Onan Ensign 4500 User manual

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MCE
Ensign
Series
4500/6500
Printed
in
U.S.A.
927-0600
8-93

Safetv
Precautions
Before
operating
the
generator
set,
read the Operator's
Manualandbecomefamiliarwithitandyour
unit.
Safe
andeffl-
cient operation
can
be
achieved only
if
the
unit
is
properly
operated
and
maintained.
Many accidentsarecaused
byfail-
ure
to
follow
fundamental
mles
and
precautions.
Thruugkout
this
manualyou
will
noticesymbolswhichalert
you
to
potenliaHy
dangerousconditions
to
theoperator,service
per-
sonnel,
or
the
equipment
itself.
.
l'
This
symbd warns
of
immediate
haz-
ards which
wiil
result in
severe
personal
fnjury
or
death,
EWARtMG,
This
symbol
refersto
a
hazardorunsafe
practicewhichcanresuitinseverepersonalinjury
or
death.
l%~cAu-tror\l
Thls
symbol
refers
to
a
hazard
or
unsafe
practh?
whichcanresultinpersonalInjuv
or
prod-
oct
or
property
damage.
FUEL,
ENGINE
OIL,
AND
FUMES
ARE
FLAMMABLE
AND
TOXIC.
Fire,
explosion,andpersonalinjurycan resultfrom
im-
proper practices.
Benzene and lead, found
in
some gasoline,
have
been
identified
by
some state and federal agencies
as
causing
cancer
Or
reproductive toxicity. When checking,draining
or adding gasoline, take care not
to
ingest, breathe the
fumchs,
or
contact gasoline.
Used
engine
oils
have
been identified
by
some state or
federal
agencies
as
causingcancgr
or
reproductive toxic-
ity.
When
checkingorchangingengine
oil,
take
care
not
to
ingest,
breathe
the
fumes,
or
contactused oil.
Do
not
fill
fueltankswiththeengine
running.
Do
not smoke
around
the
generator set area. Wipe up
any
oil or gas
spills.
Do
not
leave
oily
rags
in
enginecompartment or on
the
generator
set.
Keep
this
and surrounding area clean.
InsprxAfuel
system
beforeeachoperationand periodically
while
running.
Equip the engine
fuel
supply
with
a
positive fuel shutoff.
Always
disconnect
the
battery
ground
(-)
lead
first
and
re-
conmct
it
last. Make
sure
you connect
the
batlery
cor-
rectly.
A
direct short across the battery terminals
can
CPUSCI
anexplosion.
Do
not smokewhile servicingbatter-
ies.
Hydrogen gasgiven
off
during charging
is
very
explo-
sive.
Keep
a
fire extinguisher available
in
or near the engine
cornpa-tment and
in
other areas throughout
tke
vessel.
Use the correct
ex?inguisher
for the area. For most
types
of
fires,
an
extinguisherrated
AB6
by
the
NFPA
is
avail-
able
ancl
suitablefor
use
on
all
types
of
firesexceptalco-
hol.
EXHAUST
GASES
ARE
DEADLY
e
Provide adequateventilation. Equipthebilge
with
a
power
exhauster.
Be
surepropuhion
and
generatorset engineexhaust
zys-
ternsare
free
of
leaks. Perform
thorough,
pcriodrc
in:pec-
tions
of
the
exhaust
system
and
repair
leaksimmedistsly.
E:<haust
gases
are deadly.
Never sleep
in
the
vessel
with
the
generator
set
running
unless
the
vessel
is
equipped
with
an operating carbon
monoxide detector.
,
HOT
COOLANT
CAN
CAUSE
SEVERE
PERSONAL
INJURY
Hot
coolant
is
under pressure.
Do
not
loossn
the
coolant
pressure
cap
while
the engine
is
hot.
Let
the
engina
coal
before
opening
the
pressure cap.
MOVING
PARTS
CAN
CAUSESEVERE
PERSONAL
INJURY
OR
DEATH
Do
not
remove
any
belt guardsor covers
with
the
genm-
tor set
running.
Keep hands and
loose
clothing awayfrom moving
parts.
Do
not
wearjewelry while servicing
any
part
of
the
genera-
tor
set.
Never step
on
thegsneratorset(aswhenentering
or
leav-
ing
the enginecompartment).
It
canstressand break
unit
components, possible resulting
in
dangerous operating
conditions.
.
from
leaking
fud,
leaking exhaust fumes,
etc.
Before performing any maintenanceon thegerierator
cet,
disconnect
its
batteriesto prevent accidentalstarting.
do
not disconnector connectbattery
cables
if
fuel vapors
are
present. Ventilatethe generator
set
compartmentor
bilge
thoroughly
with
the power exhauster.
ELECTRICAL
SHOCK WILL
CAUSE SEVERE
PERSONAL
INJURY
OR
BEATH
Do
not
make adjustments
in
the
controlpanel
or
on
engine
with
unit
running.
High voltages
are
present.
Work
that
must
be
done
while
unit
is
running
should be doneonly
by
qualified
service
personnel
standing
on
dry
surfaces
to
re-
duce shock hazard.
.
DO
NOT
CONNECT
THE
GEldEFWTOR
SET
TO
THE
PUBLIC
UTILllY
OR
TO
ANY
OTHER ELECTRICAL
POWER
SYSTEM.
Etectrocuti
n
or damage
to
property
can occur
at
a
sita
remote
from the
boat where
line
cor
equipmentrepairs are being
made
if
the
st
is
connected
tothe
power
system.
An
approved
bander
switch
mu3
be
used
if
more
than
one
power source
iz
to
be
made
avail-
able
to
servicethe
boat.
Do
not workonthisequiprnentwhen
~enfa:llyor
physically
fatigued,
or
after consuming
any
alcohol or
drug
that
makes
the
operation
of
equipmmt
unsafe.
bit
8
Copy
and
post
these
suggestloris
in
potential
hazard
areas
of
the
vessel.

