Sole Diesel 100 GTAC Operator'S Manual Download Page 87

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Tightening torques

Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · [email protected]

Operator’s Manual Marine

generators sets

Section 10

–

Tightening torques

Important nuts and screws.

TIGHTENING VALUES

85 GTC / 100 GTAC / 115 GTC / 120 GTAC DNV

N · m (kgf · m)

Cylinder head

127.5 (13.0)

Crankshaft pulley

39.0 to 49.0 (4.0 to 5.0)

Main bearing caps

49.0 (5.0)

Connecting rod caps

29.5 (3.0)

Flywheel:

30-45 mm Bolts

19.5 to 29.5 (2.0 to 3.0)

50-85 mm Bolts

29.5 to 39.0 (3.0 to 4.0)

Oil pan drain plug

49.0 (5.0)

Oil filter

14.7 (1.5)

Heat exchanger drain

plug

22.5 (2.3)

Nut for B + Terminal of

starter

10.8 (1.1)

General tightening torque

9.8 (1.0)

24.5 (2.5)

M10

58.8 (6.0)

M12

98.0 (10.0)

Summary of Contents for 100 GTAC

Page 1: ...Introduction Marine generator sets Operator s manual TYPE APPROVAL DNV 85 GTC 100 GTAC 115 GTC 120 GTAC U_GNBP_EN Rev 1 02 2020 ...

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Page 3: ...rmance in the most demanding operating conditions The images text and information contained in this manual are based on the product s features at the time of publication Solé Diesel reserves the right to modify this document without prior notice Abbreviations BTDC Before Top Dead Center ATDC After Top Dead Center BBDC Before Bottom Dead Center ABDC After Bottom Dead Center API American Petroleum I...

Page 4: ...ge of packed and unpacked genset 16 Section 3 Installation 17 3 1 Genset information 17 Section 4 Operation 18 4 1 Prestart checklist 18 4 2 Genset Operation at low temperatures 18 4 3 Winterzation and preservation 19 4 4 Maintenance during the storage 20 4 5 Restoration of operational conditions 20 Section 5 Systems and scheduled maintenance 21 5 1 Operating description 21 5 2 Periodic maintenanc...

Page 5: ...intenance task Seawater filter inspection 30 Maintenance task Seawater pump impeller inspection 30 Maintenance task Zinc anode inspection 31 5 7 Inlet and exhaust system 31 Exhaust circuit description 31 Maintenance task Air filter inspection 32 Maintenance task Exhaust gas noise and vibrations inspection 33 Battery 33 Circuit protection 33 Maintenance task Starter motor inspection 34 Maintenance ...

Page 6: ...lt indicator lamp 46 Diagnostic button and fault indicator lamp 48 Section 9 Control panel 55 Section 10 Tightening torques 85 Section 11 Wiring Diagrams 86 Section 12 Alternator connections 91 12 1 Regulator connections 92 Section 13 Overall dimensions 93 Section 14 Instructions to replace and remove 96 Section 12 Inspection prior to the delivery of generator sets 98 Maintenance log 100 ...

Page 7: ...ash fire can cause severe injury or death Do not smoke or permit flames or sparks near the fuel injection system fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Catch fuels in an approved container when removing the fuel line or ...

Page 8: ...epiness mental fatigue inability to concentrate or speak clearly blurred vision Stomachache vomiting nausea Keep the area around the battery well ventilated While the engine is running or the battery is charging hydrogen gas is produced which can be easily ignited Never allow battery fluid battery contains sulfuric acid to come in contact with clothing skin or eyes Always wear safety gloves and pr...

Page 9: ... the engine has to wear suitable CLOTHING for the workplace and the situation in particular avoid loose clothes chains bracelets rings and all accessories that could become entangled with moving parts 2 The installer operator of the engine has to wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task 3 The area in which the operator is worki...

Page 10: ... voltage Operate the engine only when all guards and electrical panels are ready Hot parts coolant and steam Stop the engine and let it cool down before touching or removing any engine part Moving parts Keep hands feet hair clothing and test leads away from the belts and pulleys when the engine is running Replace guards screens and covers before operating the engine Heavy material Engine is a heav...

