SERVICE BULLETIN

TOPIC: IDENT NO: SUPERSEDES: DATE: SUBJECT: Engine Protection Shutdown All Waukesha Engines MODELS AFFECTED: Accessories 1-2620F 1-2620E November 15, 2007

The tables in this Service Bulletin list Alarm and Shutdown setpoints by engine series for various engine operation parameters. These values can be used as a guide when designing engine protection or monitoring systems. The alarm values shown are suggested values; they can be changed to suit a specific application or measurement device. By using controls that simultaneously shut off the fuel supply and ignition system upon reaching a shutdown value, the potential for engine damage is reduced. Alarm and shutdown values indicate deviation from designed operation and are not meant for continuous engine service. Engine and control systems must be designed to and operated at normal values. Disregarding this information could result in product damage and/or personal injury.

Alarm and shutdown values are based on using dry natural gas of 900 BTU/cu.ft. (35.38 MJ/m3 [25,V(0;101.325)]) Saturated Lower Heating Value (SLHV) as fuel. Refer to the Gaseous Fuel Specification for Waukesha Engines standard sheet, S-7884-7 or latest version, and the Lubricating Oil Recommendations for Waukesha Engines standard sheet, S-1015-29 or latest version, for typical changes to operating temperatures for jacket water and lube oil when running on landfill or digester gas fuels. Refer to the most recent version of the Gas Engine Price Book to determine which shutdown devices are included as standard equipment with any specific engine model.

CAUTION

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Page 1 of 8

Service Bulletin No. 1-2620F 12V/18V220GL

JACKET WATER (HT) OUTLET TEMPERATURE Normal Alarm Shutdown Normal Alarm Shutdown 100 C (212 F) 103 C (217 F) 108 C (226 F) 75 C (167 F) 77 C (171 F) 80 C (176 F) LUBE OIL HEADER PRESSURE Idle Normal Alarm Shutdown 4.2 bar (61 psi) 2.3 bar (33 psi)1 2.0 bar (29 psi)1 Rated Speed (1200 or 1500 rpm) 5.3 bar (77 psi) 4.0 bar (58 psi)1 3.5 bar (51 psi)1 Normal Alarm Shutdown Normal Alarm Shutdown
1 1

AT25GL/AT27GL
JACKET WATER OUTLET TEMPERATURE Standard Cooling System Normal Alarm Shutdown 180 F (82 C) for continuous rating 200 F (93 C) for intermittent rating 10 F (5.5 C) above normal/design temperature 20 F (11 C) above normal/design temperature 210 250 F (99 121 C) solid water 5 F (3 C) above normal/design temperature1 10 F (5.5 C) above normal/design temperature1 LUBE OIL HEADER TEMPERATURE 172 F (78 C) 187 F (86 C) 197 F (92 C) LUBE OIL HEADER PRESSURE 60 65 psi (415 450 kPa) 50 psi (345 kPa)3 45 psi (310 kPa)3 Up to 10 F (5.5 C) above design intercooler water inlet temperature 20 F (11 C) above design intercooler water inlet temperature 30 F (17 C) above design intercooler water inlet temperature Up to 10 F (5.5 C) above design intercooler water inlet temperature 15 F (11 C) above design intercooler water inlet temperature 20 F (17 C) above design intercooler water inlet temperature INTAKE MANIFOLD PRESSURE Contact Waukesha Sales Engineering MAIN BEARING TEMPERATURE Shutdown Shutdown 250 F (121 C) OVERSPEED Not to exceed 10% over governed speed. FUEL PRESSURE Alarm Shutdown NOTES: Waukesha Power Systems Engomatic Control Model 1105, 1105A, or equivalent pressure/temperature shutdown system is recommended when jacket water temperature exceeds 210 F (99C).
2 1