Table
of
Contents
SECTION
TITLE
PAGE
1
.
2
.
3
.
4
.
5
.
6
.
7
.
8
.
9
.
10
.
SAFETY PRECAUTIONS
...............................
Inside
Front
Cover
INTRODUCTION
...................................................
1-1
General
.........................................................
1-1
Installation Codes and Safety Recommendations
........................
1-1
Generator
Details
.................................................
2-1
Engine Details
...................................................
2-1
Location
........................................................
3-1
Mounting
........................................................
3-1
General
.........................................................
4-1
Requirements
....................................................
4-1
Coast
Guard
and
NFPA
Requirements
................................
4-1
General
.........................................................
5-1
Heat Exchanger Cooling
............................................
5-1
SPECIFICATIONS
..................................................
2-1
LOCATIONAND MOUNTING
.........................................
3-1
VENTILATION
.....................................................
4-1
COOLING SYSTEM
.................................................
5-1
SeaWater Cooling
................................................
5.3
Combined Cooling Systems
.........................................
5.3
EXHAUST SYSTEM
................................................
6.1
General
.........................................................
6.
1
Below Load Waterline
Installation
....................................
6-3
Above
Load Waterline Installation
....................................
6-4
FUELSYSTEM
....................................................
7.1
General
.........................................................
7-1
Installation
......................................................
7.1
Fuelianks
......................................................
7.2
Fuel tines
........................................................
7.3
SiphonProtection
.................................................
7-3
FuelSystemTest
.................................................
7-3
ELECTRICALSYSTEM
..............................................
8-1
General
.........................................................
8-1
Load
Connections
..................................................
8-1
Remote
Starting
Controls
...........................................
8-4
Batteries
........................................................
8-4
Installation
Checks
................................................
9.1
Initial Starting
and Checks
..........................................
9-1
FINAL INSTALLATIONCHECKS
......................................
9.1
DC
WIRING
DIAGRAM
.............................................
10-1
i