Page 11: ...nters into force from the time of sale to the firs end purchaser or user of the engine or generator ser In the event that the product is not immediately delivered to the end customer the warranty shall enter into force 6 months after the date of sale Any limited warranty period that has not elapsed can be transferred to the following purchaser s Unless authorised otherwise by Solé Diesel the warra...

Page 12: ...ns and maintenance services indicated in the User and Maintenance Manuals have not been adhered to properly In case of implemented warranty supporting document of the revisions and maintenance service should be exhibited proving the requirements outlined in the manuals have been followed d Deterioration resulting from time of storage exceeding 6 months and or storage conditions that do not comply ...

Page 13: ... condition shall void the warranty in all its terms In such an event the materials oil filters etc and labour involved shall be at the expense of the purchaser The purchaser should keep the invoice of the work performed as proof If the service is not covered by the warranty the purchaser must pay for all labour performed the associated materials and any other expense related to the service All shi...

Page 14: ...ENTIFICATION LABEL The nameplate is located above the rocker cover The characteristics plate of genset it s located above the alternator case The characteristics plate of canopy genset it s located outside as shown in the following picture GENSET SERIAL NUMBER In addition all gensets are marked with the serial number on the block on the fuel injection pump The standard genset can operate at temper...

Page 15: ...njectors 10 Valves 11 Fuel overflow valve 12 Air cooled only in 115 GT GTC and 120 GTA GTAC 13 Admission manifold 14 Exhaust manifold 15 Turbocharger 16 Air filter 17 Se water pump 18 Coolant water pump 19 Heat exchanger 20 Expansion tank 21 Anode 22 Coolant drain plug engine 23 Coolant drain plug tank 24 Coolant drain plug heat exchanger 25 Coolant filler cap 26 Starter motor 27 Alternator 24V 28...

Page 16: ...r sales departments and the carrier immediately and forward photographic evidence of the damage After inspecting the goods if you notice damage write a reservation on the delivery note Have the carrier countersign the note and advise Solé Diesel preferably by mail info solediesel com 2 2 Transporting and handling the packed genset When lifting and transporting the genset use EXCLUSIVELY a forklift...

Page 17: ...rage of packed and unpacked genset If the genset is left idle for prolonged periods the client must check the possible conditions of conservation in relation to the place of storage If the genset is unused for prolonged periods and stored observe all the relative technical specifications The treatment of the genset for storage is guaranteed for 6 months after the time of delivery If the user decid...

Page 18: ...T OUTLET 2 DRY EXHAUST OUTLET SEAWATER OUTLET 3 CONNECT SIPHON BREAKER if installed 4 CONNECT SEAWATER INLET 5 CONNECT FUEL INLET 6 CONNECT LEAK COOLANT OUTLET 7 FILL WITH OIL 8 FILL WITH COOLANT 9 CHECK EACH PIPE CONNECTION for oil or coolant leaks 10 CONNECT TO EARTH 11 PRIME THE FUEL SYSTEM 12 CONNECT TO CONTROLLER PANEL 13 CONNECT TO BATTERY Follow label battery connection into the genset It i...

Page 19: ...tight exhaust system connections Check that the exhaust outlet is unobstructed FUEL LEVEL Check the fuel level and keep the tank s full to ensure adequate fuel supply OIL LEVEL Maintain the oil level below dipstick high mark and above dipstick low mark OPERATING AREA Check for obstructions that could block the flow of admission air SEAWATER PUMP PRIMING Prime the seawater pump before initial start...

Page 20: ... The degree of corrosion depends on meteorological changes and climatic conditions The following recommendations are therefore of a general nature but they will help prevent or reduce the risk of damage due to rusting 4 3 Winterzation and preservation If the boat is not going to be used for a long period of time or during the winter certain tasks must be carried out to keep it in perfect operating...

Page 21: ...e of the genset increase 5 Get the genset work during 5 or 10 minutes without load as maintenance operation 4 5 Restoration of operational conditions When starting up the genset again after winter lay up certain operations must be performed Follow these steps 1 Fill the fuel tank with clean diesel The mixture of diesel oil and anti corrosion additive in tank for winter lay up can be used to operat...

Page 22: ...eals O rings rubber seals etc in cleaning solvent and dry them Use only the correct tools and instruments Use only good quality lubricating oils and greases Be sure to apply a coat of oil grease or sealant to parts as specified Use a torque wrench to tighten parts when specified tightening torques is required Replace all gaskets and packing Apply appropriate amount of adhesive or liquid gasket whe...

