Genset Start-up and Initial Runtime

The startup sequence is initiated by the user applying power to the controller by toggling the external switch to the on position.

Unit Start Sequence

Countdown Timer

A countdown will be displayed on the screen to inform the user that the start-up sequence is about to begin. This countdown is the time allowed for a used to interact with the controller and stop the start sequence

  • Display “Start Delay” and the value displayed in seconds.

  • Countdown timer is to be 30 seconds regardless of start process or preheat process

  • Short press of FI will stop start sequence and ECU will remain ON

Buzzer

During a unit start sequence the controller will activate the buzzer in order to alert the user. This alert will cease at starter engagement.

  • Buzzer to cease when starter engages

Engine Start Sequence

At the appropriate point in the Genset power on process, the controller will request an engine start by sending the appropriate message to the Yanmar ECU.

Start attempt:

  1. Countdown timer is to be 30 seconds regardless of start process or preheat process

  2. Buzzer is to sound for 20 seconds regardless of start process or preheat process

  3. Controller to request engine start, and 1500 rpm operation.

  4. Yanmar ECU to manage Preheat and Starter engagement.

  5. Successful engine start is achieved when the Yanmar ECU broadcasts the appropriate CAN message.

Engine Restart Sequence

Following a start sequence where the engine did not start as defined above., the controller will take the following actions.

Display

  • During the first restart attempt, the controller display will follow the process defined above.

  • During subsequent restart attempts, the controller is to display “20 minute delay ” and the countdown timer

Restart Rules

  • The controller is to count the number of restarts, and to continue attempting to restart the unit until the number specified in the unit configuration menu is reached

  • After user defined number of restarts is expired, controller unit is to shut down and take no further action

  • The restart counter it to reset to zero after 1 hour of unit running

First restart attempt

  • If the engine fails to start on the first attempt, the controller is to repeat the start process immediately, beginning from the countdown timer step.

Subsequent restart attempts

  • If the engine fails to start on the second attempt, the controller to initiate a 20-minute countdown timer followed by a 3rd attempt to start again

  • Upon completion of the 20 minute countdown, the controller is to repeat the start process immediately, beginning from the 20 second Countdown Timer step.

  • The number of restarts is to be user definable via the configuration menu.

  • After user defined number of restarts is expired, controller unit is to shut down and take no further action.

Post Start

Following a successful start as defined above, and the controller has requested 1500 rpm operation, the controller is to take the following actions:

  • Controller is to display “Delay to Output” This is to align with the non-energized state of the Quad Relay

  • Engine is to remain at 1500 rpm for 2 minutes, then the controller is to request speed switch to 1800 rpm and remain at that RPM for 15 mins

  • When the engine is shifted to 1800 rpm, the controller is to wait 10 seconds and then  energize quad relay

  • When the Quad Relay is energized the controller display is to revert to normal operation

Pre and Post Heat

  • Coolant temperature =/> 34°C

    • No automatic pre-heat, or post-heat required.

  • Coolant temperature =/> 20°C, < 34°C

    • 20 seconds of pre-heat, 0 seconds of post-heat

  • Coolant temperature =/> 10°C, < 20°C

    • 20 seconds of pre-heat, 1 second of post-heat

  • Coolant temperature =/> 0°C, < 10°C

    • 20 seconds of pre-heat, 10 second of post-heat

  • Coolant temperature < 0°C

    • 50 seconds of pre-heat, 10 seconds of post-heat

Genset Start Sequence and Display Timing

Engine Operation and Speed Control

  • Isochronous speed control to be used at all RPM’s

  • The controller must evaluate engine load to select between 1500 or 1800 RPM operation using the logic below.

  • The logic below applies only after completion of the Initial Runtime routine defined above

  • The Genset is to remain in Low Speed (1500 rpm) at all times regardless of engine load with the following exceptions:

    • During the initial runtime routine, the engine will run in High Speed (1800 rpm) for 15 mins as specified in “Initial Runtime Routine”

    • After that 15 minute period of High Speed (1800 RPM) operation. The controller is to shift to Low Speed (1500 RPM) operation if the Engine Load  is </= 85%  or >/= 97%

Engine Stall

If during normal operation the genset engine stalls and ceases to run, the controller will take the following actions.

  • Review alarms for cause of shut down.

  • If alarm level permits a restart (as defined in alarm section) then the controller to initiate an engine restart following the process outlined in the Genset Start Sequence above

  • Attempted restarts after an engine stall event does not require the 20 minute delay step, the controller should attempt restart immediately.

  • Attempted restarts after engine stalls are not to be considered in the count of re-start attempts as defined by the user in the configuration menu.

  • Engine stall is defined if the engine is at 100% load, is unable to maintain requested RPM and ceases to run

Unit Alarm Monitoring

During on time, the controller needs to monitor the Genset system function and react as defined in the Alarm Handling and Protection