Marine Generators

Marine Generators
Marine Generators
Introduction
KOHLER Marine Genset
1920
KOHLER built the first power generator
1922
The first KOHLER marine application
generator was built in 1922
1948
KOHLER built our very own engine
KOHLER Marine Market Segment
Pleasure Craft
Power boat, Pleasure
craft, Yacht etc
Mega Yacht
Mega Yacht, etc
Work Boat
Work boat, Tug boat,
Pilot boat, etc
Fishing Boat
Commercial fishing
vessel, Leisure fishing
boat, etc
Naval Vessel
Gun boat, Coast Guard,
Unmanned vessel, etc
Barges
Barges, Transportation, etc
Patrol Craft
Patrol boat, Survey boat,
Interceptor, etc
Ferries
Ferries
KOHLER Marine Genset
• KOHLER Marine Generators are specially designed to provide electrical
power for boating applications
• Available in both diesel and gasoline fuel type
• KOHLER designed PowerBoost™ and Fast Response™ voltage
regulators set the standard for steady, reliable power delivery to all
electrical components
• Newly designed, sturdy aluminium sound shield incorporates easily
removable, insulated modular panels to silence the generator
• Each genset is equipped with KOHLER designed & engineered
controller which offers safety shutdown protection to protect your
generator, a running hour meter for managing maintenance intervals,
and various controls including a master control switch and a remote
start/stop capability
KOHLER Marine Genset
• KOHLER provides one-source
responsibility for our generating
systems and accessories
• From alternator to controls, KOHLER
generators are built to last and
designed to perform
• Marine Generators are 100% factory
engineered, built and tested in
KOHLER’s manufacturing facility in
Wisconsin, USA
KOHLER Marine Genset Range
Consumer Marine Genset
• Gasoline – Low CO
o 50Hz & 60Hz
o 4kW to 14kW
Commercial Marine Genset
• Diesel
o 50Hz & 60Hz
o 33kWto 200kW
• Diesel
o 50Hz & 60Hz
o 5kW to 200kW
Genset Controller
•
•
•
•
ADC 2100
ADC IId
DEC3500
Remote Digital
Display
Genset Accessories
•
•
•
•
•
•
•
Siphon Break
Sound Enclosure
Breaker
Murphy Switch
Oil Level Indicator
Remote Panel
Etc…
Gasoline Range
Gasoline Range Features
• Gasoline “Low CO” Generator Family
• 4kW to 14kW, 50Hz & 60Hz
• Suitable for pleasure crafts (cruisers),
houseboats, sport boats, etc
• Environmental friendly – significantly
reduce CO emission by 99%
• Build in CO level detector
• One-side serviceability
• User-friendly controller and remote digital gauge
• Electronic fuel injection system - extremely fuel efficient
• CARB / EPA compliant
• Electronics control modules
10EKD
Gasoline Technology
Engine Control Module
o Continuously monitors and “learns” about the engine’s performance
o Adjust parameters to maintain optimum performance throughout the
engine’s life.
o Optimal performance throughout the entire load range by governing
the speed to maintain constant voltage
o Monitors all engine parameters and provides a closed-loop feedback
communication to the ADC and remote gauge
Advanced Digital Control II
o Designed for today’s most sophisticated electronics
o Easy to read 12 x 2 LCD alpha-numeric display
o Potted boards/sealed connectors for maximum corrosion protection
o J-1939, SmartCraft, NMEA 2000 selectable
o CANbus outputs
o Remote monitoring of fault conditions
o Pushbutton dial for configuration and adjustment
Gasoline Technology
Electronic Sequential Port Throttle Body
o Works with the Engine Control Module to deliver precise
fuel metering throughout the load range of the generator
o Contributes to easy engine starts
Ignition Coil
o Designed for electronic ignition control via digital EST
output
o Ensure maximum reliability, making it ideal for custom coilper-cylinder applications and engine-management systems
Integrated Fuel Pump/Cooler
o A high-pressure pump uses seawater as a cooling medium for the
internal fuel return
o This internal fuel “loop” eliminates vapor lock and the need for an
additional fuel return line
Gasoline Technology
On-board CO sensor
o KOHLER Carbon Monoxide sensor is integral to the generator
to monitors conditions under the deck.
o The ADC can deliver an alarm into the current on-board CO
sensor system for an audible operator warning as needed.
o Generator automatic shutdown when continuous presence
of CO detected.
o Meets UL spec 2034.
Cool Catalyst
o Reduce harmful elements such as hydrocarbon, carbon
monoxide and nitrous oxides in the exhaust gas.
o Keep the surface temperature of the catalyst assembly cool,