Page 23: ...ure I Lubrication system Genset oil I C C C C Oil filter C C Fuel system Fuel level I Fuel tank CL E CL I Fuel filter C Water separator filter if applicable E C Injection pump I Injector I Intake system Air filter I C C I Turbocharger I Cooling system Coolant I C C Salt water circuit I CL Anode I C Water filter I CL CL Sea water cock I Salt water pump impeller I C I I CL Electrical system Incandes...

Page 24: ...ness gauge between the rocker arm and valve cap to check the clearance 2 Loosen the rocker nut 1 3 Tighten or loosen adjusting screw 2 to adjust valve clearance by checking thickness with thickness gauge 3 4 When you have adjusted the thickness tighten the rocker nut and recheck the thickness With piston nº 1 in the top dead centre of the compression cycle adjust the play of the intake and exhaust...

Page 25: ...ch the compression pressure gauge 3 Disconnect the stop solenoid connector the fuel supply shut off and crank the genset by means of the starter and read the compression pressure gauge indication when the genset is running at specified speed If the compression pressure is lower than repair limit check the genset parts affected It is not a good practice to measure the compression pressure on only f...

Page 26: ...hrod 14 Rocker arm 15 Pipe to oil pan 16 Oil pressure sensor 17 Pipe to turbocharger 18 Turbocharger 23 Pipe to oil pan 24 Pipe from turbocharger to oil pan 25 Oil suction pump Oil specifications Use oil with 15W40 viscosity this is an all season oil for temperatures ranging between 15ºC and 40ºC or select the most suitable oil viscosity for the atmospheric temperatures on which the genset is goin...

Page 27: ...osition fill the oil circuit until the dipstick minimum mark and take note of the quantity of oil used 2 With the engine in horizontal position fill the oil circuit until the dipstick mark maximum and take note of the quantity of oil used 3 With the engine inclined fill the oil circuit with the maximum oil quantity according to the previous amount Then extract the difference between the maximum an...

Page 28: ...ASTM diesel fuel No 2 D for the best genset performance to prevent genset damage Never use kerosene heavy diesel fuel or biodiesel It is essential to use clean and filtered diesel oil The use of diesel oil that not complies with the technical specifications may affect warranty coverage and cause serious damage in the injection system and internal genset components Maintenance task Fuel level inspe...

Page 29: ...hange Procedure to change the fuel filter 1 Close the fuel supply valve 2 Disconnect fuel pipes from the fuel filter 3 Remove fuel filter with a bell key 4 Place a new fuel filter 5 Reconnect fuel pipes from the fuel filter 6 Open the fuel supply valve 7 Once finished with this operation start the genset and check for oil leaks Wash hands after any contact with diesel fuel Maintenance task Injecti...

Page 30: ...cified in anti freezing agent package labels It is advisable select the anti freezing agent concentration based on a temperature approx 5ºC under the actual atmospheric temperature Other genset coolants may affect warranty coverage cause an internal build up of rust and scale and or shorten genset life PIECE ELEMENT 1 Pump prime line 2 Coolant pump 3 Oil cooler 4 Cylinder cooling cirucit 4A Cylind...

Page 31: ...ill to the hole in the tank cap with coolant Maintenance task Seawater filter inspection It is important to install a seawater filter supplied as accessory between seawater cock and the seawater pump to avoid that any impurity might clog the seawater circuit or seawater pump To clean this filter 1 Loose the cover top turning it 2 Remove the filtering component and clean it 3 Fit it again taking ca...

Page 32: ...at exchanger 3 Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode 4 Clean the threaded hole of the heat exchanger and coat the threads of anticorrosion zinc anode Install the anticorrosion zinc anode into the heat exchanger 5 Close the coolant drain plug and open the seacock Refill the coolant circuit 6 Start the genset and check for leaks at the anticorrosion zinc anod...

Page 33: ... the point of injection is below waterline The wet exhaust is the genset s standard equipment If you want dry exhaust which is an optional equipment contact with our dealers Maintenance task Air filter inspection Genset is provided with an intake air filter Examine the element and housing for damage Replace the complete air filter if necessary It is important to ensure that the combustion air is f...