LUBE OIL HEADER TEMPERATURE

Elevated Temperature Solid Water Cooling System Normal Alarm Shutdown

INTAKE MANIFOLD TEMPERATURE Normal Alarm Shutdown Up to 10 C (9 F) above design intercooler water inlet temperature. 10 C (18 F) above design intercooler water inlet temperature1. 20 C (36 F) above design intercooler water inlet temperature1. INTAKE MANIFOLD PRESSURE Contact Waukesha Sales Engineering GAS PRESSURE AT GAS TRAIN INLET Normal Alarm Shutdown 4 6 bar (58 87 psi) 6.5 bar (94 psi)2 OVERSPEED Not to exceed 7% over governed speed. FUEL PRESSURE Alarm Shutdown NOTES:
1Alarm 2Alarm

INTAKE MANIFOLD TEMPERATURE AT25GL MODEL Normal Alarm Shutdown

INTAKE MANIFOLD TEMPERATURE AT27GL MODEL Normal Alarm Shutdown

The minimum fuel pressure at the regulator (from Tech Data Book) 85% of the alarm value

and shutdown functionality provided by ESM. functionality provided by Auxiliary Systems Interface.

The minimum fuel pressure at the regulator (from Tech Data Book) 85% of the alarm value

Do not revise any values on this page without revising the same values on the AT General Operating Limits and Diagram Temperature/Pressure Test Points and Pump Settings S-sheets for the 8L, 12V, and/or 16VATGL engines. 3 Waukesha Power Systems Control is required to have an 8 second

delay after engine start.

Page 2 of 8

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Service Bulletin No. 1-2620F VHP

JACKET WATER OUTLET TEMPERATURE Standard Cooling System Normal Alarm Shutdown 180 F (82 C) for continuous rating 200 F (93 C) for intermittent rating 10 F (5.5 C) above normal/design temperature2 20 F (11 C) above normal/design temperature2 205 F (96 C) 215 F (102 C)
1

VHP (continued)
INTAKE MANIFOLD TEMPERATURE2 Normal Alarm Shutdown Up to 10 F (5.5 C) above design intercooler water inlet temperature 15 F (8.5 C) above design intercooler water inlet temperature2 20 F (11 C) above design intercooler water inlet temperature2 INTAKE MANIFOLD PRESSURE Contact Waukesha Sales Engineering MAIN BEARING TEMPERATURE Shutdown 250 F (121 C) WED Code 6010, Eutectic alloy melting point is 252 F Oil pressure switch pressure setting is 20 Psig5 OVERSPEED Shutdown 10% over governed speed2 Waukesha Power System Shutdown 1015% over governed speed, not to exceed 1320 RPM When setting engine overspeed shutdown, do not exceed the lesser of engine or driven equipments speed limits. To avoid equipment damage, consult the driven equipment manufacturer for maximum overspeed value. FUEL PRESSURE Alarm Shutdown NOTES:
1For

Waukesha Power Systems Std. Alarm Shutdown

Note: Alarm and shutdown differ because of the 10% overload for 2 hours in 24. Elevated Temperature Solid Water Cooling System (All Applications) Normal Alarm Shutdown 210 235 F (99 113 C) for solid water 5 F (3 C) above normal/design temperature2,3 10 F (5.5 C) above normal/design temperature2,3 212 250 F (100 121 C) See Note 4 See Note 4 180 F (82 C) 195 F (91 C)2 205 F (96 C)
2

Ebullient Water Cooling System (All Applications) Normal Alarm Shutdown Normal Alarm Shutdown

Caution

LUBE OIL HEADER TEMPERATURE

The minimum fuel pressure at the regulator (from Tech Data Book) 85% of the alarm value

Naturally Aspirated Standby Rating with auxiliary cooling connected to jacket cooling. Alarm Shutdown Alarm Shutdown 200 F (93 C) 205 F (96 C) WED Code 1107 200 F (93 C) 205 F (96 C) LUBE OIL HEADER PRESSURE 6 and 12 Cylinder Models Normal Alarm Shutdown Normal Alarm Shutdown Normal Alarm 50 60 psi (345 415 kPa) 35 psi (241 kPa)2, 5 30 psi (207 kPa)2, 5 16 Cylinder Models 30 50 psi (207 345 kPa) 30 psi (207 kPa)5 25 psi (172 kPa)5 2 15 psi (14 103 kPa differential) 15 psi (103 kPa differential)2

engines equipped with ESM, refer to ECU calibration and appropriate S-08312-XX sheet to determine limits of operating conditions.

