Wednesday, January 25, 2012

PLC controlled military MEP-003A generator

I had a really nice low hour -003A that I had been using to power tools at remote job sites, backup power for my shop, etc. I was just loading it onto my flatbed trailer as needed, but I decided that it would be fun to build it into an enclosed trailer (which doubles as lockable tool storage). I wanted to make its operation as simple as possible, so my employees could start it without needing a course on MEP operation. My goal was to be able to safely start and run the entire trailer with the push of one button. It came out perfect; here are the details: I used a TECO PLC and wrote a program to control the generator, a magnetic switch (to isolate the generator's output from the load center), and the air compressor's blowdown valves. The PLC displays messages to the operator about what it is doing (for example, "engine cranking, low oil pressure bypassed," "warming up, please wait,", etc.) The start sequence goes like this: 1. Operator pushes green start button 2. PLC energizes fuel pumps, manifold heaters, and glow plugs for 40 seconds (I found this was the time needed to start the set when it was near zero degrees outside) 3. PLC energizes a relay which bypasses the low oil pressure switch, and cranks the engine (same as holding the start switch in start) for 15 seconds 4. Once running, the PLC disengages the start relay and allows the set to run unloaded for 1 minute 5. The PLC closes the magnetic switch, energizing the load center 6. Once every minute, the PLC opens ...

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