VARNA Products 15 GPM (57 LPM) Prelube Kit for MTU 4000 Series Marine Engines

Transcription

1 VARNA Products 15 GPM (57 LPM) Prelube Kit for MTU 4000 Series Marine Engines Installation and Users Manual For the following Prelube Kits: VARNA Products P/N 6423 Kit for 208 VAC 3 Phase VARNA Products P/N 6863 Kit for 240 VAC 3 Phase VARNA Products P/N 6521 Kit for 480 VAC 3 Phase This manual describes the installation and use of the 15 GPM (57 LPM) VARNA Products Prelube Kits for MTU 4000 Series Engines. This kit contains most of the components required for installation on these engines. Manufactured by VARNA Products division, Transportation Research Corp Business Drive, Cameron Park, CA 95682, USA

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3 Table of Contents Product Description... 4 SAFETY INFORMATION... 5 Prelube Kit Description... 6 Hose Selection... 7 Prelube Pump Installation... 7 Prelube Oil Pressure Switch Installation... 8 Prelube Control Unit Installation... 9 Manual Prelube Operation Semi or fully-automatic operation TROUBLE SHOOTING Table of Figures Figure 1: Wiring the Control Unit Figure 2: Control Box Dimensions Figure 3: Pump Mounting Dimensions Figure 4: Schematic for the VARNA Products Prelube Control Unit Figure 5: Schematic for Remote Push Button Station(s) /27/10 Page 3 of 16

4 Product Description VARNA Products P/N 6523 Prelube Kit The VARNA Products P/N 6523 Prelube Kit includes a 15 gpm (57 LPM) VARNA prelube pump, the VARNA prelube pump Control Unit, a low voltage control wiring set, the engine prelube oil pressure switch and related plumbing, and certain plumbing hardware necessary to install the prelube system on an MTU 4000 series engine. Prelube Kits are available for various voltages. An external check valve is not required and is not recommended for this prelube pump installation. The VARNA CF-15 Prelube pump contains its own integral freeflow check valve. This valve prevents the engine oil pump from forcing oil backwards through the prelube pump when the engine is running. The VARNA CF-15 Prelube pump contains its own integral 50 psi (3.5 bar) pressure relief valve. This valve prevents pump motor overload when the engine starts and the oil pressure from the engine exceeds 50 psi (3.5 bar). Certain installation related components need to be supplied by the installer. These include the power wiring to the Control Unit and the power wiring between the Control Unit and the pump, the oil hoses between the pump and the engine, and any desired remote operator stations. The VARNA Prelube Control Unit provides all the functions for the operation of the VARNA CF15 engine prelube pump. The prelube operation can either be manually controlled by local or remote pushbuttons, or it may be connected to various engine control devices for semi-automatic or fully-automatic prelube control. Control unit installation is quick and easy with all of the external electrical connections on a common rail for easy accessibility. The Control Unit itself has a manual prelube button that, when pushed, operates the prelube pump and illuminates when the preset oil pressure is reached at the prelube oil pressure switch. External connections are provided that allow one or more remote prelube operator stations to be connected to the Prelube Control Unit. The Prelube Control Unit is self contained with a power disconnect switch, a contactor for prelube pump motor operation, and a prelube pump motor protection circuit to protect against phase failure, motor overload, and short circuits. This kit also includes a two conductor cable for connecting to the included engine oil prelube pressure switch, and a four conductor cable for connecting any desired external prelube control signals or pushbutton stations (not-included). Low voltage control circuit components are protected by circuit breakers located within the prelube control cabinet. No spare fuses are required nor needed. 10/27/10 Page 4 of 16