Section
1.
Introduction
GENERAL
Eachmarinegeneratorset mustbeinstalledproperly
if
it
is
to
operate reliably, quietly, and most important
-
safely. Therefore, readthisentire manual beforestarting
the installation. The manual should be used only as a
guide as each installation must be considered on an
individualbasis. Foroperationand maintenanceproce-
dures, refer to the MCE Operator‘s Manual
927-0124
which accompanieseach unit
Proper installation is very important Requirements to
consider should include:
Adequate cooling air
a
Adequate combustionair
a
Discharge
of
exhaust gases
a
Discharge
of
circulatedair
Electricalconnectionsand bonding
Fuelconnections
Seawater connections
a
Accessibility for operationand servicing
a
Level mountingsurface
a
Adequate support under mounting points
a
Noiselevels
INSTALLATION
CODESAND SAFETY
RECOMMENDATIONS
The insthation must follow recommendations of the
American Boat and Yacht Council (ABYC) and the
National FireProtectionAssociation (NFPA).
The installer should be familiar with and follow the
appropriate guidance found in the following
publications:
ABYC
“Safety
Standards
for
Small
Craft”from:
ABYC
15
East
26th
St
NewYork, NY
10010
NFPA302
“Fire
Protection
Standard
for
Motor
Craif”from:
NFPA
470
AtlanticAvenue
Boston, MA
02210
USCG 33CFR183from:
U.S.
GovernmentPrintingOffice
Washington, D.C.
20404
~AWARNING
1
INCORRECT SERVICE
OR
REPLACEMENTOF PARTSCANRESULT IN SEVERE
PERSONAL INJURY, DEATH, AND/OR EQUIPMENTDAMAGE. SERVICE PER-
SONNELMUSTBE QUALIFIEDTOPERFORMELECTRICALAND/OR MECHANI-
CALSERVICE.
1
=I


Section
2.
Specifications
GENERATOR
Type
................................................
RevolvingField,4-Pole, Self-Excited
Standby Ratings:
60 Hertz, 6.5 MCE
...........................................
6.5
kW, (6.5 kVA
@
1.0
PF)
60 Hertz, 4.5 MCE
...........................................
4.5 kW, (4.5 kVA
@
1.0
PF)
50
Hertz,
5.0
MCE
...........................................
5.0
kW,
(5.0
kVA
@
1.0 PF)
AC VoltageRegulation
.............................................................
+5%
Frequency Regulation
......................................................
.5%
(3 Hertz)
ENGINE
EngineType
............................................
Onan@MCE, 2-Cylinder Opposed
EngineSpeed (r/min)
.........................................................
I800/1500
Exhaust Outlet HoseSize
...............................................
.2.0 in. (50.8 mm)
Fuel..
..............................................................
Unleaded, 88 octane
FuelInletSize..
............................................................
.1/4-18 NPT
FuelConsumption, Average
@
FullLoad:
60 Hertz, 6.5 MCE
....................................................
1.3 gph
(5.0
Lph)
60 Hertz, 4.5 MCE
....................................................
1.6 gph
(6.1
Lph)
50
Hertz,
5.0
MCE
....................................................
1.1 gph (4.2 Lph)
FuelInletSize..
.........................................................
1/4-18 NPTF
FuelReturnOutletSize
...................................................
.1/8-27 NPT
MinimumColdCrankingAmps
@
0°F (-18°C).
......................................
360
Voltage
...........................................................................
12
Capacity, Heat ExchangerSystem..
....................................
.10 Quarts(9.4 L)
Heat Rejection:
60 Hertz
@
Load, Block
&
Exhaust Manifold..
............................
800 BTU/min
50
Hertz
@
Load, Block
&
ExhaustManifold..
............................
650 BTU/min
HeatExchangerSystem,ThermostatOpen
.........................
.2.2 gpm (8.3 L/min)
Sea Water, HeatExchangerSystem
..............................
.3.0 gpm (11.4 L/min)
SeaWater CoolingSystem
......................................
-3.0
gpm
(1
1.4 L/min)
Heat ExchangerSystem,ThermostatOpen
.........................
.2.2 gpm (8.3 L/min)
SeaWater, HeatExchangerSystem
...............................
.2.5 gpm(9.5 L/min)
SeaWater CoolingSystem
.......................................
.2.5 gpm (9.5 L/min)
SeaWater Pump
Dry
Lift, Maximum
............................................
3
ft
(0.9 m)
TotalAir Required(Generator Coolingand Combustion):
60 Hertz..
....................................................
.146 ft3/min (4.1 m3/min)
50
Hertz
....................................................
120cu. ft./min (3.4 m3/min
EngineOil Capacitywith Filter
............................................
.3Quarts
(2.8
L)
Battery Requirements:
CoolingSystem:
CoolingFlow Rate, 60 Hertz:
CoolingFlow Rate,
50
Hertz:
2-1


