SGCO 3000 EcoPower™
Contents
1. Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION Page No EMI BULLETIN EMI 3000 Package EMI package includes New 5 Years or 12 000 Hours Extended Life Coolant ELC New EMI 3000 Water Pump P N 11 9442 includes HNBR elastomer seals and EPDM O rings New EMI 3000 Dual Element Oil Filter P N 11 9182 identified by black and gold colors New EMI 3000 Dual Element Oil Filter Head P N 11 9354 New EMI 3000 API Rating CG 4 Mineral Oil New EMI 3000 Fuel Filter P N 11 9342 identified by black and gold colors The EMI 3000 package allows standard genset maintenance intervals to be extended to 3000 hours However please note that units equipped with the EMI 3000 package do require regular inspection in accordance with Thermo King pretrip inspection and maintenance recommendations CAUTION With both EMI 3000 and standard non EMI 3000 units operating in the field there are several important rules to remember Extended Life Coolant ELC is RED in color while conventional coolant is GREEN or BLUE GREEN Do NOT add RED coolant to cooling systems using GREEN or BLUE GREEN coolant Do NOT add GREEN or BLUE GREEN coolant to cooling systems using RED coolant The EMI 3000 oil filter is NOT interchangeable with previous oil filters 3000 Components Extended Life Coolant and EMI 3000 Water Pump decal tag on the coolant expansion tank wi2. Page No INameplate Instructions English and Spanish language operating instructions Compliance Compliant with the Machinery Directive 89 392 EEC amending Directive 91 368 EEC Electro Magnetic Compatibility Directive 89 336 EEC and Low Voltage Directives 73 23 and 93 68 EEC Ambient Temperature Structure 40 C to 52 C 40 F to 125 F Operation and Starting 26 C to 52 C 15 F to 125 F Running 40 C to 52 C 40 F to 125 F Output Power Rating 15KW Designed to supply operating power for container refrigeration units complying with ISO 1496 2 ound Pressure Level Dimensions 74 dBA 5 point average at 7m Height 1053 mm 41 45 in Depth 710 mm 27 97 in Length 2337 mm 92 0 in 818 kg 1804 Ibs Total Weight including Gen Set oil coolant dry fuel tank and battery Genset to be provided with decal indicating gross weight inclusive of fuel r PRODUCT SPECIFICATION 486VG direct injection Specification No SGCO 3000 EcoPower Rev E Page No Low oil level and high coolant temperature Arrangement No 1 at flywheel end Starter motor injector pump mounted on front side of engine Bore 86 mm 3 39 in nominal Light Gray Water Lacquer Displacement 2 09 liter 128 Gear drive for camshaft and injection pump Horsepower 34 1 1 3 4 2 Oil Pressure ho
3. Display Menus Data Menu Analog inputs Digital inputs Digital outputs Internal states Alarm list Menu Message list Menu Commands Menu PTI Manual function test Misc Functions Menu Date time C F mode Program version Timers counters Configuration Menu Event log Menu SG ALARMS MESSAGES OPERATING INSTRUCTIONS Alarms Messages Operating instructions See Thermo King SGCO Maintenance Manual Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION Page No OPTIONS CUSTOMER SPECIFIED COLOR The frame assembly and panels can be painted per customer request but must be noted in advance CUSTOMER UNIT SERIAL NUMBER DECALS Customer decals can be included per customer request but must be noted in advance MOUNTING HEADER PIN Replace quick clamp connections with header pin mounting FUEL MONITORING Capable of logging any event which causes changes in fuel levels outside of the range of normal genset operations INSTALLATION DIAGRAM Specification No SGCO 3000 EcoPower Rev MM PRODUCT SPECIFICATION Page No Specification No SGCO 3000 EcoPower Rev E PRODUCT SPECIFICATION Page No DECAL DRAWING Specification No SGCO 3000 EcoPower Rev MM PRODUCT SPECIFICATION Page No FUEL FILTER DRAWING