significantly reducing heat build-up in the generator.
o Keeps all under-the-deck generator components cool and
therefore, safe to the touch.
Carbon Monoxide Detection
Diesel Range
New & Improved 40kW to 200kW Range
• Industry leading in smallest size, lowest noise, lowest vibration
• Improved engine:
• Transition to EPA Tier III (Certain models)
• Manage engine obsolescence through transition
• Target 50% reduction in engine SKUs, kit rationalization
• New DEC3500 panel-mount paralleling-capable controller
• Redesigned sound shield with improved sound attenuation and cold/hot
air management
• Improved mounting for superior vibration isolation
• Kohler FRX alternator – shorter length, higher outputs
Redesigned Look
“Step” style
sound
shield
“Box”
controller
Dec 3+
Dec550
Engine: 4045DFM70
“Square” style
sound shield
“Panel Mount”
controller
Dec3500
Part Number:
GM51621(12V),
Alternator: FRII
GM51614 (24V)
Model: 4P7B
Tier: II (Non-EPA)
Alternator: FRX
Model: 4P7BX
Engine: 4045DFM70
Part Number:
GM51621(12V),
GM51614 (24V)
Tier Level: II (Non-EPA)
Engine production:
Continues after 1/1/2013
50/60 Hz switchable: No
Legend
Existing part
New part
55EOZDJ with Sound Shield
55EOZDJ with Service Door Removed
Customer Connection Panel
• Easy connection
• Reduce installation cost
• One side connections
FRX Alternator
Major Improved over FRII
• Improved cooling methods resulted in higher outputs / shorter length
• Neodymium magnets in PMG improved forcing, reduced length
• Added a new frame size between the 4P and 4S – more sizing options
• Optional “saddle mounted” junction box for Marine and International
markets
Exciter Size Comparison
FRII Alternator 115mm stack
“FRX” Alternator 25mm stack
Manufacturing Engineering Change
• New exciter winder for 3 phase 20 pole
armature
• Tooling to wind 3 new stator laminations
• Open end turn rotor winding tooling and
technique
• Open end turn stator technique
• Handling high energy magnets
Patent Evaluation
Patent submittal has been made for the open
end turn stator construction
Controllers
ADC2100 Controller
Down Button
7SEG
Alphanumeric
Display
LOP
On / Off
Button
Up Button
Run / Off / Auto Toggle Switch
ADC2100 Controller
•
Features
o
7-segment alphanumeric display
o
Runtime hours
o
Crank status
o
Diagnostics / fault codes / data
o
Monitoring / diagnostics
o
Master control switch
o
Programmable crank cycle
o
SAE J-1939 CANbus output
o
Environmentally protected
o
Potted electronics components and sealed
connectors
o
Interfaces with plug and play 2” remote digital
gauge – TT1450
ADC2100 Controller
•
Diagnostics & Shutdowns
o
High battery voltage (HB)
o
Low battery voltage (LB)
o
High engine temperature (HET)
o
Loss of coolant (LOC)
o
Low oil pressure (LOP)
o
Over-crank (OC)
o
Over-frequency (OF)
o
Under-frequency (UF)
o
Over-Voltage (OU)
o
Under-voltage (UU)
o
Over-speed (OS)
o
Auxiliary fault (AF) - user “defined”
ADCIId Controller
2 x 12 Character LCD Display
On / Off
Button
USB Port
Selector
Knob
Start / Stop
Button
ADCIId Controller
•
Stacked Circuit Assembly
•
Custom Plastic Enclosure
•
Sealed For Reliability
ADCIId Controller
•
Features
o
6kVA to 11kVA diesel marine genset
o
2 Buttons – On / Off, Start / Stop
o
2 Line x 12 character LCD display
o
All user interaction through push button
knob
o
Front accessible USB port
o
Easy setup and installation
o
Quick change over between installations
o
Numerous standard voltage settings
o
Regulator voltage and gain adjustments
o
Download settings through USB port
ADCIId Controller
•
USB host port
•
Power Management
o
Download software
o
o
Download system
parameters
Dedicated power management
microprocessor
o
Capable of shutting down entire
controller
o
Monitors external world –
Repowers electronics as needed
o
Monitors communications lines
o
Upload system history
o
Records the last 100 events
that occurred in the system
o
Includes faults and setting
changes
o
Upload language files
o
Future release
o
o
Instant “ON” when CAN
activity is received
Monitors battery voltage
o
For Issuing Low Battery/High
Battery Warning
ADCIId Controller
•
•
ADCIId controllers consume very low operating and standby power
Power Management
ADC IId Controller
Power draw in sleep mode
100 A
Power draw in “on” mode
235 mA
Off-On transition time
35 mSec
Delay for sleep mode
2 hours
Patented “Hybrid” Voltage Regulator
Digital Regulator
ADC IId Hybrid
Regulator
Item
Analog Regulator
Response Time