Page 34: ...dicate an exhaust leak Seal leaks as Needed Battery The minimum recommended capacity is from 100Ah However this value serves as a general reference since it relates to the maximum intensity it can offer for starting the generator set The connection of the battery for a standard engine Positive battery is connected to the starter Negative battery is connected to the relay support The connection of ...

Page 35: ...ension deflection If the tension is incorrect loosen the adjusting bracket bolt and mounting bolt and move the alternator in or out Item Assembly Standard V belt deflection 10 12 mm An excessive tension may cause a quick wear of the belt and alternator bearings Otherwise if the belt is excessively loose or has oil and insufficient load it can cause the belt to skid Never adjust the belt tension wi...

Page 36: ...ring maintenance control the condition of the bearing and check that no grease has leaked the lifespan of the bearings depends on the vibrations and axial strains they undergo vibrations can increase considerably with a bad alignment and on the working conditions So check for any unusual signs vibrations unusual noises If undue vibrations or noises appear after long term usage these could be due t...

Page 37: ...rs sets Section 6 Troubleshooting If a fault occurs in the genset proceed as follows Within the period of warranty Contact to Sole Diesel Official Service See Solé Diesel warranty Outside the period of warranty Contact to Sole Diesel Official Service See Solé Diesel warranty Stop the genset determine the cause and repair it before continuing driving the motor ...

Page 38: ...ttery Battery connections loose corroded or incorrect Verify that the battery connections are correct clean and tight Faulty cranking relay stop solenoid Check the cranking relay and the stop solenoid If necessary replace Faulty starter motor Replace if it is inoperative GENERAL Compression weak Check the compression LUBRICATION SYSTEM Oil viscosity too high Check the oil viscosity according to te...

Page 39: ... LOW OUTPUT VOLTAGE GENERAL Engine overload Reduce the electrical load Governor inoperative Contact with our dealer ALTERNATOR AC AC output circuit breaker open Close AC circuit breaker Wiring terminals or pin in the exciter field open Check for continuity Main field rotor inoperative open or grounded Test and or replace the rotor Stator inoperative open or grounded Test and or replace the stator ...

Page 40: ...y adjusting potentiometer BLACK SMOKE FUEL SYSTEM Fuel filter clogged Change fuel filter Fuel injectors dirty or faulty Clean test and or replace the inoperative fuel injector Injection pump incorrectly set Contact with our dealer INLET AND EXHAUST SYSTEM Air filter clogged Replace air filter element LOAD GENSET Propeller to large not enough rpm The power curve of the genset is not adequate Carry ...

Page 41: ...water cock clogged or restricted Clean the cock check the seawater pump impeller for damage Faulty seawater pump Check seawater pump impeller pump sealing Water cooler clogged Clean the water cooler and the tube stack fitted in the heat exchanger Coolant level low Restore the coolant to normal operating level Thermostat inoperative Replace the thermostat INLET AND EXHAUST SYSTEM Air filter clogged...

Page 42: ...ect the exhaust system Replace the inoperative exhaust system components HIGH FUEL CONSUMPTION GENERAL Compression weak Check the compression Overload Reduce the electrical load Governor inoperative Contact with our dealer FUEL SYSTEM Fuel injection timing out of adjustment Adjust the fuel injection timing INLET AND EXHAUST SYSTEM Air filter clogged Replace air filter COOLING SYSTEM Thermostat blo...

Page 43: ...1 Ignition sequence 1 3 4 2 Inlet valve Open BTDC 46 5º Close ABDC 55 5º Exhaust valve Open BBDC 100 5º Close ATDC 51 5º Inlet valve clearance cold genset mm exhaust valve clearance cold genset mm 0 3 0 5 RPM rpm 1500 85 GTC 1800 100 GTAC 1500 100 GTC 1800 120 GTAC Starting system Electric starter Lubrication system System description Forced lubrication by gear pump Oil specifications Use oil with...

Page 44: ...oolant pump Centrifugal type Sea water pump Centrifugal type Coolant circuit capacity l 17 5 Thermostat valve Start opening 83ºC End opening 98ºC Maximum permissible coolant outlet temperature ºC 105 Inlet and exhaust Air supply Turbocharging Turbocharging with charge air cooling Exhaust System Cooled exhaust manifold Dry exhaust manifold optional equipment Electrical system Voltage Polarity V 24V...