4. stainless steel hinge and positive 1 4 turn latch A bolt storage tube is welded to the frame to secure the bolt between trips The rotor washer clip to prevent spinning off during normal use positively retains the lower mounting bolt plate washer assembly Provision tube for mounting bolt when not in use The Genset envelope considered the need to access the refrigeration unit control box while mounted on all common refrigeration units from Thermo King Carrier Klinge and Seacold for either 8 6 or 9 6 containers Genset components filters hoses wire harness etc are installed and securely fastened to ensure dependable long term operation and ease of serviceability All wires hoses tubes etc are fastened properly to protect integrity and prevent wire chafing 10 Ring terminals are used on all high voltage connections tructural Design 1 2 The Genset is designed to withstand amp operate satisfactorily in over the road trucking railway operations amp aboard ships The Genset is rated to withstand shock levels of a minimum 3 g s acceleration force in the horizontal direction amp 6 g s acceleration force in the vertical direction The Genset is designed to have no harmful resonance frequencies between 20 and 100 Hz and is rated for vibration levels of 2 g s in all directions tructural Frame Steel material Fuel tank ASTM A 469 METRIC 11320 10 0 134 3 5mm Structur
5. increases to 32 C 90 F selectable Internal self checking diagnostic capability Hour meter Multi language menu capability SG CONTROLLER INTERFACE The SG controller interface contains the following features and components A LCD Digital Display B Alarm LED C Power LED D Six keypad keys 1 Escape use escape a new setting or jump to the parent menu Up use to scroll up through the menu display or increase the value of a setting Down use to scroll down through the menu display or decrease the value of a setting Alarm use to go directly to the alarm list menu and view the alarm information in the display Language use to change the display language English and Spanish are currently available E Unit On Off switch 2 3 4 Enter use to enter or execute controller menu tasks or commands 5 6 Specification No SGCO 3000 EcoPower Rev E PRODUCT SPECIFICATION Page No SG CONTROLLER INPUTS OUTPUTS MENUS Microprocessor Outputs Engine oil pressure Start relay Alternator Voltage Preheat relay Battery Voltage Fuel pull relay Engine Coolant temperature Fuel hold relay Air filter switch On light Coolant level sensor Alarm light Engine oil pressure switch Engine oil level sensor Air heater preheat feedback Fuel pull relay feedback Fuel hold relay feedback Excitation feedback Flywheel sensor 9 9 9 9 9 9 9
6. whether the generator set is operating or shutdown In the case of long shutdown periods the automatic air bleed system insures sufficient air free fuel available to the injectors to successfully start the engine without manually bleeding the lines and injector assembly Fuel Tank Drainage Supplied with a drain plug in the bottom of the tank for purging contaminants Fuel Filters Injection Pump Thermo King s self evacuating filter SEF is both a fuel filter and a water separator in one spin on canister Thermo King Part 11 9342 Clockwise viewed from gear end ransfer Pump Lobe 5 0 mm 0 197 in Injection Timed at See Maintenance Manual ightening Torque 41 N m 27 5 ft lb Injection Lines ID 1 4 mm 0 055 in INozzle Type YDM PD Injection Lines OD 6 mm 236 in ENGINE STARTER MOTOR 12 V DC Over running clutch Clockwise viewed from pinion end 2 3 kW Pull in Current of Solenoid 52 Amps 19 Amps Method of Engagement Magnetically engaged sliding pinion Voltage 2VDC Rated Voltage 12 5 Volts Non energized position Low speed Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION Page No GENERATOR Synchronous type generator consisting of a 4 pole alternator ype with integral revolving Insulation armature 8 pole exciter with rotating rectifiers Maximum 10
7. 5 C in accordance with om 2 A Standard MG 1 22 40 Method of Cooling Drive disc radial fan Sprayed with epoxy Varnish Treatment rimer air dried wound I Vacuum pressure impregnated Varnish Treatment Main P gt i Main Rotor amp Exciter vacuum pressure pass and baked with epoxy varnish Stator amp Exciter Field impregnated with epoxy varnish and baked Cast steel housing Cast Engine Flywheel Housing surfaces are machined for the mounting bolts Class F per NEMA Standard MG 1 1 65 6307 sealed and lubricated with Rear Bearing synthetic hydrocarbon Generator Rating Nominal Output Power 15 KW Voltage 460 Kilovolt Amperes 18 75 kVA Phss B Power Factor 8 Frequency 60 Hz 1800 ELECTRICAL POWER RECEPTACLE Spring loaded water dirt Current Limit Protection protection cover AIR FILTER Heavy duty media filter with cyclonic action and pressure HOSES Intake Air Hose Silicone or high temperature structural EDPM Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION Page No MUFFLER RADIATOR COIL E coat coating for corrosion I Copper internally cross Tube Material PP 7 resistance or equivalent 2 54 mm 0 100 in Fin Material y According to DIN 1787 wall Configuration thickness 0 762 mm 0 030 in ins am TEXACO Extended Life Surface Area 9 6 m 103 f Coolant Fluid Coolant 41