Section
3.
Location
and
Mounting
LO
CAT1
ON
Generatorsetlocationispreferableinthesameroomor
compartmentasthepropulsionengine,asthisisusually
a
well
ventilatedarea,insulated,closetothefuelsupply
andisthecenterofelectricalloaddistribution. However,
a generator set cannot be installed in the propulsion
enginecompartmentunlessspecificconditionsaremet.
USCG
regulation
33CFR183
pertainsto gasoline fuel
systems, and requiresa generator set operating in a
gasoline fuel environment to be “ignition protected.”
This means aset capableof operatinginan explosive
environmentwithoutignitingthatenvironment. Properly
installed and operated, the
MCE
generator set can
operate inan explosive environment.
Gasolinefireorexplosioncanresult
inseverepersonaliniuryordeath.
Do
notinstallagasolinegeneratorsetinthesameroomor
compartment
of
a
dieselpropulsionengineorgenerator
set. Thediesel unitmay not be ignifionprotected and
mayignitegasolinefumes.Besure
a
gasolinegenerator
set
is
insfalledin its own room or compartment.
MOUNT1
NG
Thefloormustbeflatandgivesupportdirectlyunderthe
genset mounting points (Figures
3-1
and
3-2).
A
one
inch
(25
mm)
clearance aroundthe unit is requiredto
permit rockingon its mounts without restraint; and
4.2
inches
(106
mm) for servicingthe oil filter. Additional
spacemustbeallowedforproperventilationforcooling
and combustion,as well as serviceaccess.
Also
allow
accessfor periodicmaintenancesuchasoilfill,coolant
fill,
spark plug replacement, etc. The entire exhaust
system must be accessible
so
a periodic visual and
audiblecheckfor leakagecanbemadebytheoperator.
Install
two
hold-downclampsortwothroughboltstothe
drippanon bothsidesof thegeneratorset.Tightenthe
clamps securelyto the mounting base with bolts and
flatwashers.
Selecta locationthat will allow adequate space on all
sidesfor ventilationand servicingtheset, preferablyon
andparallelwiththekeelorvessel center line. Keepthe
generator set awayfrom livingquarters, andaway from
bilgesplash and vapors.
3-1

2
(i
I
3
FIGURE
3-1.
DRIP
PAN
DIMENSIONS
DIMENSIONS
IN
(
4.k
"i"
)
ARE
METRIC
3-2

(HEAT EXCI
SIDE
VIEW
NOTES
I
I
.DIMENSIONS IN
t
l
ARE
MILLIMETERS
2.DRY
WEIGHT! 335
LBS
(152
Kgl
COOLANT
FILL
iANGER
MODEL
ONLY)
C
CONNECTION
.I2
(d
HOLE(FARSIDE1
FRONl
IL
FILL COOLANT FILL
(HEAT
EXCHANGER MODEL ONLY1
1.19
4
I
/WET
EXH!
1
’
18.04(30.2)
{
20.43
4
l518.9)
2.00
ID
HOSE 20.25
(50.8) (458.31 4.18
(106.2)
OIL
FILTER
REMOVAL
(514.3)
FIGURE
3-2.
OUTLINE DRAWINGS
3-3