Flicker Rejection


Robustness


RMS Measurement


Adjustability


ADCIId Controller
•
Setup & Installation
o
o
Quick Change Over Between Installations
o
Numerous Standard Voltage Settings
o
Regulator Voltage and Gain Adjustments
o
Download Settings Over USB Device Port
Fuel Priming
o
o
Use button interface to start and stop priming operations
Software Updates
o
Update of software thru USB mass storage device or thru USB
connection thru personal computer
ADCIId Shutdowns and Diagnostics
•
System Shutdowns
•
System Warnings
o
Over Voltage
o
Low Battery Voltage
o
Under Voltage
o
High Battery Voltage
o
Over Frequency
o
CO Presence Detected
o
Under Frequency
o
Auxiliary Fault
o
Low Oil Pressure
o
Out Of Fuel
o
High Engine Temperature
o
CO Presence Critical
o
Low/Loss of Coolant
o
CO Detector Fault
o
Locked Rotor Condition
o
CO Detector Missing
o
Over crank
o
Exhaust Temperature Too High
o
Power Limit Exceeded
o
Numerous Engine Sensor Faults
•
Engine Shutdowns
DEC3500 Controller
Emergency
Stop Button
Alarm Silence /
Lamp Test Button
Warning
Light
Off / Reset
Button
Push Button / Rotary
Selector Dial
Fault Light
Auto
Button
Run
Button
USB
Port
Controller Transition
DEC 3+
Box style
DEC 550
Box style
DEC 3500
Panel –mount
Paralleling
Controller Features & Comparison
Controllers
DEC3+
DEC550
DEC3500
``
Standard Features
Analog Gauges and Meters






with Comm. Module


Customization of Parameters


Voltage Regulation Included


Field Current Protection




Digital Graphical LCD Display
LED Status Indicator
Mobbus Local Monitoring (RS-485)
Engine Control Unit Communication

USB Support

Upgradeable Through Front Panel

Extended Engine Information

 JDEC ECU
Controller Features & Comparison
Controllers
DEC3+
DEC550
DEC3500
``
Standard Features
Extended Engine Information

 JDEC ECU
Power Metering


Monitor III Software Capable

 Site Tech
Protectives (Reverse Power etc.)