Page 45: ... 115 GTC 240 100 GTAC 120 GTAC Frequency Hz 50 85 GTC 115 GTC 60 100 GTAC 120 GTAC Current Υ Δ A 122 7 213 4 85 GTC 114 3 228 5 100 GTAC 144 3 251 115 GTC 138 3 276 6 120 GTAC Installation Ø Int Hose sea water inlet mm 38 canopy version 42 standard version Ø Int Hose diesel fuel inlet mm 12 Ø Int Hose diesel fuel outlet mm 12 Ø Int Hose exhaust outlet1 mm 90 Ø Int Hose exhaust outlet cabin mm 90 A...

Page 46: ... without our Parallel Kit So if you have installed this kit see the Parallel Kit Manual to operate the genset On the other hand if it has not been installed you have to design the control part of the genset For this reason it is necessary take into account the requirements of the electrical wiring according to the ECU cabinet connector where you have to connect Input signal from the controller to ...

Page 47: ...unt that over cranking can cause water ingestion So do not try to restart the genset and identify the crank fault cause STOP THE GENSET 1 Energize ECU power relay NC Normal Close type to stop powering the ECU Consequently the genset will stop Apply a voltage of 24 VDC to PIN 8 of the ECU cabinet connector ECU power signal This signal has to be maintained until the genset stops On top of that it ha...

Page 48: ... limits Faults in the electronics are registered or stored in the control unit and shown by the fault indicator lamp The fault indicator lamp is extinguished as soon as the fault has been removed Only when the electronics has been switched to emergency running speed need the engine be switched off briefly in order to extinguish the fault indicator lamp Also corrected or non current faults remain s...

Page 49: ...inet Reading out a current fault memory blink codes The fault indicator lamp shows a fault e g it flashes or lights continuously The Diagnostic button is depressed for a time period of 1 s to 3 s The regulator recognizes the request for a read out and starts to display the faults The read out of the blink code is only possible after extinguishing of fault indicator lamp or after the initialization...

Page 50: ...lashing sequence of the first stored fault example fault number 01 speed sensor 1 After 2 s 1 long After 2 s 1 short After fault code output 5 s pause then display of flashing or continuous light Steps for reading out the next fault a The fault indicator lamp indicates a fault e g it flashes of lights continuously Press diagnostics buttons 1 to 3 the flashing or continuous light of the fault indic...

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Page 56: ...nd Comes from ID RPU Connected to other ground terminals of analog inputs BINARY OUTPUTS ECU Stop Signal 24V when controller wants to stop engine Alarm lamp buzzer 0V when controller wants to activate alarm Cranking Signal 0V when controller wants to start engine ANALOG INPUTS ECU Stop Signal Comes from to binary output cranking signal through cranking relay Coolant Pressure Sensor Comes from sens...

Page 57: ... switch of engine Coolant Termperature Switch Comes from switch of engine Emergency Stop Comes from Emergency Stop Switch BINARY OUTPUTS ECU Stop Signal 24V when controller wants to stop engine Connected to binary output pick up relay Pick up Relay 24V when controller wants to stop engine Connected to binary output ECU Stop Signal Pick up Relay Comes from to binary output pick up relay through pic...

Page 58: ...4 2013 ComAp a s Written by Ladislav Kadanik Vladimir Sebian and Pavel Doubek Prague Czech Republic Operator guide Compact Controller for Industrial and Marine Applications InteliDrive DCU Expandable engine controller with electronic engines support Industrial Applications SS and AS Marine Applications AUX EME CMB and PRP January 2013 version r2 ...

Page 59: ...er and software revision 10 How to change the display backlight intensity 10 How to change controller language 10 How to find active alarms 10 Controller screens 11 Functions available from ID DCU front panel keys 14 Alarm management 15 Warning 15 Shut down 15 Cool down 15 Sensor fail 15 Controller monitoring 17 Direct connection to the PC 17 DriveMonitor 17 DriveMonitor screen example ID DCU Indu...

Page 60: ... J1939 EME InteliDrive Emergency operational mode EMS I Electronic Management System version I EMS II Electronic Management System version II Fls Controller sensor fail alarm FMI Failure Mode Identifier GSM modem Modem for Global System of Mobile communication History List of alarms and operational states with Reason Date and Time and adjustable values set that is stored in controller can be liste...