8. 6445 amp rated to 40 C 40 F Propeller Aluminum 1400 cfm BATTERY Maintenance free 12 VDC Cold Cranking Amps Threaded post terminals and Solid state battery charging 26 Terminal Posts standard battery cable Amps output integrated into SG connections are provided controller 330 x 173 x 238 mm 13 x 6 8 x 9 4 in Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION Page No SG MICROPROCESSOR CONTROLLER The SG Microprocessor Controller is a one piece self contained microprocessor for diesel generator sets This system automatically controls the generator set operation by providing Ability to operate at variable speeds for enhanced fuel consumption Automatic unit preheat and engine start up during initial start up or unattended restart Variable air intake heater preheat time Automatic Pre Trip capability Provides unit shutdown protection due to high engine coolant temperature low engine oil pressure low engine oil level fuel relay feedback failure or 230 460V alternator overload Automatic unit restart attempt 20 minutes after High engine water temperature Engine failure to start Check fuel alarm 230 460V alternator overload Fuel relay feedback failure Low engine oil pressure Exterior Deutsch downloading port with protective cap provided Delayed alternator excitation for 15 seconds or until engine coolant temperature
9. Date January 17 2008 r PRODUCT SPECIFICATION Spec No SGCO 3000 EcoPower Rev E SGCO 3000 CLIP ON FUEL SAVING TWO SPEED GENERATOR SET With SG Controller TECHNICAL SPECIFICATION Approval dm Ingersoll Rand Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION Page No TABLE OF CONTENTS FUEL SYSTEM ENGINE STARTER MOTOR SPEED SOLENOID GENERATOR ELECTRICAL POWER RECEPTACLE AIR FILTER MUFFLER RADIATOR COIL RADIATOR FAN BATTERY SG CONTROLLER INTERFACE SG CONTROLLER INPUTS OUTPUTS MENUS SG ALARMS MESSAGES OPERATING INSTRUCTIONS OPTIONS INSTALLATION DIAGRAM DECAL DRAWING FUEL FILTER DRAWING EMI BULLETIN Specification No SGCO 3000 EcoPower Rev E PRODUCT SPECIFICATION Page No REVISIONS Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION Page No GENERAL DESCRIPTION Thermo King Corporation Construction 1 8 9 The generator set is designed for mounting to the upper front structure of an ISO container The design incorporates a quick connection to the upper container corner castings Additional attaching points on the container vertical structural members provide a secure mounting arrangement These lower mounting bolts are retained by a steel plate
10. E The new oil filter head is equipped with a threaded port to accept an ESOC Environmentally Safe Oil Change fitting for quick oil changes EMI 3000 Fuel Filter The new EMI 3000 fuel filter is required to extend the maintenance interval to 3000 hours It can be interchanged with fuel filters used on previous Thermo King gensets Specification No SGCO 3000 EcoPower Rev MM PRODUCT SPECIFICATION March 6 2007 March 29 2007 June 21 2007 August 24 2007 January 17 2008 Page No Revisions Original release Update engine emission official approval request being submitted Update engine emissions for 2008 engines unit weight panels doors and bumpers Section added exterior downloading port to SG description Moved fuel heater from fuel system to option section added option section updated battery section General updates
11. al member ASTM A 635 METRIC 11342 10 and 11416 10 0 250 6 0mm Structural steel frame and integral fuel tank is chemically cleaned through an 8 stage pretreatment line with a multi metal iron phosphate passivation primed with a epoxy polyester powder 1 5 2 0 mils and top coated with a black polyester TGIC triglycidyl isocyanurate powder 2 5 4 0 mils for a final mil thickness of 3 5 5 0 anels Doors and Bumpers Hardware Panels and doors are chemically cleaned through a 6 stage pretreatment line with a multi metal iron phosphate passivation and top coated with white polyester 2 5 4 0 mils TGIC triglycidyl isocyanurate powder 2 Door material Aluminum 063 1 6mm thick Panel material Aluminum 063 1 6mm minimum thickness Two solid rubber bumpers are installed to protect the Genset housing during handling see installation diagram for actual dimensions The upper bumper is 6 5 wide x 2 high x 1 thick The lower bumper is 7 wide x 6 high x 34 thick All hardware screws washers nuts amp clamps are stainless steel for maximum protection from salt water corrosion Powerpack mounting bolts and lower unit mounting bolts are zinc dichromate steel for strength and corrosion resistance This excludes hardware supplied by original equipment manufacturer suppliers Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION
12. iesel POWERCOOL Plus INOTE Use a glycol refractometer to accurately determine the freeze point and concentration of engine coolant Anti Freeze solution refractometer works with both extended life and conventional coolants Specification No SGCO 3000 T EcoPower Rev E PRODUCT SPECIFICATION Page No EMI 3000 Dual Element Oil Filter and Oil Filter Head All Yanmar TK 486 engines with serial number L32024 and after include an EMI 3000 oil filter head P N 11 9354 and gasket P N 33 2931 EMI 3000 dual element oil filter P N 11 9182 and API rated CG 4 mineral oil These components are required to extend the maintenance interval to 3000 hours The EMI 3000 oil filter identified by black and gold colors is NOT interchangeable with the previous oil filters The EMI 3000 oil filter head gasket and oil filter can be retrofitted on previous Yanmar TK 486 engines service category CG 4 describes oils for use in high speed four stroke cycle diesel engines used in both heavy duty on highway 0 05 wt sulfur fuel and off highway less than 0 5 wt sulfur fuel applications CG 4 oils provide effective control over high temperature piston deposits wear corrosion foaming oxidation stability and soot accumulation CG 4 or better mineral oil can be used in older units However an EMI 3000 oil filter and oil filter head is required to extend recommended maintenance intervals to 3 000 hours NOT
13. ll identify units with extended life coolant ELC ELC extends the coolant change interval up to 12 000 hours or 5 years ELC requires a water pump with HNBR elastomer seal bellows and EPDM elastomer O rings Therefore ELC should not be used on older units with standard water pumps All Yanmar TK 486 engines with serial number L16553 and after include a new EMI 3000 water pump for use with extended life coolant ELC Compatible Water Pump 11 9442 ELC Nameplate 91 9269 Thermo King ships all water cooled engines from the factory with a 50 antifreeze concentrate and 50 water mixture in the cooling system ELC coolants are available in 100 full strength concentrate or pre mixed 50 50 mixture Thermo King recommends the use of 50 50 pre mixed ELC coolant to assure that de ionized water is used ELC 100 concentrate must be mixed 50 50 with de ionized or distilled water NOT tap water to ensure cooling system integrity The following Extended Life Coolants are approved by Thermo King for use in ELC units for five years or 12 000 hours Texaco ELC 16445 100 concentrate Texaco ELC 16447 premixed 50 50 mixture Havoline Dex Cool 7994 100 concentrate Havoline Dex Cool 7995 premixed 50 50 mixture Shell Dexcool 94040 Shell Rotella 494041 Havoline XLC 30379 100 concentrate Europe Havoline XLC 33013 premixed 50 5096 mixture Europe Saturn General Motors Dex Cool Caterpillar ELC Detroit D
14. t More than 127 kPa 18 5 psi 1600 rpm More than 2942 kPa 427 psi 250 rpm 12 3 liters 13 quarts 21600 22600 kPa 3100 3300 081 Engine Rotation Oil Pump Type Clockwise viewed from pulley end 2008 manufactured engines are compliant with EPA and CARB regulations ENGINE LUBRICATION SYSTEM Trochoid Delivery Volume 15 7 liters 4 15 gallons min 1000 pump rpm API CI grade or better Use straight or multi weight oils appropriate for the ambient temperature delivered with 10W30 oil Oil Filters Full Flow Dual lube Full flow bypass filter Thermo King Part 11 9182 Oil Change Interval PreHeat Consult applicable service manual ENGINE ELECTRICAL SYSTEM Intake Air Heater Resistance 0 2 Ohms Rated Voltage 11 Volts Rated Current 77 Amperes r PRODUCT SPECIFICATION Fuel Tank FUEL SYSTEM 125 gallon steel fuel tank integral with frame Two filler necks are located on opposite sides of the tank Tank is fumigated internally to protect against corrosion Fuel Tank Mounting Specification No SGCO 3000 EcoPower Rev E Page No Integral to Genset Held with 200 Ib tension chain Anti Siphon Rated at 30GPM Automatic Air Bleed Thermo King furnishes a patented air removal system for purging air from the injector pump and fuel supply lines The air bleed system works
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