Alarm and shutdown functionality provided on engines equipped with ESM.

3 Waukesha Power Systems Engomatic Control Model 1105, 1105A, or equivalent shutdown system is recommended when jacket water temperature exceeds 210 F (99 C).

Power Systems Engomatic Control Model 1106, 1106A, or equivalent shutdown system is recommended for ebulliently cooled engines.
5

4Waukesha

Waukesha Power Systems Control is required to have an 8 second delay after engine start.

LUBE OIL FILTER DIFFERENTIAL PRESSURE

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Page 3 of 8

Service Bulletin No. 1-2620F 16V150LTD

JACKET WATER (HT) OUTLET TEMPERATURE Normal Alarm Shutdown Normal Alarm Shutdown 99 C (210 F) 105 C (220 F) 110 C (230 F) 88 C (190 F) 93 C (199 F) 96 C (204 F) LUBE OIL HEADER PRESSURE Idle Normal Alarm Shutdown 2.4 bar (35 psi) 2.0 bar (29 psi)1 1.6 bar (24 psi)1 Rated Speed (1500 or 1800 rpm) 3.6 bar (52 psi) 2.8 bar (40 psi)1 2.4 bar (35 psi)1 Normal Alarm Shutdown
1 1

F1197
JACKET WATER OUTLET TEMPERATURE Normal Alarm Shutdown Normal Alarm Shutdown 180 F (82 C) 200 F (93 C) 210 F (99 C) 160 210 F (71 99 C) 225 F (107 C) 235 F (113 C) LUBE OIL HEADER PRESSURE 40 50 psi (276 345 kPa) 15 psi (103 kPa) 10 psi (69 kPa) Not Applicable INTAKE MANIFOLD PRESSURE Contact Waukesha Sales Engineering MAIN BEARING TEMPERATURE Contact Waukesha Sales Engineering OVERSPEED Shutdown Not to exceed 15% over governed speed INTAKE MANIFOLD TEMPERATURE LUBE OIL HEADER TEMPERATURE

LUBE OIL HEADER TEMPERATURE

INTAKE MANIFOLD TEMPERATURE Normal Alarm Shutdown Up to 10 C (9 F) above design intercooler water inlet temperature. 11 C (20 F) above design intercooler water inlet temperature1. 14 C (25 C) above design intercooler water inlet temperature1. INTAKE MANIFOLD PRESSURE Contact Waukesha Sales Engineering. GAS PRESSURE AT GAS TRAIN INLET Normal 0.05 0.09 bar (0.75 1.25 psi) OVERSPEED Shutdown 50 Hz: 1750 rpm 60 Hz: 1980 rpm FUEL PRESSURE Alarm Shutdown NOTES:
1

F817
JACKET WATER OUTLET TEMPERATURE Normal Alarm Shutdown Normal Alarm Shutdown LUBE OIL HEADER PRESSURE Normal Alarm Shutdown 35 45 psi (241 310 kPa) 15 psi (103 kPa) 10 psi (69 kPa) Not Applicable INTAKE MANIFOLD PRESSURE Contact Waukesha Sales Engineering OVERSPEED Shutdown Not to exceed 15% over governed speed 180 F (82 C) 195 F (91 C) 205 F (96 C) 160 230 F (71 110 C) 240 F (116 C) 250 F (121 C)

LUBE OIL HEADER TEMPERATURE

The minimum fuel pressure at the regulator (from Tech Data Book) 85% of the alarm value

Alarm and shutdown functionality provided by ESM.