Section
4.
Ventilation
GENERAL
Theinstallationofboatventilationsystemsmustmeetall
Coast Guardand
NFPA
requirements. Establishingthe
correct
air
flow quantity
is
particularlyimportantwith
small compartments under 1000cubicfeet
(28
m3), or
installationsinclosequarters. Ventilationsystemsmeet-
ingCoast Guard requirements for gasolineengines in
passenger vessels (Table 4-1) will normally suffice,
however specialconsiderationmust begivento com-
partment conditionsduring operation.
TABLE
4-1.
PASSENGERVESSEL
VENTILATION REQUIREMENTS
SIZE
OF
MINUTESREQUIRED
COMPARTMENT TO EXCHANGETOTAL
Cu.
Ft.
(m3)
AIR VOLUME
Less
than
500
(14)
2
500
to
1000 (14
to
28)
1000
to
1500(28
to
42)
1500
and
Up
(42
and
Up)
3
4
5
REQUIREMENTS
Marinegeneratorsetsmusthaveairventilationforthree
very important reasons:
1.
Toremoveflammableorotherharmfulgases.
Coast
Guard regulations require power blowers in the
generator set and propulsionengine rooms be run
atleastfourminutespriortostartingtheengineand
during operation. The operator must also inspect
the engine room
for
the presence
of
fuel vapors
prior to starting, especially when gasoline fueled
equipmentisused(seetextunderCoastGuardand
NFPA
Requirements).
2.
To
provide engine combustion
air
and generator
coolingair.
CoastGuardregulationsrequirepower
exhausters in all installations, and one blower in
each exhaust duct. Exhausters must have an air
capacity
1-1
/2
to
2
timesthe minimum generator
set total air requirements. The
MCE
generator set
requiresatotaloperationminimumof 146cubicfeet
perminute
(4.2
m3/min).
3.
To
control compartment temperature during
gensetoperation.
Thiswillavoidoverheatingwhich
can resultinshutdownfromvapor lock,engineand
related control component damage, and power
loss.
As
a general rule, the operating environment
for a gasoline genset should not be higher than
14OOF (60OC) maximum. Lower temperatures are
recommended. Often an operating power blower
mayberequiredto maintaintemperaturewhenthe
gensetisoperating, especiallywhen theboat isnot
moving.
The compartment must have air inlets and outlets to
providethis air. Inletducts shouldhave cowlsor equi-
valentfittings of twicethearea of the duct, largerifthe
opening
is
screened.
Do
not use recessed
or
flushed
inlets,or louveredtransom outlets.
Ifthegasolinefueltankisinaseparatecompartment,
it
also must beventilated.
COAST
GUARD
AND NFPA
REQUIREMENTS
Bothorganizationsrequireat least
two
inletductsand
two
outlet ducts extending to the bilge for gasoline
generator set installations in
a
closed Compartment.
When not in a closed compartment, at leastone duct
shouldbe installedinthe fore section of the boat and
another aft. The
NFPA
recommends a vent size of at
least
two
square inches per foot
(42.3
cm2/m) of boat
beamfor totalinletarea andtotaloutetarea.
BoatsclassifiedaspleasurevesselsbytheCoastGuard
musthavesufficientventilationto eliminateaccumula-
tionofflammablegases. Boatsunder
65
feet
(20
m) long
classifiedas passenger vessels requireventilationbe
sufficienttochangethe compartmentairwithinagiven
time interval(Table 4-1).
Forpassengervessels,theCoastGuardrecommendsa
mechanicalexhaustingsystemtomeettherequirement
in Table 4-1. The exhaust blower motors should be
outsidethe compartment.
If a gasolinefuel tank is in aseparate compartment, it
must be ventilated to the same requirements as the
enginecompartment.
4-1


Section
5.
Cooling
System
GENERAL
Throughout this manual, flotationwater drawn into the
boatforenginecoolingiscalledseawater. Water recircu-
latedthroughthe engineclosed systemiscalledcaptive
water. Thus, confusion is avoided with other generic
terms describing water use.
The
two
typesof marinecoolingsystemscoveredinthis
manual are
heat exchanger
and
sea wafer
cooling. An
explanation
of
each system, and the advantages and
disadvantages of each are covered inseparate chapter
headings. The heat exchanger system is ordered most
often and is standard on the
MCE
generator set Sea
water coolingisan available option.
System
Plumbing
Toadequatelycoolthegeneratorsetunderallconditions,
the plumbing system must be properly planned and
installed. Excess lengths of plumbing increases flow
resistanceand results inreducedcooling.An air leak in
theseawaterintakewillreducecooling,causecorrosion,
and can even destroy the neopreneimpeller inthe
sea
water pump. The neoprene impeller must never be run
dry, andshould be primedbeforeinitialstart
Thewaterlineshouldhaveaminimuminsidediameterof
0.75
inch
(1
9
mm). Forrunsover
20
feet
(5.2
m), increase
thelineonepipesizeforeachadditional
10
feet
(2.6
m) of
length.Waterlinescanbeeithercoppertubingorflexible
hose. Be sure a length of flexible hose is used at the
generator set connectiontoallowset movementandfor
noiseabatement
Unlesstheseawater isvery clean, Onanrecommendsa
water strainer or filter to protectthe sea water cooling
system. See Figure
5-1.
Onanhasahullstrainer(furnishedwithsomemufflerkits)
that can be used with a flush through-hull fitting. The
strainer(Figure
!SI),
installedwiththeslotsparalleltothe
keel,helpspreventpressureorvacuumwhen theboatis
underway. Always useaflush-typeinletwith a hydrody-
namic marinemuffler.
The flush-fype through-hull wafer
inlef must have
an
openingatleastas
lameas fhe wafer inlef line.
TO
GENERATOR
SET
RECOMMENDED
WATER
STRAINER
OR
FILTER
FLUSH
THRU-
HULL
FllllNG
STF
CROSS-SECTION
VlMl
HULL.
--WNER
CS-1312-1
FIGURE
5-1.
SEA
WATER
INLET
Staggerthegeneratorsetwaterinlet
so
itisnotdirectlyin
linewithotherinlets. Notdoing
so
canreducetheamount
of sea water available tothegenerator set when under-
wayandcauseoverheating. Never usescooptypewater
inletfittings with ahydrodynamicmuffler.
-1
Do
not use scoop
fype
wafer inlet
fit-
tings with
a
hydrodynamic muifler.
Forward
facing
scoopscandevelopsuiiicienf
rampres-
sure
to force wafer
past
the
generator
sefs
sea
wafer
pump. Thiscanfloodfheexhausfsystemandfheengine
cylinders. This
happens
when the generator set
is
not
running and theboat
is
underway.
Rear
iacing scoops
develop vacuumwhichcanimpede
ding
wafer flow.
HEAT EXCHANGERCOOLING
This coolingsystem,standard on thegenset, keepssea
water andthe resultingsedimentdeposits
(salt,
silt,etc.),
from the engine cooling jacket It also provides more
uniform coolingand temperature control inthe engine.
Seawater and captivewater arekeptseparated,andthe
enginewaterjacketstayscleanforoptimumheattransfer.
5-1

