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G3516E Generator Set GAS00001-UP(SEBP3934 - 37) - Systems & Components

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Product: GENERATOR SET
Model: G3516E GENERATOR SET GAS
Configuration: G3516E Generator Set GAS00001-UP

Systems Operation
G3516C and G3516E Engines
Media Number -KENR6834-06

Publication Date -01/08/2013

Date Updated -05/08/2013

i02601326

Compressor Bypass
SMCS - 1050

A rapid reduction in the generator's power output can cause a rapid increase in the engine speed. The
increased engine speed causes the turbocharger to produce boost pressures that are greater than the
requirement for the engine operation.
Turbocharger surge - In response to the excess pressure in the air inlet system, the flow of air across the
turbocharger compressor wheel is reversed. This reversal of the air flow is called a turbocharger surge.
During a turbocharger surge, the turbocharger overspeeds temporarily. This places a greater axial load on the
thrust bearing and higher than normal torque on the shaft. The turbocharger surge can result in severe damage
to the turbocharger.
The compressor bypass group reduces the opportunity for a turbocharger surge.

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G3516E Generator Set GAS00001-UP(SEBP3934 - 37) - Systems & Components

Illustration 1

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Flow of the compressed air/fuel mixture during activation of the compressor bypass group (50 Hz arrangement)
(1) Actuator for the bypass valve
(2) Bypass valve
(3) Throttle
(4) Throttle actuator
(5) Fuel metering valve

The master Electronic Control Module (ECM) monitors the engine speed. The ECM responds to a rapid
increase in the engine speed by sending a command signal to actuator (1). This causes the actuator to move a
shaft that is connected to a plate inside bypass valve (2). The bypass valve opens.
The bypass valve is connected before throttle (3). Tubing is connected from the bypass valve to the inlet for
the turbocharger compressor. When the bypass valve is opened, the compressed air/fuel mixture is diverted
through the tubing away from the throttle. This reduces the back pressure that is caused by excessive pressure
in the air inlet system.
Note: The bypass valve for the 60 Hz arrangement is connected to two sets of tubing: one set of tubing is
connected to the inlet for the right turbocharger and the other set of tubing is connected to the inlet for the left
turbocharger.
Additionally, the ECM sends two other command signals. A command to throttle actuator (4) opens the
throttle in order to reduce the resistance that contributes to back pressure. A command to fuel metering valve
(5) reduces the fuel supply in order to reduce the engine speed and the turbocharger's speed.
The combined effect of these actions reduces the opportunity for a turbocharger surge.
The ECM determines a time period that is required for opening of the bypass valve. After the time period has
expired, the ECM sends a command signal to actuator (1) in order to close the bypass valve. Normal
operation resumes.
The compressor bypass group is also operated during engine shutdown. This reduces the opportunity for a
turbocharger surge during engine shutdown. Additionally, any air/fuel mixture that may have been trapped in
the tubing is purged.
Active Bypass
The compressor bypass valve is commanded to a wide range of positions if the engine is equipped with an
Auxiliary Sensing Module (ASM). This is called active bypass. The ASM uses inputs from the manifold air
pressure sensor and the boost pressure sensor in order to determine the pressure drop across the throttle plate.
The ASM determines the amount of active bypass that is required in order to maintain the desired pressure
drop across the throttle plate. The ASM transfers the information to the master ECM via the Cat Data Link.
The master ECM sends a command to the actuator for the bypass valve in order for the bypass valve to move
to the desired position.
Copyright 1993 - 2016 Caterpillar Inc.
All Rights Reserved.

Thu Aug 4 00:45:06 UTC+0100 2016


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