INTAKE MANIFOLD TEMPERATURE

Page 4 of 8

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Service Bulletin No. 1-2620F VGF

JACKET WATER OUTLET TEMPERATURE Standard Cooling System Engines less than or equal to 176 BMEP Normal Alarm Shutdown 180 F (82 C) for continuous rating 200 F (93 C) for intermittent rating 10 F (5.5 C) above normal/design temperature 20 F (11 C) above normal/design temperature 205 F (96 C) 215 F (102 C) Alarm and Shutdown differ because of the 10% overload for 2 hours in 24 Normal Alarm Shutdown Normal Alarm Shutdown

VGF (continued)
LUBE OIL HEADER PRESSURE F18/H24 Models 67 83 psi (462 572 kPa) 40 psi (276 kPa)2 35 psi (241 kPa)2 L36/P48 Models 66 82psi (455 565 kPa) 40 psi (276 kPa)2 35 psi (241 kPa)2 INTAKE MANIFOLD TEMPERATURE With Standard Intercooler Water Temperatures of 85 130 F (29 54 C) GL/GLD/GSI/GSID Engines with less than or equal to 176 BMEP Normal Alarm Shutdown Up to 10 F (5.5 C) above design intercooler water inlet temperature 15 F (8.5 C) above design intercooler water inlet temperature 20 F (11 C) above design intercooler water inlet temperature

Waukesha Power Systems Std Alarm Normal Shutdown

Elevated Temperature, Solid Water Cooling System Engines less than or equal to 176 BMEP All Applications Normal Alarm Shutdown 210 265 F (99 130 C) for solid water 5 F (3 C) above normal/design temperature1 10 F (5.5 C) above normal/design temperature1

With Elevated Intercooler Water Temperatures of 131 176 F (55 80 C) Normal Alarm Shutdown Up to 10 F (5.5 C) above design intercooler water inlet temperature 10 F (5.5 C) above design intercooler water inlet temperature 15 F (8.5 C) above design intercooler water inlet temperature

Elevated Temperature, Solid Water Cooling System 200 BMEP Engines All Applications Normal Alarm Shutdown 210 F (99 C) solid water 10 F (5.5 C) above normal/design temperature1 15 F (8.5 C) above normal/design temperature1

LUBE OIL HEADER TEMPERATURE Jacket Water Temperature of 180 F (82 C) and Intercooler Temperature of 85 130 F (29 54 C) Engines less than or equal to 176 BMEP All Models Normal Alarm Shutdown 170 195 F (76.5 90.5 C) 200 F (93 C) 205 F (96 C)

With Elevated Intercooler Water Temperatures of 158 176 F (70 80 C) 200 BMEP GLD Engines Only Normal Alarm Shutdown Up to 10 F (5.5 C) above design intercooler water inlet temperature 10 F (5.5 C) above design intercooler water inlet temperature 15 F (8.5 C) above design intercooler water inlet temperature

Jacket Water Temperature of 265 F (129 C) and Intercooler Temperature of 85 130 F (29 54 C) Engines less than or equal to 176 BMEP All Models Normal Alarm Shutdown 170 195 F (76.5 90.5 C) 200 F (93 C) 205 F (96 C)

INTAKE MANIFOLD PRESSURE Contact Waukesha Sales Engineering MAIN BEARING TEMPERATURE Contact Waukesha Sales Engineering OVERSPEED Shutdown Not to exceed 15% over governed speed. FUEL PRESSURE Alarm Shutdown NOTES:
1Waukesha Power Systems Engomatic Control Model 1105, 1105A, or equivalent pressure/temperature shutdown system is recommended when jacket water temperature exceeds 210 F (99 C). 2

Jacket Water Temperature of 210 F (99 C) and Intercooler Temperature of 158 176 F (70 80 C) 200 BMEP GLD Engines Only Normal Alarm Shutdown 190 F (88 C) 200 F (93 C) 205 F (96 C)

The minimum fuel pressure at the regulator (from Tech Data Book) 85% of the alarm value

Waukesha Power Systems Control is required to have an 8 second delay after engine start. Waukesha Power Systems Control is required to have a 5 minute delay after engine start for all applications that run with (less than or equal to) 125 F intercooler water.

