Académique Documents
Professionnel Documents
Culture Documents
Leo Beattie
Series 50G/60G Natural Gas Engine
Presenter\Name of Presentation
Revised Date 4
Agenda
• Introduction / Background
• Specifications, Ratings and Emissions
• Glossary of Terms and Engine Sensors
• Series 50G / 60G Engine Components
– Major Engine Control Systems
– Other Unique Engine Systems
– Vehicle Fuel System
• OEM Interfaces with Engine
• Unique Requirements for Gas Engines
• Summary
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Revised Date 5
Mission Statement
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Revised Date 6
DDC Milestones
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Revised Date 7
DDC Alternate Fuel Projects
• Methanol Fueled
– Urban Buses
– Heavy Duty Trucks
– Generator Set
• Ethanol Fueled
– Urban Buses
– Heavy Duty Trucks
Presenter\Name of Presentation
Revised Date 8
DDC Alternate Fuel Projects
Presenter\Name of Presentation
Revised Date 9
Series 50G / 60G Development
Presenter\Name of Presentation
Revised Date 10
Series 50G / 60G Release Dates
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Revised Date 11
Commonality With Diesel
Presenter\Name of Presentation
Revised Date 12
DDC Natural Gas Engine Features
Presenter\Name of Presentation
Revised Date 13
Specific Features of DDC
Natural Gas Gensets
• Fuel Inlet Pressure Range 5"- 20" H2O
Presenter\Name of Presentation
Revised Date 14
Series 50G / 60G Coach Specifications
Series 50G Series 60G
Engine Type 4-Cycle (Dedicated Fuel) 4-Cycle (Dedicated Fuel)
Displacement 8.5 Liters 12.7 Liters
Compression Ratio 10:1 10:1
Engine Control DDEC IV, On-Engine DDEC IV, On-Engine
Ignition Electronic Spark Electronic Spark
Aspiration Turbocharged Turbocharged
Fuel Control DDC Closed Loop DDC Closed Loop
Throttle 60 mm Electronic 68 mm Electronic
Rated Power 275 @ 2100 RPM 330 @ 2100 RPM
Peak Torque 890 Ft-Lb @ 1200 RPM 1400 Ft-Lb @ 1200 RPM
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Revised Date 15
Series 50G / 60G Genset Specifications
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Revised Date 16
DDC Series 50G / 60G Gas Engines
Rating Application Availability
Series 50G 275 HP @ 2100 RPM Transit Bus Now
890 FT-LB EPA / CARB
Series 60G 330 HP @ 2100 RPM Motor Coach 3rd. Quarter „98
1400 FT-LB EPA / CARB
Gen Set
340 - 450 HP @ 1800 RPM Stand-By Now
Gen Set Now
230 - 400 HP @ 1500 RPM Stand-By
Presenter\Name of Presentation
Revised Date 17
Series 50G Exhaust Emissions
G/HP-HR
Rating 275 HP - 890 FT-LB NOx NMHC CO PM
*No Catalyst
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Revised Date 18
Series 50G ULEV Exhaust Emissions
*With Catalyst / No DF
Presenter\Name of Presentation
Revised Date 19
Series 60G Exhaust Emissions
G/HP-HR
Rating 330 HP - 1400 FT-LB NOx NMHC CO PM
*No Catalyst
Presenter\Name of Presentation
Revised Date 20
Series 50G Transit Sites
Vancouver
(50 Units)
Hamilton / Kitchener
INEEL Area (58 Units)
(6 Units)
Pennsylvania
(47 Units) NY / New Jersey
Monterey / Sonoma Springfield Cleveland Area (100 Units)
Denver
(25 Units) (7 Units) (190 Units)
(5 Units)
El Paso
Tucson (35 Units)
(44 Units) Houston Orlando
Indonesia Laredo (10 Units) (11 Units)
(41 Units) (15 Units)
Pinellas
(3 Units)
Presenter\Name of Presentation
Revised Date 21
Natural Gas
Compressed and Liquid
Natural Gas
• Methane
– Product of Decomposing Organic Material
» A By-Product of Decarbonization of Coal
• Odorless, Colorless, and Non-Toxic
– Mercaptan is Added to Gas as an Odorant