Page 61: ...for engine controls and engine monitoring KWP2000 Scania Communication protocol LOC Controller Local mode mhx Extension for controller firmware Motorola HeX file MID Message Identification Assignments OFF Controller mode when power supply is switched on but all binary outputs and start commands are disabled engine start is blocked PID Parameter Identification Assignments PPID Proprietary Parameter...

Page 62: ...nly To avoid personal injury do not perform any action not specified in the User guides for ID DCU Marine or ID DCU Industrial WARNING VERY IMPORTANT Be aware that the binary outputs can change state during and after software reprogramming Before the controller is used again ensure that the proper configuration and setpoint settings are set in the controller Disconnect the Binary outputs Starter a...

Page 63: ...modes single or variable speed ID DCU Industrial and emergency auxiliary harbor or propulsion ID DCU Marine Engine monitoring and protections 2 or more level analog inputs protection adjustable delays Speed measurement from magnetic pick up or from ECU redundant channel ID DCU Marine only Running hours meter number of starts counter Configurable 14 Binary inputs and Outputs and 8 Analog inputs Set...

Page 64: ...Data Sheets describe basic technical specification and purpose of various types of controllers o Getting Started Guide will help you to answer some basic questions that typically occur during the first contact with engine controller o User guide is Installation Application and Reference guide in one book o Communication Guides describe communication interface among controller s and superior system...

Page 65: ...n SS or AS mode hold time 1 sec 7 GREEN Engine running 8 Flashing RED Not acknowledged new alarm present in Alarm List Stable RED Acknowledged alarm present in Alarm List 9 GREEN On Off output is active 10 On Off Button for Close load or Clutch Binary output control 11 PAGE Cycles through the display screens MEASUREMENT ADJUSTEMENT HISTORY 12 Select the set point select the screen or increase set ...

Page 66: ...equested set point 5 Set points marked are password protected necessary to input corresponding password first to enable setpoint edit 6 Press ENTER to edit 7 Use or to modify the set point When or is pressed for 2 sec auto repeat function is activated 8 Press ENTER to confirm or PAGE to leave without change Press PAGE to leave selected set points group Hint Depending on the configuration of ID DCU...

Page 67: ...ER to confirm selection and exit window How to find active alarms Active alarm list and J1939 alarm list are the last two screens in the MEASUREMENT menu Select MEASUREMENT menu Press You will see the list of all active alarms with the number of alarms at the top right corner Inverted alarms are still active Non inverted alarms are not active but not yet confirmed Press FAULT RESET accepts all ala...

Page 68: ... s n Language list and switch Language screen Fast edit screen Available using Up or Down front panel keys ECU diagnostics code list Alarm list 1 Main screen ID Mode RPM1 Vbatt Engine state Indication Local Alarm in AL or ECU list Remote data connection active Access Lock 2 Analog 1 to Analog 4 4x single bargraph 3 Analog 5 to Analog 8 4x single bargraph 4 Battery ID DCU bargraph 5 ID DCU BI 1 to ...

Page 69: ... due to MaxCrank time is over Statistic values can be adjusted from DriveMonitor password 3 level protected History records Following table does not contain Wrn Sd and Fls messages from external units Events specification Protection type Information available on binary output Alarms Wrn Analog input 1 to 8 WRN YES Sd Analog input 1 to 8 SD YES ID DCU Binary input 1 to 14 Configurable YES ID DCU Ba...

Page 70: ...ul active call on channel 1 ActCallCH2 OK Successful active call on channel 2 ActCallCH3 OK Successful active call on channel 3 Extern start Manual engine starter handling Engine stop Engine changed state from Emerg man ON Emergency manual mode ON Emerg man OFF Emergency manual mode OFF Clutch ON Binary output clutch was closed Clutch OFF Binary output clutch was opened Stop button ID DCU panel bu...

Page 71: ...se Enter Up Main screen Contrast decrease Enter Down Info screen Enter Page Local mode ON Enter Mode Right Local mode OFF Enter Mode Left Fast edit Enter hold for 4 sec Fault code reset Fault reset Alarm list ECU fault code reset Fault reset ECU Alarm list Requested speed increase Up Fast edit screen Requested speed decrease Down Request confirmation and exit Enter active when Engine params EnLoca...