5 SAFETY INFORMATION High voltages in and around this equipment can cause serious or fatal injury. Installation, maintenance, or repair should be done by qualified personnel. Improper use of this equipment can cause serious or fatal injury. WARNINGS and CAUTIONS WARNING The prelube pump output pressure hose to the engine is pressurized by the engine oil pump at all times while the engine is running. A hose capable of containing 150 psi (10 bar) engine lubrication oil at 275 F (135 C) must be used. Failure of this hose can drain the engine of oil and cause serious or fatal burns. WARNING This equipment operates on 460 VAC. Only qualified personnel should install or maintain this equipment. Before working on this equipment make sure that ALL power to this equipment has been disconnected and that no other sources of power exist that may create an electrical shock hazard within this equipment. Electric shock can cause serious or fatal injury. WARNING This equipment uses both high voltage power and low voltage control. Note that the high and low voltage systems are isolated from each other. Crossing or other misuse of these systems can create serious electrical shock hazards in remote locations outside of this equipment. Electric shock can cause serious or fatal injury. WARNING This equipment can be accidentally or purposely remotely operated at any time. Always insure that all means of energizing this equipment have been locked out or otherwise disabled during installation and maintenance of the prelube pump. Unexpected prelube pump operation during installation and maintenance can cause electrical shock hazards or entanglement in moving or rotating parts resulting in serious or fatal injuries. CAUTION The prelube pump can be accidentally or purposely remotely operated at any time. Make sure that all means of energizing the prelube pump are locked out or otherwise disabled before changing oil filters, disconnecting the associated oil lines, or maintaining any other equipment that may cause oil spillage by unintended prelube pump operation. CAUTION Maximum vibration in the 10 to 55 Hz. range is 1 g RMS. Excessive vibration can damage the control box. The control box must be mounted in locations that do not receive direct vibration from the engine or other sources. CAUTION It is always good practice to completely install the prelube pump and hoses to the engine prior to connecting power to the motor. CAUTION The source panel must provide suitable circuit protection to protect the cable between the source panel and the Prelube Control Unit. 10/27/10 Page 5 of 16

6 Prelube Kit Description The Varna Products 6523 Prelube Kit includes two major components. The first is the VARNA Products CF-15 engine pre-lube/post-lube pump with internal check and pressure relief valves. The second is the Prelube Pump Control Unit complete with a power disconnect switch, prelube pump motor protection, and a manual prelube button. This kit also includes the necessary support components such as cord grips for the electric cables, the small electric cables for connecting the pressure switch and remote control station, and various plumbing fittings for connecting the prelube pump to the engine. The following is a complete list of the components contained in this kit: P/N NAME/DESCRIPTION 6085 CF-15 prelube pump for /460 V 3Ø AC operation VAC Prelube control Unit Prelube Oil Pressure Switch Cable, 30 Feet (9.1 Meters) Remote Control Cable, 20 Feet (6.1 Meters) Prelube Oil Pressure Switch Pressure Switch Connection Tee ¼ inch straight thread pump fitting (Parker 20FOX) inch straight thread pump fitting (Parker 16FOX) ¼ inch NPT engine fitting (Parker 20-16FTX) inch NPT engine fitting (Parker 16FTX) 6407 MTU 4000 series Engine Pressure Port Fitting each M10-1.5x40 class 8.8 Cap Screw P/N P/N P/N 6085 P/N 6423 for 208VAC 3 Phase P/N 6863 for 240VAC 3 Phase P/N 6521 for 480VAC 3 Phase P/N 6433 P/N 6443 P/N 6287 P/N 4814 P/N 6444 P/N 6445 P/N x P/N /27/10 Page 6 of 16