• Fuel Composition
– Composition is Controlled in Processing
– Regional Changes Due to Different Suppliers
– Seasonal Changes Due to Usage Demands
Presenter\Name of Presentation
Revised Date 23
CNG Fuel Composition
Methane 88 (%)
Presenter\Name of Presentation
Revised Date 24
LNG Fuel Composition
Methane 98 (%)
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Revised Date 25
Comparisons
DIESEL GAS CNG LNG
NOTE: One Gallon of Diesel Fuel is Equal to 140 Cubic Feet of CNG
618 Cubic Feet of CNG is Equal to 1 Cubic Foot of LNG
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Revised Date 26
Handling and Safety
Safety Concerns
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Revised Date 28
Safety Concerns
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Revised Date 29
Boiling Point of Liquids
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Revised Date 30
Ignition Limits
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Revised Date 31
Background
Glossary of Terms
Engine Sensors
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Revised Date 32
Glossary of Terms
• SING
– Spark Ignited Natural Gas Engine
– Relies on Spark Plugs to Ignite Air/Fuel Mixture
» Same Cycle as a Typical Car Engine
– Unlike Compression Ignition Engines (Diesel)
– Dedicated Fuel (Only Burns Natural Gas)
– DDC Utilizes Series 50G and 60G Engines Which are 4
Stroke (Cycle) Engines
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Revised Date 33
Four Stroke Cycle
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Revised Date 34
Glossary of Terms
• Absolute Pressure
– Any Pressure Reading that Includes Atmosheric Pressure
» Standard Atmospheric Pressure is 14.7 psi
» Units are Followed by a “A” (PSIA, KPAA, ect)
• Gage Pressure
– Pressure Reading that does not Include Atmoshperic
Pressure
» Units are Followed by an “G” (PSIG, KPAG, ect)
• Example: Tire Pressure Gage Reads 30 psi
» Gage Pressure is 30 PSIG
» Absolute Pressure is (30+14.7) 44.7 PSIA
Presenter\Name of Presentation
Revised Date 35
Glossary of Terms
• AFR
– Air Fuel Ratio - % Air to Fuel Entering Engine
– # 1 Parameter to Control on SI Engine
» Performance
» Fuel Economy
» Emissions
• Stoichiometric AFR
– Optimum AFR That Yields Complete Combustion
– For Natural Gas This Ratio is Typically 16.4
Parts Air to 1 Part Fuel (Gasoline is 14.7 to 1)
Presenter\Name of Presentation
Revised Date 36
Glossary of Terms
• Lean Burn
– Engine Design That Operates Leaner Than
Stoichiometric AFR to Reduce Exhaust Emissions and
Exhaust Temperatures
• Lambda
– A Method of Expressing Air Fuel Ratio
» Greater Than 1 Indicates Leaner Than Stoichiometric AFR
» Less Than 1 Indicates Richer Than Stoichiometric AFR
Presenter\Name of Presentation
Revised Date 37
Glossary of Terms
• Adaptive Learn
– Ability of the Fuel Control System to “Remember” Air
Fuel Ratio Control Corrections. This “Learned”
Information is Not Lost When the Engine is Shut Down
• Engine Knock
– Undesirable Condition That Occurs in Spark Ignition
Engines that Leads to Increased Cylinder Pressures and
Temperatures and Possible Component Damage
– Fuel Mixture Ignites Prematurely and Uncontrolled
Presenter\Name of Presentation
Revised Date 39
Glossary of Terms
– Generates High Frequency “Ringing” in Combustion
Chamber
– Primarily Caused by Rich Air Fuel Ratio, Poor Fuel
Quality or High Intake Manifold Temperatures
• Lean Misfire
– Engine Miss Caused By Incomplete Combustion
» Ignition System Problems
» Cold Intake Air Temperatures
