, engine control devices, and engine monitoring devices are protected by the auto restart module, low coolant sensor (if equipped), circuit breaker, low oil pressure switch, and high water temperature switch. These safety devices monitor system operating conditions and open a set of electrical contacts when an unsafe condition occurs. If a safety device opens and there is an interruption of electrical current, the electronic governor module will be de−energized, which will also de−energize the fuel solenoid, interrupt the fuel flow to the engine and stop the engine.

De−energizing the fuel solenoid shuts off the fuel sup­ply to the engine; thus stopping the engine. Safety device specifications are provided in Table 2–3.

Table 2–3  Safety Devices

ENGINE
Unsafe Condition:	Low engine lubricating oil pressure
	Safety Switch	Low oil pressure switch (LOP) - Automatic reset
	Switch Setting	Opens below 18 psig (1.27 kg/cm)
Unsafe Condition:	High engine cooling water temperature
	Safety Switch	Water temperature switch (HWT) - Automatic reset
	Switch Setting	Opens at 230F (110°C)
Unsafe Condition:	Excessive current draw by the safety relay, fuel heater, water temperature gauge, oil pressure gauge or total time meter
	Safety Switch	Circuit breaker (CB−2) − Automatic reset
	Switch Setting	Trips at 30 amps
Unsafe Condition:	Excessive current draw by the electronic governor module
	Safety Switch	Fuse 1, 2, 3 (replace)
	Switch Setting	Trips at 10 amps
INTAKE HEATER
Unsafe Condition:	Excessive current draw on intake heater circuit
	Safety Switch	Circuit breaker (CB−3) − Automatic reset
	Switch Setting	Trips at 50 amps
BATTERY CHARGER
Unsafe Condition:	Excessive current draw on 12 volt supply circuit.
	Safety Switch	Circuit breaker (CB-4) - Automatic reset
	Switch Setting	Trips at 50 amps
Unsafe Condition:	Excessive current draw on 460 volt feed circuit
	Safety Switch	Fuses BCF3, BCF4, BCF5 (replace)
	Switch Setting	Trips at 5 amps
GENERATOR
Unsafe Condition:	Excessive current draw by load
	Safety Switch	Circuit breaker (CB1, 460 volt) - Manual reset
	Switch Setting	Trips at 26 amps (460 vac)
VOTLAGE CONTROLLER
Unsafe Condition:	Excessive current draw on 460 volt feed circuit
	Safety Switch	Fuses VCF1, VCF2, VCF6, VCF7 (replace)
	Switch Setting	Trips at 5 amps

2.9         UNIT SPECIFICATIONS

1.      Fuel Tanks:
	Nominal Tank Sizes	50 Gallon Steel
	Fill Capacity	52 Gallons (197 liters)
	Draw Capacity	50 Gallons (189 liters)
	Nominal Tank Sizes	50 Gallon Aluminum
	Fill Capacity	52 Gallons (197 liters)
	Draw Capacity	50 Gallons (189 liters)
	Nominal Tank Sizes	65 Gallon Steel
	Fill Capacity	67.5 Gallons (256 liters)
	Draw Capacity	65 Gallons (246 liters)
	Nominal Tank Sizes	80 Gallon Aluminum
	Fill Capacity	85 Gallons (322 liters)
	Draw Capacity	80 Gallons (303 liters)
2.      Weights:
	Battery	63 lb (28.6 kg)
	Generator (A-C)	197 lb (89 kg)
	Engine (Dry) - without Accessories	439 lb (199 kg) approximate
	Unit (with 50 gallon steel tank, dry)	-
	Unit (with 50 gallon aluminum tank, dry)	-
	Unit (with 65 gallon steel tank, dry)	1555lb (705 kg)
	Unit (with 80 gallon aluminum tank, dry)

2.10     ENGINE DATA

1.      Bore /Stroke:	3.26 in. (83 mm) / 4.03 in. (102.4 mm)
2.      Compression Ratio:	22.0 : 1
3.      Cylinders (Number):	Four
4.      Displacement:	135.2 cubic inches (2.22 liters) (2216 cm3)
5.      Firing Order:	1−3−4−2
6.      Lubrication System:	Oil Pressure Safety Switch Setting Opens	18 psig (1.27 kg/cm2)
	Capacity	Engine − 15.0 US quarts (14.2 liters), includes standard filter.
	Oil Level Indicator	Dipstick in oil pan or fill cap To check oil level on engines with the dip­stick mounted in the fill cap, remove the cap and wipe the dipstick clean. Insert the cap back onto the oil fill tube, then remove to check level. It is not necessary to screw the cap back into the fill tube when checking level. DO NOT add oil if level is within the “safe” range. If needed, add oil to bring level within the “safe” range. Screw cap fully into fill tube after checking level.
	Lube Oil Specification	Use a heavy duty lubricating oil conforming to American Pe­troleum Institute (API) Service Classification CF or better.
	Lube Oil Viscosity	Outdoor Temperature
		Fahrenheit: 0°F to 45°F Centigrade: −18°C to 7°C SAE: 10W30 or Mobile Delvac 1*
		Fahrenheit: 45°F and above Centigrade: 7°C and above SAE: 10W30 or 15W40 or Mobile Delvac 1*
		* Mobile Delvac 1, 5W−40 or 15W−40 is the only approved synthetic oil.
7.      Fuel and Fuel Heater Thermostat (FHT):
Fuel	Winter	Diesel No. 2 with winter blends
	Summer	Diesel No. 2
FHT	Winter	Close on temperature fall @ 45+/− 6.5°F
	Summer	Open on temperature rise @ 75+/− 6.5°F
	Power Consumption: 150 Watts @ +/− 10% at 14 VDC
−Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable emission regulations for the area in which the engine is operated. − Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use of ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas. Therefore, please use No.2−D S15 diesel fuel. Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
8.      Intake Heater:	Amperage − 42 amps at 12 VDC
	Resistance (cold) − Approx. 0.3 ohms
9.      Horsepower:	24.8 HP @ 1800 RPM at sea level. (SAE J1995 Gross Power Rating)
10.   Cooling System:	Capacity	6 U.S. quarts (5.68 liters) − includes 1 quart (0.95 liter) in coolant recovery bottle. (Refer to section 4.4.5)
	Anti−Freeze: Extended Life	The cooling system is factory charged with a 50/50 mix of ex­tended life coolant (ELC) and deionized water. This mixture provides protection to −34°F (−37°C). For replacement, with extended life coolant (ELC) meeting ASTM D4656 specifica­tion and deionized water. A 50/50 mix is recommended. Ex­tended life coolant is red or orange in color. DO NOT mix with conventional coolant.
	Water Temperature Safety Switch Setting:
	Opens	230 +/− 5°F (110 +/− 3°C)
	Resets	200°F (93°C) − minimum
	Thermostat:
	Starts to open	177 to 182°F (80 to 84°C)
	Fully open	203°F (95°C)
	Low Coolant Sensor:
	Opens	Los of 32 ounces of coolant or more
	Closes	Refilling of radiator to proper level
11.   Lubrication System:	Oil Pressure	35 to 60 psig (3.3 to 5.2 kg/cm)
12.   Electrical:	Generator	400−500 VAC @ 60 hz 360−460 VAC @ 50 hz