7 Hose Selection The engine oil can reach temperatures of 275 F (135 C). Both the pressure and suction hoses for the prelube pump must be rated for engine lubrication oil at a minimum of this temperature. The pressure hose must also be rated for 150 psi (10 bar) working pressure or better. Prelube Pump Installation 1. Location of the CF-15 prelube pump a. The best elevation for installing the CF-15 prelube pump is at or just above the normal engine oil level. Installation drawings are shown in Figure 3. b. The motor should be horizontal. The base can be down, up or at any angle. The pump can be repositioned on the motor to any of four positions. c. Locate a suitable port in the engine oil pan for connecting the prelube pump suction hose. Also locate a suitable engine oil pump outlet port for the prelube pump pressure hose connection. Be aware that similar ports may serve different functions. Consult the engine documents to determine the proper port. d. The prelube pump location should minimize the length of the pump inlet hose. The shorter the pump inlet hose the better the pump performance in cold weather. Call VARNA Products engineering department at Pacific Time for information on suction lines longer than 4 feet. e. Other locations for the prelube pump are workable but may compromise the pump performance somewhat. If there is any question, please contact VARNA Products engineering department at Fabricating the suction hose from the engine pan to the pump. a. Engine oil can reach temperatures of 275 F (135 C). The suction must be rated for engine oil at this temperature. b. The suction hose length and diameter are important to pump performance. A suction hose longer than 4 feet (1.2 Meters) will reduce the performance of the pump increasing the time for prelubing the engine. A suction hose diameter smaller than 1 1/4 inches will severely reduce prelube pump performance. Call VARNA Products engineering department at Pacific Time for specific installation information about your installation. c. Make up a 1-1/4 inch diameter hose that extends from the engine oil pan port to the pump inlet port with female JIC fittings on both ends. 3. Fabricating the pressure hose from the pump to the engine. a. WARNING THE OUTPUT PRESSURE HOSE FROM THE PUMP TO THE ENGINE IS PRESSURIZED BY THE ENGINE OIL PUMP AT ALL TIMES WHILE THE ENGINE IS RUNNING. A HOSE OF ADEQUATE DESIGN CAPABLE OF CONTAINING 150 PSI ENGINE OIL AT 275 F (135 C) MUST BE USED IN THIS LOCATION. FAILURE OF THE PRESSURE HOSE CAN DRAIN THE ENGINE OF OIL AND CAUSE SERIOUS OR FATAL BURNS FROM SPRAYING HOT OIL. 10/27/10 Page 7 of 16

8 b. Using the proper quality hose material, make up a 1-inch diameter hose from the pump pressure port to the engine pressure port with female JIC fittings on both ends. While this pressure hose is less sensitive to length than the suction hose, it is always good practice to create a clean installation with no extra length of hose to get into the way. 4. Connecting the prelube pump and hoses to the engine. a. While it is possible with some oil spillage for the creative mechanic to install these fittings and hoses without first draining the oil, it is highly recommended that the engine be drained of oil prior to this operation. b. Mount the pump in its intended location. c. Install P/N 6287 and P/N 6288 connector fittings into the prelube pump. d. Replace the engine oil pump outlet port cover with the VARNA P/N 6407 adapter using the three P/N 6509 bolts supplied. Be aware that similar ports may serve different functions. Consult the engine documents to determine the proper port. e. Install the P/N 6445 adapter into the P/N 6407 adapter plate. f. Install the P/N 6444 adapter into the engine oil pan. g. Connect the suction hose from the oil pan fitting to the pump inlet port. h. Connect the pressure hose to the pump outlet port fitting. i. Fill the pressure line with clean engine oil. This makes sure that the pump has some oil to lubricate its parts and reduces the amount of air pumped into the engine during initial startup. j. Connect the other end of the pressure line to the pressure port fitting on the engine. Prelube Oil Pressure Switch Installation 1. The prelube oil pressure switch is installed at the same location as the engine oil pressure switch. 2. Disconnect and remove the existing engine oil pressure switch. It will be reinstalled later on the running port of the tee. 3. Install the VARNA P/N 6443 pressure switch connection tee in the pressure switch port. 4. Install the VARNA P/N 6433 prelube pressure switch into the side port of the pressure switch connection tee. 5. Install the Tee in to the engine oil pressure port. 6. Reinstall the engine oil pressure switch into the end port of the tee. 7. Reconnect the engine oil pressure switch electrical connection. 8. See Installation of The Prelube Control Unit on page 9 for instructions on connecting the prelube pressure switch wire. 10/27/10 Page 8 of 16

