Archive for the ‘MER News Bulletin’ Category
MER EFFICIENCY AND PRODUCT SUPPORT-BY DESIGN
MER = MORE
High Fuel Efficiency-MER industrial and marine generators provide very low fuel consumption, and this is due to our specification for more copper per kilowatt rating. The fuel savings is in the tens of thousands of dollars over the life of the machine. Our complete load survey is done by telephone, up-front at no cost. However, before we’ll sell you a machine, all of the present loads and future upgrades are taken into account. If you’re purchasing for a work boat, we’ll ask things like, “Are you planning to upgrade your refrigeration system?”, or “What are you spending for fuel now?” Similarly, “Can you continue fishing if fuel reaches $6?”
Custom Machines-Our generator is customized to your application. It might need a special power-take-off, a larger oil pan, extended oil-change interval, or a coolant filter. The MER fab shop builds jacketed marine manifolds to protect crew members from burns as they work in the engine room. This is especially important when the boat is underway.
Motor Starting-On the electrical side of things, we supply generators capable of very heavy motor-starting or exceptional voltage stability for on-board electronics. We also have PMG models that do both. All of our diesel generator sets are available in 50 and 60Hz, with either electronic regulators or internal regulation. Optional control systems by Deep Sea Electronics provide remote monitoring via the internet. This covers things like oil pressure, coolant temperature, and other parameters as detailed as the fuel level in each tank. This valuable asset aids hard-working crews working long hours, hundreds of miles away.
MORE COPPER MEANS LESS FUEL
Play Favorites-Got a favorite engine or generator end? We’ll provide Deere, Isuzu, Cummins, Kubota, Yanmar, Marathon, Meccalte, or Stamford. Our generators come in one or two-bearing configurations for mounting on either end of the engine. Our optional galvanized steel skid keeps the engine room looking great.
Better Design-SolidWorks computer aided design (CAD) capability insures smooth and efficient assembly. Need a higher capacity cooling system for equatorial waters, or how about a special compact heat exchanger system? No problem. Our detail oriented experts in production will fabricate, assemble, align and mount the critical parts of each machine. This includes Low VOC painting, calibration and testing of each machine. The final test is at 105% of the machine rating, and the technician signs the test sheet-just like any aircraft technician does.
Not Just Efficient Generators-After the machine is finished there are two more jobs to do: We deliver it in one of our fuel efficient trucks. Secondly, we recycle; separating all metals, and trash, including spent printer cartridges, and filtering shop solvent for re-use.
Product Support-After the sale MER provides electronic documentation and product support. Call us for specifications, service instructions, wiring and plumbing diagrams, as well as photos of how things work. It’s available electronically in your choice of format: Fax, e-mail, and I-phone. However, if you’re too busy catching fish to study the latest computer technology, that’s OK, we’ll print what you need and mail a paper copy!
DRAWINGS OF THE LAYOUT HELP YOU ORDER THE RIGHT PARTS
MER Options-These include LED lighting that lets you buy a smaller gen-set from the start. Using just 1/8th the power of high pressure sodium lighting. This is the future of marine lighting. There’s one more thing about marine lighting-High Pressure Sodium lights compete for the motor starting power the generator can produce. Then there are our precisely sized exhaust systems that eliminate fuel robbing back pressure. They also last longer.
Parts and Service-Our inventory is one of the largest in the Northwest including engines and transmissions; with the parts and fluids to keep them running. Both Parts and Service Departments are available 24hrs. And yes, it is expensive to roll-out our people at two in the morning and have parts hand-carried to the airport, but we’re here for you.
MER Training-Our technical instructors are experienced gear-heads who put on a variety of classes, ranging from Beginning Engines all the way to Shaft Alignment.
New Product Pipeline-Is your engine room too loud or too hot? Is changing oil making a mess? Just keep an eye on our web site to see the latest: www.merequipment.com. Clicking the Blog tab at the top of our web page brings you here, to the MER Technical Support Blog, one of the best in the industry. http://www.merequipment.com/blog/.
Just think of us as the Hot Rod Shop of the future: We build powerful custom machines that use less fuel, instead of more. We also do a lot more than electrical power generation. Call any time: 800-777-0714, or stop in and tell us about your project.
Deere Marine PowerTech Engines-Propulsion, Generator and Auxiliary Drive Engines
6068AFM:
Propulsion-The AFM series combines a 4-valve cylinder head with a High Pressure Common Rail Fuel System and the benefit of a jacket water after-cooler and single circuit keel-cooling. The compact engine has multiple power-take-off (PTO) options for powering auxiliary equipment.