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Page 5 of 8

Service Bulletin No. 1-2620F VSG

JACKET WATER OUTLET TEMPERATURE Normal Alarm Shutdown 180 F (82 C) 200 F (93 C) 210 F (99 C) LUBE OIL HEADER TEMPERATURE with a Jacket Water Temperature of 180 F (82 C) F11G Model Normal Alarm Shutdown Normal Alarm Shutdown Normal Alarm Shutdown 205 F (96 C) 215 F (102 C) 225 F (107 C) F11GSI Model 190 F (89 C) 200 F (93 C) 210 F (99 C) LUBE OIL HEADER PRESSURE 65 87 psi (448 600 kPa) 40 psi (276 kPa) 30 psi (207 kPa) Up to 15 F (8.5 C) above design intercooler water inlet temperature 20 F (11 C) above design intercooler water inlet temperature 25 F (14 C) above design intercooler water inlet temperature

INTAKE MANIFOLD TEMPERATURE (GSI) Normal Alarm Shutdown

INTAKE MANIFOLD PRESSURE Contact Waukesha Sales Engineering MAIN BEARING TEMPERATURE Contact Waukesha Sales Engineering OVERSPEED Shutdown Not to exceed 15% over governed speed. FUEL PRESSURE Alarm Shutdown The minimum fuel pressure at the regulator (from Tech Data Book) 85% of the alarm value

Page 6 of 8

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Service Bulletin No. 1-2620F GENERATOR ALARMS AND SHUTDOWNS

KATO CLASS F INSULATION GENERATORS See Kato drawing for setpoint recommendations on standby units Generator Winding (Prime Power) Alarm Shutdown Alarm Shutdown 311 F (155 C) 329 F (165 C) Generator Bearing 185 F (85 C) 203 F (95 C) LEROY SOMER CLASS H INSULATION GENERATORS Prime Power (105 C) Generator Winding Alarm Shutdown Alarm Shutdown Alarm Shutdown Alarm Shutdown 194 F (90 C) 203 F (95 C) 194 F (90 C) 203 F (95 C) 392 F (200 C) 401 F (205 C) 392 F (200 C) 401 F (205 C) Class H is Leroy Somer standard. Only class H settings should be used for the LSA461 to LSA51 low voltage generators. These values are ISO standard and should be used as maximums only.

Prime Power (105 C) Generator (Sleeve or Roller) Bearing

MARATHON ELECTRIC MAGNAMAX DVR GENERATORS Prime Power (105 C) Generator Winding Alarm Shutdown Alarm Shutdown Alarm Shutdown Alarm Shutdown 293 F (145 C) 311 F (155 C) 230 F (110 C) 248 F (120 C) Prime Power (105 C) Generator Bearing

Standby Power (130 C) Generator Winding

Standby Power (130 C) Generator (Sleeve or Roller) Bearing

Standby Power (130 C) Generator Winding 338 F (170 C) 356 F (180 C) 230 F (110 C) 248 F (120 C) Prime or Standby Generator Winding Temperature Switch (GWTS) Shutdown Comments 302 9 F (150 5 C) Switch N.O. or N.C. GWTS is not located in the winding a lot like the RTD or thermocouple so a lower temperature device is used. No alarm GWTS is available at this time.

Comments:

Standby Power (130 C) Generator Bearing Alarm

LEROY SOMER NA (MAGNETEK) CLASS F INSULATION GENERATORS Generator Winding (Prime Power) 311 F (155 C) 329 F (165 C) Generator Bearing Alarm Shutdown 185 F (85 C) 194 F (90 C) Shutdown

LEROY SOMER CLASS F INSULATION GENERATORS Prime Power (105 C) Generator Winding Alarm Shutdown Alarm Shutdown Alarm Shutdown Alarm Shutdown 302 F (150 C) 311 F (155 C) 194 F (90 C) 203 F (95 C) 347 F (175 C) 356 F (180 C) 239 F (115 C) 248 F (120 C)

Prime Power (105 C) Generator (Sleeve or Roller) Bearing

Standby Power (130 C) Generator Winding

Standby Power (130 C) Generator (Sleeve or Roller) Bearing

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999

Page 7 of 8

Service Bulletin No. 1-2620F NEWAGE GENERATORS

GENERATOR WINDING
INSULATION CLASS WARNING SHUTDOWN

F
A E B F H 194 230 248 284 338

C
90 110 120 140 170

F
230 266 284 320 374

C
110 130 140 160 190

COMMENTS: These values are recommended by the British Standard BS4999 Part 72, which Newage Int. follow.

Page 8 of 8

WAUKESHA ENGINE DRESSER, INC. WAUKESHA, WI 53188-4999