9 Prelube Control Unit Installation 1. Locate the Prelube Control Unit in an appropriate location for electrical equipment associated with the engine. There are cable grips installed for the power cable from the power source to the Control Unit and for the motor cable from the Control Unit to the Prelube Pump Motor. For mounting dimensions, see Figure Install the two 4-conductor power cables (user supplied) to and from the Prelube Control Unit. a. The minimum conductor size for these power cables is 16 AWG (1.5mm 2 ). Note that larger conductor sizes may be dictated by the length of the run, by the circuit protection device in the source power panel, by specific codes, or by standard practice. b. Connect the first 4 conductor power cable from the 460 VAC 3 phase source panel to the blue L1, L2, L3, & Ground terminals inside the Prelube Control Unit. c. Connect the second 4 conductor power cable from the gray T1, T2, T3, & Ground terminals inside the Prelube Control Unit to the appropriate Prelube Pump motor terminals for 460 Volt operation. 3. Install the prelube oil pressure switch cable from the Control Unit to the prelube oil pressure switch at the engine. a. This is the 30 foot (9.1m) long 2-conductor VARNA P/N cable supplied with this kit. Install the end the cable with the sheath cut back about 5 inches into the right front cord grip and connect the wires to the two orange connectors as shown in the Figure 1 on page 9. b. This cable is routed from the Control Unit to the Prelube Oil Pressure switch previously installed on the engine. The black wire is connected to one of the terminals on the Prelube Oil Pressure Switch and the white wire is connected to the other terminal. 4. Remote prelube station(s). a. If a remote control device is not used, remove the front left cord grip and close the hole with a suitable plug. b. A 20-foot (6.1m) long 4-conductor P/N cable is supplied in this kit. Install the end with the cable sheath cut back about 5 inches (125mm) into the right front cord grip and connect the red, green, black, and white wires to the red, green, black and white set of connectors also shown in Figure 1. c. Rout this cable to the location of the remote prelube station. If necessary, this cable can be extended by attaching an additional length of AWG-16 (1.5mm 2 ) wire. Note: The maximum length of AWG-16 (1.5mm 2 ) cable from the Control Unit to furthest remote switch is 44 feet (13.4m). Longer cables may result in insufficient current to operate the contactor in the Prelube Control Unit. d. At the remote location, use a switch or relay to contact the white wire in the Control Cable to the Black wire in the same cable. While the switch or relay 10/27/10 Page 9 of 16

10 is closed, the Prelube Pump will run. NOTE: The current draw through the switch or relay will be about 400 ma steady with a 4 Amp inrush. The voltage across the open switch or relay contacts will be approximately 24 VAC. e. Optional: Connect the green and Red wires in the Control Cable to a 24 Volt rated pilot lamp. When the prelube pump is running, the prelube button lamp will indicate that the preset oil pressure has reached at the prelube pressure switch. This signal may also be used to energize a 24 VAC relay to signal an automated engine control that the preset engine prelube oil pressure has been reached. 5. Verify that the Prelube Pump is installed and plumbed according to its installation instructions. 6. Turn on the power source to the Prelube Control Unit. 7. Turn the Manual Disconnect on the Prelube Control Unit to the ON position. 8. Verify the pump rotation by quickly tapping the RUN PRELUBE button on the Control Unit and visually checking the rotation of the fan in the motor. The pump motor must rotate counterclockwise when viewed from the fan end. 9. Verify that there is oil in the engine sump. 10. Push and hold the RUN PRELUBE button on the Control Unit. The prelube pump will run until the button is released. The lamp will illuminate when the preset engine prelube oil pressure has been reached at the prelube pressure switch. The Remote Prelube Operator station wires connect to the BLACK, WHITE, RED, and GREEN terminals here. The Power wires from the Source Panel connect to the BLUE terminals here. The Prelube Oil Pressure Switch wires connect to the ORANGE terminals here. The Power wires to the Prelube Pump motor connect to the GRAY terminals here. Figure 1: Wiring the Control Unit 10/27/10 Page 10 of 16