Generator Drive-This year the generator rating increases to 150kWe.
Auxiliary Drive (6068HF)-These variable speed, radiator cooled engines are available up to 258HP at 2200RPM. Deere has several engines for use in auxiliary applications driving hydraulics. They’re all available with multiple pump drives attached to either end of the engine, and also generators opposite the pump drive.
6090AFM75:
Propulsion-Like the 6068AFM above, the AFM designation denotes a keel-cooling system with engine jacket water and the after-cooler on one circuit to the keel-cooler. Power ranges from 285 HP at 2100 to 425 at 2400RPM. The high pressure common rail (HPCR) fuel system provides superior atomization and very efficient combustion. High efficiency coolant jacketed turbocharging supplies more combustion air to the cylinder through the 4-valve cylinder head. John Deere’s powerful electronic engine control directs this “symphony” of power production.
Generator Drive-The generator rating increases to 225kWe this year.
Auxiliary Drive (6090HF)-Power ratings up to 375HP at 2200.
6135SFM:
Propulsion-This 13.5 liter engine has separate heat exchangers for both the engine circuit and the -cooler circuit. The 824 cubic inches help take the power level to 650 at 2300RPM in a commercial rating, and then on to 750 at 2200RPM, in the M-5 rating. Like all of Deere’s new electronic engines, the 6135SFM benefits from much greater engine control computing power, further reducing fuel consumption.
Generator Drive-The generator rating is 325kWe for this new engine.
6135AFM:
Pre-production 6135AFM engines are now working in the field and will soon be released, providing another high power keel-cooled engine option.
Auxiliary Drive-(6135HF) Power ratings to 600HP at 2100RPM.
MER Stocks The Kubota Lowboy
Custom, Tailored, Specific-
Three ways to describe MER products. Everyone knows our after sale support is the best in the marine market. Have you considered our before-the-sale support? Take a MER custom marine generator for example: During the first phone call our technical sales people identify how you’ll use the generator; its exhaust outlet direction, dipstick and oil filter location-for easy service, voltage, frequency, type of cooling, space constraints, and most importantly the size and type of electrical loads on the boat.
Motor starting loads are the most critical part of the picture. Where the generator is concerned, in terms of running a marathon, heaters and lighting are just like a long level straight stretch. Motor starting loads however, are like a short, but very steep, uphill climb for the runner. We consider kilowatts (speed the electrical work gets done on the boat), but also very important, we consider kilovolt amps (the load the generator feels).
Consider this analogy: Someone on the shore of a river is timing the speed of a swimmer going downstream at a rate of 3 miles an hour, for a one-mile stretch of the shoreline. The swimmer’s speed along the shore is like the kilowatt rating (kW), and the effort the swimmer must make to do it is like kilo-volt-amp rating (kva). Next the swimmer changes direction, and with much more effort swims upstream against the current, taking the same time to cover the one mile distance as measured by the shoreline. The speed (kW) is the same, but the effort required by the swimmer (kva) is much greater.
Some loads just make the generator feel like it’s swimming upstream.
Next we find the kind of power-take-off configuration needed for the boat’s hydraulic pump drive. With nearly a hundred options, we’ll get it just right. If it’s really unusual, our in-house inventors will design and build the solution. Finally, we are experts at logistics and availability: This is vital since equipment suppliers are stocking far less product than ever before.
New Products
This year MER added three new brands of equipment to our extensive product line.
The Cummins line of marine diesel engines complements our extensive line of engine products. These engines fill certain horsepower gaps resulting from the wave of recent changes from more strict EPA requirements. Check our prices on the B series remanufactured MECHANICAL engines that come complete with mounts, wiring and instrument panels. Cummins/Onan marine generators use Kubota engines up to 32kW and John Deere on up to 99kW. These are among the quietest enclosed generators available and they are designed to accept the Onan field installable enclosure, even after the sale.
Equipment Source Incorporated (ESI) now supplies MER with Kubota packaged generators as well as their own line of rugged ESI packages based on Kubota engines and Meccalte generator ends.
Meccalte Generators have excellent quality control and a diverse product line from 1-2400kW generators. The 60 year old Italian manufacturer has extensive robotic manufacturing capability: (http://www.meccalte.com/index.php?s=180).
So, give us a call and learn how our products will save dollars, by greater efficiency.
After the decision is made to use a dry exhaust system instead of a wet system, the next chore is to decide where the silencer will be mounted.
One option is high up on the boat, under the stack cowling, if so equipped. Another place if space allows, is in the engine room, where fishermen often opt to mount the silencer overhead or on the back engine room bulkhead.