Figure
5-2
shows the flow directionof sea water and
captivewater. The sea water pump constantlyrenews
thecoolwater bathintheheatexchangerandexhaust
system. The captive water is circulated by a pump
through the engine block, heat exchanger, and the
exhaust manifold. The captive water temperature and
flow rateare controlled
by
thermostats.
Eachgensethasarecoverytankkittobeinstalledinthe
captivecoolingsystem. Thetank (similar to automotive
application)isconnectedto the overflow fitting below
thepressurecap. Itkeepsthecaptivesystemfilled with
coolantwhich helpspreventcorrosion and sediment.
Thetankshouldbelocatedforeasychecking
of
coolant
level, andfor serviceability.lnstallationinstructionsare
furnishedwith the kit.
BELT-DRIVEN
SEA
WATER PUMP HEAT EXCHANGER
r-
I
FROM
SEA
WATER INLET
The captivecoolingsystemshouldalwaysusea
50-50
mixture of ethyleneglycol and distilled water to help
prevent corrosion.See the
lnstallation Checkout
sec-
tionfor filling instructions.
If a heat exchanger other than the Onan standard is
installed, several precautionsarerequiredas follows:
Theheatexchangermustproperlycoolthegenera-
torsetunderallloadconditions.TheOnansystemis
designed to coolthesetatfull loadwithsea water
inlettemperatures up
to
1
OOOF
(38OC).
Extramargin
(10%)
must be allowed for varying conditions of
pumps, coolantand scalebuildup.
Minimumcaptivewater andseawaterflowrequired
by the generator set must be met. The heat
exchangerwill also have minimum and maximum
flow requirementswhichmustbemetforcoolingat
its capacity. The generator set requirementsare
listedinthe
Specificafion
section.
r*
I
I
t
I
I
I
I
.-*----
t
MANIFOLD
(MIXER)
EXHAUSTAND
SEA
WATER OUTLET
TO
MUFFLER
by Separate Pump
--P
Captive CoolingWater
Circulatedby
cs1369
....
FIGURE
5-2.
COOLANT
FLOW, HEATEXCHANGER COOLINGSYSTEM
5-2

SEA WATER
COOLING
The sea water coolingsystem isshown in Figure
5-3.
This
system
uses
the belt-driven
sea
water pump to
directwater throughthe engine coolingsystemandout
theexhaustsystem.The electriccirculatingpump
is
not
usedonthissystem. The engineblocks have adrilled
coolantbypassholetoallowsomecoolantflowregard-
lessofthermostatopening.Thisallowsforexhaustcool-
ing and protection of the pump. The sea water and
exhaust is disposed
of
similarly as described in Heat
ExchangerCoolingwithahydrodynamicmuffler(above
or
belowwater lineinstallation).
Theseawater comesintodirectcontactwiththeengine
coolingjacket, and this system should be avoided for
use
in salt
or
contaminated water. Such water can
cause engineblockcorrosionand/or plugging; there-
fore, heatexchanger systems are recommended.
.
COMBINED
COOLING
SYSTEMS
Onandoesnotrecommendcombiningthegeneratorset
coolingsystemwiththe propulsionenginecoolingsys-
tem. This involvesa great amount of experience and
knowledgefor the installer, as wellas complete know-
ledge
of
characteristicsof boththe generator set and
propulsionengines.
Propulsion engines use scoop-type
waterinlet fittings whichmustnot be
usedfora generator set witha hydrodynamicmuffler.
Whennotoperating,rampressurecanforcewaferpast
the generator set’s sea water pump and flood the
exhaust system. From here it can flow back, flooding
the engine cylinders and possibly the engine com-
partment.
BELT-DRIVEN
SEA
WATER
PUMP
EXHAUST
MANIFOU)
I
,-
I
EXHAUSTMANIFOLD
/I\
FROM
SEA
I
(MIXER)
/I\
+
WATER
INLET
I
re
I
EXHAUSTAND
SEA
WATER OUTLET
TO
MUFFLER
I
I
+
I
I
I
FIGURE
5-3.
COOLANT
FLOW.
SEA
WATER
COOLING
5-3