 Software
EtherNet Remote Monitoring



Potted
Lloyd’s Type Approved


Droop Compensation Method

V bias/ S bias Method

Kohler-only Pgen Method

DEC3500 Features
• Isochronous (real and reactive) load sharing with other DEC3500
equipped generator sets
• Random first-on logic to prevent two or more generator sets from closing
to a dead bus
• Automatic synchronizer with dead bus closing
• Soft loading and unloading
• Protective relay functions include:
• Loss of field
o
Over current
o
Reverse power
o
Over frequency
o
Under frequency
o
Over power
o
Under voltage
o
Over voltage
DEC3500 Features
• Paralleling 3 types
1.
Droop (leverage method from DEC3+ and DEC550)
2.
V-bias and S-bias (leverage method from DEC3+ and DEC550)
3.
P-gen Kohler-only system (external load share module not required)
o
External V-bias and S-bias input from non-Kohler equipment
o
Note: seamless transfer capability included
• Ruggedized Controller Design
o
Potted (encapsulated) for corrosion and vibration protection
o
IO incorporated into board for less failure points
• Future Controller Enhancements
o
Graphical multi-language display
o
Start/stop Key FOB (depending on market demand)
Paralleling Type Explained
• Remote Speed and Voltage Bias
o
Paralleling via Speed and voltage bias requires an external (customer
supplied) load share module
o
Speed and voltage wiring between the load share model and the paralleled
generators is required
o
Synchronizing, load sharing, protective relays, generator management, and
load add/shed functions are provided by the load share module and
switchgear
o
In this case, DEC3500 controller merely provides a control interface and
protective functions for the generator set
• Droop
o
Legacy
Paralleling Type Explained
• PGEN
o
Paralleling via Pgen requires a single communication wire between two
DEC3500 controlled generators.
o
Software includes integrated control for synchronizing, load sharing,
protective relays, generator management, and load add/shed.
o
Fully automatic
Reasons for Paralleling
• Redundancy
• Increased power capacity
• Decreased fuel consumption
• Reduced chance of wet stacking/fuel on water
• Increased reliability
• Greater flexibility
• Individual generators can be serviced in prime power
applications
PGEN Connection
Generator Management
Starts and stops generators based on the requirements of the load.
Start/stop order is determined by one of the following:
o
o
Manual/Fixed
o
Starting order of the generators is determined at the time of configuration.
o
Controllers automatically negotiate to ensure that no two units have the same order number
o
Setting the order number on one controller which conflicts with the order of another controller
will cause the two controllers to exchange order numbers.
Run Time
o
The Start/Stop order is determined based on the run time hours
o
The generator with the most run time hours will stop first.
o
The order of each should reflect the relative run time of that generator if all the generators are
running or all the generators are stopped.
o
The generator with the lowest run time will be started first.
o
Because a generator will not be accumulating run time when it is stopped, it is necessary to add
a stability threshold to each generator which is not running or the generators will start 12 minutes
after they stop (0.2 hours). (Eliminates unnecessary starts and stops)
PGEN Example (with customer-supplied
motorized breakers)
Port Gen
Night Gen
Starboard Gen
Pgen
M
Motorized circuit
breakers – customer
supplied to Kohler
specifications
M
M
Load
to Branch Circuits
Load Distribution Panel – Customer Supplied option
•
•
•
•
•
•
•
Generator voltages must be similar
Any size Deere-powered generator may be used
DEC3500 basic load management functions– prioritize ‘on’ time based on user input for size, hours, fuel levels, & emissions
Controllers communicate to each other over 100 ft.
Single and three phase paralleling available
Seamless transfer to shore power
Customer supplies motorized breakers to Kohler specifications
PGEN Example (with unit mounted
motorized breakers)
Night Gen.
M
Port Gen.
M
Starboard Gen.
M
to Branch Circuits
Unit mounted
motorized
breakers –
Kohler supplied
Paralleling comments
• Generator voltages must be similar
• Any size Deere-powered generator may be used
• DEC3500 basic load management functions– prioritize ‘on’ time based on user input for size, hours, fuel levels, and
emissions
• Controllers communicate to each other over 100 ft.
• Single and three phase paralleling available
• Seamless transfer to shore power
• DEC3500 Controllers can be setup and factory tested in parallel for a nominal fee
DEC3500 Summary
• The First of its kind
• The KOHLER DEC3500 paralleling controller is factory-installed and pre-tested;
patents and certifications pending.
• Huge Savings
• The paralleling software is built in, saving you thousands in equipment and installation
costs.
• Instant Paralleling
• PGEN connection parallels two or more KOHLER generators with a single
communication wire for maximum power potential. Plus the DEC3500 controller is
compatible with existing systems, making repowers easier than ever.
• Remote Monitoring
• Monitor and control generator from anywhere on the vessel — even at multiple
locations.
• Repower-Ready
• When wired for V-bias/S-bias inputs or droop, the DEC3500 controller can parallel with
existing load share modules, providing shipbuilders with even more installation options.
DEC3500 Summary
• Corrosion Protection
• Potted circuit boards and sealed connectors protect the controller against the worst
marine environmental conditions.
• Fewer Failure Points
• Fewer connections makes for better reliability.
• No More Exhaust and Over-Fueling Issues
• KOHLER J-Series generators eliminate under loading and over-fueling — the root
cause of fuel-on-the-water issues. With the DEC3500 paralleling controller when the
first generator’s load is light, the second generator automatically drops off. When the
load is heavy, the second generator automatically comes online and provides the
power needed to carry the load.
• Proper Engine Combustion
• Our electronically controlled high-pressure common rail fuel system provides just the
right amount of fuel at just the right time to eliminate the effects of poor performance
(cylinder wall glazing, engine slobber, etc.)
• Up-Front Money Savings
• No need for expensive load banks, exhaust treatment systems or costly repairs. With
KOHLER, everything is easier and more cost-effective.
Installation Simplicity & Cost Saving
Kohler Paralleling System:
So Advanced, It’s Simple.
• The new KOHLER
DEC3500 paralleling
system eliminates the need
for oversized switchgear,
• costly add-ons and
complicated installations.
Now all you need is a
single communication wire
to parallel two
• or more generators on your
yacht. No switchgear, no
installation issues, no
problem. It’s the first of its
kind
Remote Digital Panel Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Generator status
Voltage (L1-L2, L2-L3, L3-L1, L1-L0, L2-L0, L3-L0)
Current (L1, L2, L3)
Frequency
Average power
Oil pressure
Coolant temperature
Fuel flow
Run time
Battery voltage
Analog input status
System status (i.e. pre-alarms and faults)
Paralleling status screen(s)
Load Management screen(s)
Start/stop control
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