Now there is another option: On the engine itself, bolting directly to the top of the flywheel housing. Our product line now includes Cowl Silencer brackets that fit the range of smaller Isuzu diesel engines, including models: 3CA, 3CB, 4LE1, 4LE2, 4TNV98, and the 4TNV98T. MER builds Cowl silencer mounting brackets to allow mounting on the back of the engine, in the little “dead space” above the generator end (or the transmission). Our new brackets provide plenty of room for the exhaust insulation blanket and provide vibration-proof stability for long life. Made of MIG welded mild steel, the brackets are available galvanized, or can be painted your choice of colors.
- Deere’s Common Rail Fuel System Reduces Emissions While Increasing Efficiency
Customers ask us:
Should you use lubricity additives in this new Ultra- Low Sulfur Diesel fuel, or not?
In a word, YES, strictly according to your engine maker’s specification. Part of the reason is that ultra high pressure common-rail fuel systems came into wider use at the same time. The other reason is, the process that reduced fuel sulfur from 500 ppm to 15 ppm also decreased the fuel lubricity. Decreasing the sulfur dioxide emissions is an important step for all living things. It’s also true that engines and ultra high-pressure fuel systems need more lubricity than ever, to prevent equipment damage and premature equipment failure. Diesel-fuel lubricity is the ability to provide surface-contact lubrication that helps protect fuel systems. In diesel engines, rotary and distributor-type fuel injection pumps rely on fuel as lubricant. Increasingly sophisticated diesel fuel injection equipment runs at higher operating temperatures with high injection pressures, multiple injections, & finer tolerances—all requiring clean, lubricious fuel for performance & longevity.
Measuring lubricity is based on a rather simplistic test: a hardened steel ball runs against a hardened steel plate vibrating under load while immersed in fuel to give a “wear scar” diameter on the plate. It’s called the High-Frequency- Reciprocating-Rig test—HFRR. When the scar diameter is smaller, the better the results. The ASTM specifications (American Society for Testing & Materials) set 520 µm (microns) as the maximum wear scar for diesel fuel sold in the US. Some say it’s good enough. However, general industry agreement holds to the higher European standard of a 460-µm maximum scar. Fuel-injection equipment manufacturers got together and agreed: If over 460, their fuel-injection equipment might not meet expected lifetime performance and emissions targets.
They also said if you put in additives to increase lubricity, take care to use the right additive—but not too much of it. Too much conditioner causes internal pump-plunger and injector deposits. It’s actually come to the point where even equipment manufacturers accept biodiesel as a proven nontoxic & superior lubricity agent without the adverse effects of overdosing on other additives. But you still can’t get biodiesel in Alaska and it’s unstable, so you can’t store it or take it with you. Other than that, it’s great. We’ve put man on the moon, yet America’s diesel engines rely on measuring a scuff mark on metal. Seems almost barbaric. Caveman tools. It’s like the swine-flu shot: Should you get it? Does it benefit? Are there risks? Take in all the information, ask around, and make your own decision. And rest assured we will continue following this issue & revisit it here and on the blog again.
DURABILITY AND EFFICIENCY ARE MORE IMPORTANT THAN EVER!
This is the most challenging economy most of us have faced. There are fewer dollars available, so it’s time to take a look at how to save precious operating dollars:
Follow along on the above illustration, starting at the top and working in a clockwise direction.
MER Heat Shields-Neither high tech or expensive, we add intake heat shields where needed, to minimize heat transfer into the intake air supply. Result: Better fuel efficiency.
Better Filtration-Our engines are equipped with either dual-element, or cleanable, low restriction air filters. Our new intake air silencer will make life on the boat much more comfortable. Result: Better fuel efficiency and lower maintenance cost.
Safety Systems-Our engines are so smart that they know when to sound an alarm, derate, or even stop to prevent engine damage. Result: Saves replacing your engine at half-life due, for example, to a failed coolant hose.
Belt Tensioners-Our belt tensioners keep the alternator, coolant pump and accessories turning like they should. Result: Saves replacing a good alternator due to belt slippage.
Lube Systems-Our engine pre-lube pump fully lubricates the engine (or transmission) before you start it up. This saves engines wear. Our system is valved to to also pump out old engine oil at oil change time. Result: Engines last longer and are easier to maintain. You will never have to worry again about whether or not the crew tightened the drain plug!
Custom PTOs-Our pto drives provide powerful and flexible options for running your accessories. Auxilliary drives off the engine are also available. Result: No vibration or clutch slippage, just trouble-free and productive time on the water.