» Low Fuel Pressure / Restricted Fuel Flow
Presenter\Name of Presentation
Revised Date 40
Glossary of Terms
• BTU
– British Thermal Unit
» Measurement Unit of Heat Energy
• The Amount of Heat Needed to Raise The Temperature of One
Gallon of Water One Degree F in One Minute
• VSG
– Variable Speed Governor
» Holds the engine at a requested constant speed regardless of load
fluctuation
• Generator drive engines only
Presenter\Name of Presentation
Revised Date 41
Glossary of Terms
• Foot Throttle
– Otherwise Known as Accelerator or Foot Pedal
– Electronic Resistor to Input Foot Pedal Signal Into DDEC
System
– Same Function Between Gas and Diesel
• Air System Throttle
– Butterfly Valve in Gas Engine Air Intake
– Controls Engine Speed
– Indirectly Receives Input From Foot Pedal
Presenter\Name of Presentation
Revised Date 42
Engine Sensors
Presenter\Name of Presentation
Revised Date 43
Engine Sensors
Presenter\Name of Presentation
Revised Date 44
Engine Sensors
Presenter\Name of Presentation
Revised Date 45
Engine Sensors
• Oxygen Sensor
– Measures Oxygen Content in Exhaust
– Mounted in Exhaust Pipe After Turbocharger
• SRS / TRS Sensors
– Same as Diesel
– Mounted in Front Gearcase
• Knock Sensor
– Reacts to Engine Knock or “Ringing”
– Sensor Mounted on Left Side Cylinder Block
Presenter\Name of Presentation
Revised Date 46
Gas Engine Unique MPSI Reader
Parameters
• Gas Valve
– Feedback Signal Indicating Gas Valve (PSV) Position
» Full Range 0-100%
» Normally Around 40-70%
• TPS
– Throttle Position Sensor
» Foot Pedal Position - Same as Diesel
» Full Range 0 - 100%
• Throttle Plate
– Air System Throttle Plate Position
» Ranges From 0 - 100%
Presenter\Name of Presentation
Revised Date 47
Gas Engine Unique MPSI Reader
Parameters
• Fuel TMP
– Fuel Temperature at Inlet to Fuel Mixer
– Units are Degrees F
• Fuel PSR
– Fuel Inlet Pressure at Inlet to Impco Regualtor
– Units are PSIA
• Air Inlet PR
– Pressure or Vacuum in Intake Manifold
– Units are PSIA
Presenter\Name of Presentation
Revised Date 48
Gas Engine Unique MPSI Reader
Parameters
• Baro PSR
– Current Barometric Pressure
– Units are PSIA
• Exhaust TMP
– Exhasut Gas Temperature at Outlet of Turbocharger
– Units are Degrees F
• Exhaust Gas AFR
– Exhaust Gas Air Fuel Ratio Expressed as Lamda
– Unit-less
– Ranges from 1.0 (Rich) to 1.55 (Lean)
Presenter\Name of Presentation
Revised Date 49
Gas Engine Unique MPSI Reader
Parameters
• Loop Status
– Indicates if Control System is in Open or Closed Loop
Status
» Due to Software Issues, Do Not Use at This Time
• Knock Volts
– Indication of Knock Sensor Output to DDEC ECM
• Knock Control
– Indication of Whether the Engine is Taking Preventative
Action in Response to Knock Sensor Input
Presenter\Name of Presentation
Revised Date 50
Engine Modules
• Igniter Module
– Interface Between DDEC and Spark Plug Coils
• Oxygen Sensor Module
– Interface Between DDEC and Oxygen Sensor
• SNEF Module
– Interface Between DDEC and Knock Sensor
Presenter\Name of Presentation
Revised Date 51
Series 50G / 60G Engine Components
Presenter\Name of Presentation
Revised Date 52
Series 50G Transit Bus Engine
Coil Over Plug
Ignition Coils
Insulated
Exhaust
Manifold
Fuel Mixer
Insulated
Turbine
Housing
Presenter\Name of Presentation
Revised Date 53
Series 50G Transit Bus Engine
Low Pressure Fuel Pressure
Regulator Sensor
PSV
Oxygen Sensor
Module
Ignition System
Module
Adaptorless
Air Compressor
DDEC IV
ECM
Knock Signal
Processor
OEM Pigtail
Interfaces
Presenter\Name of Presentation