Section
6.
Exhaust
System
GENERAL
Theinstallationof
two
water-cooled exhaustsystemsare
covered in this section. They are below-loadwaterline
andabove-loadwaterline,andarecoveredundersepar-
ate headings.
All
exhaust systems for water-cooled
marine installationsmust meet each of the following
requirements. Failureto meettheserequirements could
result in severe property damage, personal injury or
death.
b
The entireexhaust system must beaccessible
so
a
periodicvisualandaudiblecheckforleakagecanbe
made bythe operator.
0
The exhaustsystem must bewater cooled, andthe
water injected as near to the generator set as
possible.
0
All
exhaust system sections preceding the point of
water injectionmust bewater jacketedor effectively
insulatedor shielded.
0
The exhaust line must be installedto prevent back
flowofwatertotheengineunderanyconditions; and
the exhaustoutlet mustbeabovetheloadwaterline.
Water backflow into the enginewilldamage
it
The generatorset exhaustsystem
must
not
becom-
bined with the exhaust system of another
engine.
0
A
flexible section of marine exhaust hose must be
used nearthe enginetoallowfor engine movement
and vibration during operation.
All
exhaust system
hoses mustbeCERTIFIEDfor marine use.
0
Theexhaustsystem mustbeof sufficientsizetopre-
vent excessive back pressure. See Back Pressure
data inthissection.
Installexhaustthroughhullfittingaftof sink, shower
orother cabin drainstopreventbackflowof exhaust
gases into thevessel.
Material
UsematerialrecommendedbyABYC in
“Safety
Standard
for
Small
Crafi,
”Section P1. Theexhaust linemustbeat
leastas largeastheengineexhaustmanifoldoutlet
See
followingsection on Back Pressure.
Exhaustgas containscarbonmonox-
ide, an odorless, colorless, highly
poisonousgas thatpresents the hazard of severe
per-
sonal injuw
or
death. Place special emphasis on the
following:
0
Be
sure
the flexible exhausthose
is
designed and
certified
for
marineexhaustline use.
Use
two
clampsat each end
of
all flexible exhaust
hose connections.
Do
not make shatpbends in the exhausthose.
0
Position exhaust outlet
to
prevent backflow of
Use flexible hose designed and CERTIFIED for marine
exhaustlineuse. The mufflermustbeatthelowestpoint
of theentireexhaustsystem.Themufflertopshouldbeat
least 12 inches
(305
mm) below the exhaust manifold
outletIfitishigher,backflowofwatertowardthemanifold
ismorelikely.
Makesurethe hosedrainstowardthemufflerat
a
grade
of
1
/2
inchper linealfoot
(42
mm/m). An uphillsection
between the exhaust manifold and muffler can cause
backflow of water and is not permissible
-
NO
EXCEPTIONS.
exhaust gasesinfothe vessel.
Be
sure that the vertical rise
of
the exhaust hose mea-
suredfromthebottomofthemufflertoitspeakisnotmore
than
48
inches(1.2
m)
as shown inFigure6-1.
Theexhausttubing(onbothaboveandbelowloadwater-
line installations) must be pitched downward to the
through-hulloutletfittingataminimumdowngradeof 112
inch per lineal foot
(42
mm/m). There must also be a
12-inch
(305
mm) minimumdrop from this peak to the
through-hull outlet fitting as shown in Figures 6-1 and
6-2.
Allowspacebetweenthemarinemufflerand
its
mounting
surface by use of spacers under the mountingflanges.
Thisallowsaircirculationunderthemuffleranddiscour-
ages condensation build-up.
6-1
This manual suits for next models
1
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