Anti-Corrosion Strategies-Deere Extended Life Coolant, and Pen Ray Need-Release coolant conditioners stop electrical activity in the engine cooling system. Result: Your engine will last longer.
Marine LED Lighting-We are finding that our new LED marine lights require only one eighth the power of conventional sodium ar quartz lights. If you use lights for night fishing, our LEDs will put more light in the water and require less power doing it.
Magnetic Filters-Our Fuzz-Buster transmission filters grab and hold the small metal paticles that wear-out your transmission. Result: Longer and more dependable transmission life.
Fuel Priming Systems-The MER Diesel Prime system makes fuel filter changes and start-up easier and faster. Result: No more “grinding” on the starter motor to prime the fuel system.
Custom Engine, Transmission, and Generator Mounts-Our mount kits enable you to mount any equipment in a secure, vibration-free manner. Results: Provides for easy alignment and very quiet operation.
Compressed Air Systems-Our direct coupled engine-driven compressors supply large amounts of compressed air at a pressure of 120 psi. The compressors are “drive-thru”, meaning that additional accessories can be driven off the back of the air compressor. Result: No noisy electric air compressor on-board.
Exhaust Systems-Cowl and EM exhaust silencers, when coupled to high quality flex assemblies, provide quiet performance that lasts. Result: Lower over all maintenance cost.
- The New Deere 4045 Common-rail Diesel Engine
The Deere 4045 Is Now Common Rail, further increasing power, while reducing exhaust emissions.
Speaking of low emissions-visit our new emission retrofits page to learn how to improve the air quality in your neighborhood. Meet air quality standards with older equipment by retro-fitting your equipment.
Retrofitting after-treatment equipment will often reduce emissions of Hydrocarbon, Carbon Monoxide, and Particulate Matter by 70-90% and more.
Indoor forklifts, underground mining equipment, and drill rig engines must now meet State and Federal Air Quality Standards. MER can bring your equipment into compliance.
The MER-Alaska Service Program-MER has always supported Alaskan fisherman with replacement parts and technical support, now we are expanding our effort to include an on site technician for your 2009 pre and post season needs.
MER has also increased our online support capability by expanding our website, and our blog. Our regular blog “broadcast” will soon complete its first year of technical support for our customers. Better support lowers your cost of operation: http://merpower.wordpress.com
Introducing Karl Pettersen – Bristol Bay/MER Tech - Karl is a graduate of UTI Technical College in Arizona and has specific factory training from John Deere and Yanmar. Karl will be at the helm of the F.V. Arctic Osprey, in Bristol Bay from June 17th through July 20th, but will be available for service-both before and after. Contact Stevie by email (stevie@merequipment.com) to schedule your service work, or a re-power with a Deere, Isuzu or Yanmar.
Let MER show you how installing a 6.5 or 12KW Isuzu Genset can pay for itself in fuel savings. The 12KW uses only .5 gallon per hour. Avoid running your main just to keep the RSW powered up. Our Cowl and EM Silencers will make it whisper.
Introducing Stevie Schmidt — Parts and Service Professional – Stevie has been in this industry for over 20 years, and has done everything from tying long line black cod gear to selling parts. For the last 3 years, Stevie has done an excellent job as our Service Writer and Field Service Coordinator. Stevie started our coolant system preventive maintenance program: Ask her how to reduce your maintenance and repair costs.
Please give her a call at 800-777-0714 to get parts moving for your bristol bay order, or to schedule Karl to visit your boat.
MER Marine Service Training- Classes will cover topics that will reduce your maintenance costs while making the boat safer:
In an expanding effort to meet our customer’s needs, the MER service department is pleased and excited to introduce our engine maintenance training classes.
Beginning this Spring and carrying on throughout the year, MER will be conducting engine specific maintenance classes geared toward amatuers, do it yourselfers, and professional maintenance staff.
Classes will be available for John Deere, Isuzu, and Yanmar, as well as Kanzaki and Hurth gearboxes. Please e-mail stevie@merequipment.com for times and dates of classes on your specific engine and a copy of the syllabus.
We will cover such topics as fuel system maintenance, cooling system maintenance-both fresh and raw water, electrical system diagnostics and repair, and basic engine maintenance.
Our Spring Special-includes a 10% discount on all parts and labor, when we change the oil and fuel filters, change oil, check zincs, adjust the valves and do a cooling system inspection. This special includes a 63 point inspection of the boat’s marine power system. The list of inspected items is available from http://www.merequipment.com/49948/MER-Service-Checklist.html.