Revised Date 54
Basic Engine Unique Parts
Series 50G / 60G Cylinder Kit
Cylinder Kit
• Shorter Connecting Rod
Presenter\Name of Presentation
Revised Date 57
Series 50G / 60G Liner Cooling
COOLING
CHANNEL
INLET NOTCH COOLING
IN BLOCK CHANNEL
EXIT HOLE
MAIN COOLANT
STREAM
Presenter\Name of Presentation
Revised Date 58
Series 50G / 60G Cylinder Head
Cylinder Head
• Hardened Valve Seats
& Valve Stems
• Optimized Valve Seat Angle
• Improved Material Exhaust
Valves & Guides
• Low Flow Valve Stem Seals
• Stainless Steel Spark
Plug Adaptors
Presenter\Name of Presentation
Revised Date 59
Series 50G / 60G Camshaft
Presenter\Name of Presentation
Revised Date 60
Series 50G /60G Overhead
Presenter\Name of Presentation
Revised Date 61
Series 50 Balance Shaft
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Revised Date 62
Manifold Wrap
Presenter\Name of Presentation
Revised Date 63
Series 50G / 60G Engine Controller
• DDEC IV
– Provides Control for Fuel,
Air & Spark Systems
» Lower Emissions
» Optimum Fuel Usage
» Good Performance
– Acceleration
– Driveability
– Knock Sensor
» Reduces the Probability of
Costly Engine Damage
– Complete Diagnostics &
Troubleshooting
» Easy to Diagnose Problems
» Minimal Downtime
» Low Maintenance Costs
Presenter\Name of Presentation
Revised Date 64
Commonality With Diesel
Presenter\Name of Presentation
Revised Date 65
Series 50G / 60G Fuel Control Systems
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Revised Date 66
Series 50G / 60G Coach Fuel System
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Revised Date 67
Series 50G / 60G Coach Fuel System
Presenter\Name of Presentation
Revised Date 69
Series 50G / 60G Coach Fuel System
Presenter\Name of Presentation
Revised Date 70
Series 50G / 60G Coach Fuel System
Electronic PSV
• DDEC Interface
to Control Air / Fuel Ratio
• Fully Electronic Fuel
Control Valve
• Incorporates DDEC
Diagnostics
• No Maintenance Required
Presenter\Name of Presentation
Revised Date 72
Series 50G / 60G Coach Fuel System
Venturi / Mixer
• Similar to a Carburetor
• Balanced To Provide
Correct Air /Fuel Ratio
• No Moving Parts
• No Maintenance Required
Presenter\Name of Presentation
Revised Date 73
Series 50G / 60G Coach Fuel System
Throttle
Intake Elbow
Mixer / Venturi
Air
from
CAC
PSV
Fuel
Inlet
Fuel Balance
Line
Air / Fuel
Fuel Transfer to Engine
Tube
Oxygen Sensor
• Wide Range O2 Sensor
to Monitor All Speeds
& Loads
• No Calibration
Required
• Minimal Drift
• Excellent Durability
Results to Date
Presenter\Name of Presentation
Revised Date 75
Series 50G / 60G Coach Fuel System
• Converts O2 Sensor
Output into DDEC
Input
• Provides Sensor
Heater Control
• Self Contained -
Engine Mounted
• No Maintenance
Required
Presenter\Name of Presentation
Revised Date 76
Series 50G / 60G Coach Fuel System
Presenter\Name of Presentation
Revised Date 77
Series 50G / 60G Coach Fuel System
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Revised Date 78
Series 50G / 60G Exhaust Temperature
Sensor
• Monitors Turbine Outlet
Temperature
• Triggers DDEC Engine
Shutdown if
Overtemperature is
Detected
• Fast Response
• No Maintenance Required
Presenter\Name of Presentation
Revised Date 79
Barometric Pressure Sensor
Presenter\Name of Presentation
Revised Date 81
Air and Fuel Temperature Sensor
Presenter\Name of Presentation
Revised Date 82
Series 50G / 60G Transit Bus Engine
Closed Loop Fuel System
Other DDEC Engine
Protection Sensors & Signals
Interface
Module
Baro
Sensor
DDEC IV
Charge Intake Pressure