11 Manual Prelube Operation 1. The engine prelube pump can be operated by pushing the prelube button on the control box. Additionally, the prelube pump can be operated at any of the optional remote prelube operator stations. 2. The Prelube pump will run while the button is pushed or the black and white wires in the control cable are connected by a switch or relay. 3. When the preset prelube oil pressure is detected at the engine prelube pressure switch, the button lamp will light. Note: The lamp is optional in remote prelube operator stations. Semi or fully-automatic operation The VARNA Products Prelube Control Unit has three external control signals that can be used to operate the prelube pump and report the state of the engine prelube pressure switch. 1. The first signal is the Pressure Switch Signal. It is an input signal to the Prelube Control Unit from the engine Prelube Pressure Switch. A contact closure between the two orange connector blocks in the Prelube Control Unit while the prelube pump is operating will illuminate the button lamp in the control unit and any connected remote lamps. Relays may be connected to the lamp circuit to signal external equipment of this event. 2. The second signal is the Operate Pump Signal. It is an input signal to the Prelube Control Unit from a remote switch or a relay contact closure that is used to run the prelube pump. A contact closure between the White and Black connector blocks in the Prelube Control Unit will cause the prelube pump to run. The prelube pump will continue to run until the contact closure opens. 3. The third signal is the Prelube Complete signal. It is a 24-VAC output signal from the Prelube Control Unit used to illuminate any connected button lamps, other lamps and/or relays. It is on the Red and Green connector blocks in the Prelube Control Unit. This signal is derived from the Pressure Switch signal. 10/27/10 Page 11 of 16

12 Figure 2: Control Box Dimensions 10/27/10 Page 12 of 16

13 Figure 3: Pump Mounting Dimensions 10/27/10 Page 13 of 16

14 Figure 4: Schematic for the VARNA Products Prelube Control Unit Figure 5: Schematic for Remote Push Button Station(s) 10/27/10 Page 14 of 16

15 TROUBLE SHOOTING 1. The button does not illuminate and the Prelube Pump does not run: a. Check that the circuit breaker to the Prelube Pump Control Unit is on. It might be tripped or turned off. b. Check that the disconnect switch on the Prelube Control Unit is on. It might be tripped or turned off. i. If the disconnect trips immediately upon pushing the prelube button, verify that each of the 3 phase power lines into to the Prelube Control Unit has power. Also check for broken or shorted wires leading to the prelube pump motor. ii. If the disconnect switch trips after 3 or more seconds, check for a jammed pump or failed motor. c. Check that the low voltage component protection circuit breakers are on. They are located inside the Prelube Control Unit on the right side. To reset the duel circuit breaker force the blue lever down into the off position and then back to the on position. The button circuit breaker will pop out when tripped. To reset it, push the button back in. A miswired Remote Control station or shorted remote station wires will cause one or both of these circuit breakers to trip. 2. The pump runs but the button lamp does not illuminate to indicate prelube pressure at the engine. a. Verify that there is adequate oil in the engine. Note: Changed oil filters or other maintenance may require a longer prelube time to purge the filters and oil lines. b. Check if maintenance has been performed that would allow air in the oil lines to the pump. While the pump will self prime, it may take some time. c. Check if the engine is hot and therefore the oil is thin. Oil may be present in the engine but thin oil could be flowing through the bearings and other oil paths faster than the prelube pump can supply it. Oil is flowing through the engine but it does not produce enough pressure to operate the prelube pressure switch. d. Check for a failed button lamp. e. Check for breaks or disconnects in the wires to the prelube oil pressure switch. f. Check for leaks in the Prelube Pump suction line and fittings. These leaks are hard to find. A relatively small suction leak can keep the pump from priming. g. Check for proper prelube pressure switch setting. h. Check that the prelube oil pressure switch is functioning properly. 3. The button light turns on immediately when the button is pushed (no delay while the engine is filling with oil). a. Check if the engine is running and therefore oil pressure is already present. b. Check for shorts in the wiring to the prelube oil pressure switch. c. Check that the prelube oil pressure switch is functioning properly. d. Check for proper prelube pressure switch setting. 4. The prelube pump runs whenever power is applied to the control unit. a. Check for shorted wire(s) to the remote prelube station. b. Check for shorted or miswired remote prelube cable at the Control Unit or at the remote prelube station. 10/27/10 Page 15 of 16

16 VARNA Products Phone #: Business Drive Cameron Park, CA USA Industrial Oil & Fuel Pumps & Control Kits for: Prelube Transfer Drain/Fill 10/27/10 Page 16 of 16