Air Gas & Temperature
Cooler Temperature
Turbo
Compressor
Venturi
Air
Intake Mixer ENGINE
Electronic
Control Valve Throttle
(PSV) Actuator
Gas to Engine
Exhaust
Gas O2 Sensor
Pressure
Input Gas Exhaust
Pressure Temperature
DDEC (70 - 120 PSIG) Sensor
Zero Pressure Controlled
Regulator Solenoid Valve
Presenter\Name of Presentation
Revised Date 83
Series 50G/ 60G Fuel Control System
Troubleshooting
Presenter\Name of Presentation
Revised Date 84
Series 50G / 60G Fuel Control Systems
Presenter\Name of Presentation
Revised Date 85
Series 50G / 60G Genset Specifications
Presenter\Name of Presentation
Revised Date 86
Specific Features of DDC
Natural Gas Gensets
• Fuel Inlet Pressure Range 5"- 20" H2O
Presenter\Name of Presentation
Revised Date 87
Series 50G/60G Generator
Set Fuel System
• Fuel is Introduced into the Air Upstream of
Turbocharger
• Utilizes Similar Concept / Components as Coach
Fuel System
– DDEC Controlled
– Venturi Mixer
– PSV for DDEC Fuel Control
• Open Loop Design
– No Oxygen or Barometric Sensor
Presenter\Name of Presentation
Revised Date 88
Series 50/60G Genset Gas Engine
Insulated Exhaust
Manifold & Turbine
Housing
Presenter\Name of Presentation
Revised Date 89
Mixer Inlet, GENSET
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Revised Date 90
Mixer & PSV, GENSET
Presenter\Name of Presentation
Revised Date 91
DDC Pulsewidth Stepper Valve
Electronic PSV
• DDEC Interface
to Air / Fuel Ratio
Control
• DDEC Diagnostics
• No Maintenance Required
Presenter\Name of Presentation
Revised Date 92
Series 50G DDC Fuel System
• Mixer / Venturi
– Inherently Balanced
to provide Correct
Air /Fuel Ratio
– No Moving Parts
– No Maintenance Required
Presenter\Name of Presentation
Revised Date 93
Series 50/60G Electronic Throttle
• Full Control by DDEC
– Idle & Governor
Speed Control
– No Internal / External
Adjustments
– Auto Calibration
During Startup
– Diagnostic Fault
Protection
– Fail Safe “Closed”
Feature
Presenter\Name of Presentation
Revised Date 94
Regulator, Low Pressure
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Revised Date 95
GENSET, Front
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Revised Date 96
GENSET, Right Bank
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Revised Date 97
GENSET, Left Bank
Presenter\Name of Presentation
Revised Date 98
Flywheel, GENSET
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Revised Date 99
MAP Sensor
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Revised Date 100
Air and Fuel Temperature Sensor
Presenter\Name of Presentation
Revised Date 101
Natural Gas Genset Fuel System
OTHER DDEC
ENGINE PROTECTION
SENSORS & SIGNALS
INTAKE PRESSURE
& TEMPERATURE
DDEC KNOCK
FUEL TEMP. CHARGE SENSOR
SENSOR AIR IGNITION
COOLER COILS
TURBO
VENTURI COMPRESSOR
MIXER
AIR
INTAKE
THROTTLE
ENGINE
BOOST ACTUATOR
PRESSURE LOW PRESSURE
ELECTRONIC REGULATOR
CONTROL VALVE EXHAUST
INPUT GAS
PRESSURE
5”- 20” H2O
TURBO
WASTEGATE
VALVE
Presenter\Name of Presentation
Revised Date 102
Series 50G / 60G Fuel Control System
Troubleshooting
Presenter\Name of Presentation
Revised Date 103
Series 50G / 60G
Air System
Series 50G / 60G Electronic Throttle
• Full Control by DDEC
– Idle & Governor
Speed Control
– No Internal / External
Adjustments
– Auto Calibration
During Startup
– Diagnostic Fault
Protection
– Fail Safe “Closed”
Feature
Presenter\Name of Presentation
Revised Date 105
Series 50G / 60G Turbocharger
Turbocharger
• Water Cooled Center Section
• Insulated Turbine Housing
• Dual Poppet Wastegate
with Heavy-Duty Arm
• “Long Can” Wastegate Actuator
• Recirculation Valve
• Strengthened Compressor Backplate
• “V” Band Turbine Housing
Presenter\Name of Presentation
Revised Date 106
Wastegate Actuator
Presenter\Name of Presentation
Revised Date 107
Wastegate Poppets
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Revised Date 108
Wastegate Calibration
Presenter\Name of Presentation
Revised Date 109
Turbocharger, GENSET
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Revised Date 110
Air System
Presenter\Name of Presentation
Revised Date 111
Series 50G / 60G Closed Breather
Presenter\Name of Presentation
Revised Date 112
Series 50G / 60G Air Control System
Troubleshooting
Presenter\Name of Presentation
Revised Date 113
Series 50G/ 60G
Ignition System
Series 50G / 60G
Coil Over Plug Ignition System
Presenter\Name of Presentation
Revised Date 115
Series 50G / 60G Ignition System
Presenter\Name of Presentation
Revised Date 116
Series 50/60G Ignition System
Presenter\Name of Presentation
Revised Date 117
Series 50G / 60G Spark Igniter Module
Presenter\Name of Presentation
Revised Date 118
Spark Plug Tube, Upper
Presenter\Name of Presentation
Revised Date 119
Spark Plug Tube, Lower
Presenter\Name of Presentation
Revised Date 120
Spark Plug
Presenter\Name of Presentation
Revised Date 121
Series 50G 60G Ignition Control System
Troubleshooting
Presenter\Name of Presentation
Revised Date 122
Cylinder Cut-Out
Presenter\Name of Presentation
Revised Date 123
Series 50G / 60G
Other Engine Systems
Knock Sensor
Presenter\Name of Presentation
Revised Date 125
SNEF Module
Presenter\Name of Presentation
Revised Date 126
Sensor Harness
Presenter\Name of Presentation
Revised Date 127
DDEC System
Presenter\Name of Presentation
Revised Date 128
DDR Reader
Presenter\Name of Presentation
Revised Date 129
DDEC Tools
Presenter\Name of Presentation
Revised Date 130
Vehicle Systems
• Fuel Supply
– High Pressure Regualtor
– High Pressure Fuel Solenoid
– Filters
» Coalescing
– Low Pressure Fuel Solenoid
– Fuel Lines
– Vehicle Fuel Systems
Presenter\Name of Presentation
Revised Date 132
Regulator, High Pressure Fuel
Presenter\Name of Presentation
Revised Date 133
Typical High Pressure Fuel Control
Solenoid
Presenter\Name of Presentation
Revised Date 135
Low Pressure Fuel Solenoid
Presenter\Name of Presentation
Revised Date 136
CNG Vent Lines
Presenter\Name of Presentation
Revised Date 138
CNG Fuel System
Presenter\Name of Presentation
Revised Date 139
LNG Fuel System
Presenter\Name of Presentation
Revised Date 140
LNG Tank
Presenter\Name of Presentation
Revised Date 141
LNG Vaporizer
Presenter\Name of Presentation
Revised Date 142
Power Requirements
Throttle Power Supply
Presenter\Name of Presentation
Revised Date 144
Throttle Relay
Presenter\Name of Presentation
Revised Date 145
Unique Requirements
Presenter\Name of Presentation
Revised Date 146
Oil Requirements
Presenter\Name of Presentation
Revised Date 147
Coolant Requirements
Presenter\Name of Presentation
Revised Date 148
Series 50G Maintenance Intervals
Urban Coach Service
Component / Item Maintenance Required
Replace Every 6,000 Miles &
Lubricating Oil & Filter
Check Oil Level Daily
Drain Daily & Replace Element
Coalescing Fuel Filters
Every 6,000 Miles
Throttle Body & Actuator Inspect Every 6,000 Miles
Presenter\Name of Presentation
Revised Date 149
Summary and Wrap-Up
Presenter\Name of Presentation
Revised Date 150
Series 50G/60G Natural Gas Engine
Presenter\Name of Presentation
Revised Date 151