Page 72: ...d as Warning alarms are displayed and stored under configured name Battery voltage alarm level Shut down When a shutdown occurs InteliDrive DCU opens outputs FUEL SOLENOID STARTER Possible shut down alarms Over speed Under speed Start fail Binary inputs configured as Shut down alarms are displayed and stored under configured name Analog inputs configured as Shut down alarms are displayed and store...

Page 73: ...ve screen when value is out of limits binary input protection is active Broken wire Broken wire BW alarm is indicated on ID RPU module only Alarm indication Alarm list and History record prefixes Prefix Meaning Wrn Warning Sd Shutdown Cd Cooldown Bw Broken wire Fls Sensor fail Three state Alarm list indication Wrn Water temp Active not accepted alarm Wrn Water temp Active accepted alarm Wrn Water ...

Page 74: ...nts otherwise the internal PTC protection activates and interrupts RS232 communication In such case disconnect RS232 line wait a minute for PTC recovery and try again The simple solution is to assure that the PC supply 240 20V is ground free GND terminal is not connected 5 GND 2 RxD 3 TxD PC 5 GND 2 RxD 3 TxD RS232 RS232 230 VAC 0 VDC CONTROLLER Battery Required the same voltage potential between ...

Page 75: ...n active call is activated To receive AID file the DriveMonitor must be in Active call waiting window Off line connection enables open and list Application AID file stored in PC Hint More detail regarding different types of connection see in IG IS Communication guide Control window displays all ID DCU and I O states enables engine control ID RPU window not available in Industrial version Setpoints...

Page 76: ...ne running RED event in Alarm List 8 Button for Close Open load or clutch Binary output control 9 Binary inputs list 10 Binary outputs list 11 Alarm list 12 ECU Alarm list 13 Defined analog input bar graph Oil press 14 Undefined analog input 15 ECU Alarm fault reset button 16 Engine speed measurement 17 Bar graph of battery voltage 18 Connection indication 19 Archive type indication 20 DDE Server ...

Page 77: ...y Registers The response to an incoming message is sent with minimum 4 096 ms delay after message reception The complete description of Modbus communication protocol can be found in Modbus Protocol Reference Guide PI MBUS 300 and Open Modbus Specification Release 1 0 Both documents are available from web site at http www modicon com openmbus Modbus Multipack message It is special communication obj...

Page 78: ... K16 5x10kohm Hint Fuses must be dimensioned in descending order in direction from batteries to devices Hint It is required to use two independent actuators for engine stopping 1 Actuator controlled by ID RPU STOP SOL output 2 Actuator controlled by ID DCU BOx output configured to Stop Solenoid function Hint Emergency stop button contacts type NC Normally Closed can be directly incorporated into c...

Page 79: ...ation Flash memory data retention time 10 years Protection front panel IP65 Standard conformity Low Voltage Directive EN 61010 1 95 A1 97 Electromagnetic Compatibility EN 61000 6 2 October 2001 EN 61000 6 4 October 2001 IEC 60533 Ed 2 1999 11 Vibration 5 25 Hz 1 6mm 25 100 Hz a 4 g Shocks a 200 m s2 Dimensions and weight Dimensions 183x123x47mm See chapter terminals and dimensions Weight 800g Bina...

Page 80: ...nce 2 2 out of measured value Voltage measurement tolerance 1 1mV out of measured value Current measurement tolerance 1 0 5mA out of measured value Group 2 AI5 AI8 Number of inputs 4 bipolar Resolution Up to 16 bits Jumper selectable range V mA thermo coupler Maximal resistance range 2500 Maximal voltage range 1000 mV or 100 mV or 5 V Hint The maximal input voltage offset is in the range from 2 to...

Page 81: ...f Minimum measured frequency 4 Hz Maximum measured frequency 10 kHz min input voltage 6Vpk pk Frequency measurement tolerance 1 5 Solenoid driver power outputs Galvanic separated separate terminals for supply Number of outputs 2 Fuel solenoid Stop solenoid Maximum current 8 A DC one channel only Maximum current 12 A DC both channels together Supply voltage range 8 36 VDC Protections OFF STATE Brok...

Page 82: ...ns PRIFAIL Primary A battery fail switched to B battery ESTOP Binary input Emergency stop state BWSS Stop solenoid output BW indication BWFS Fuel solenoid output BW indication Binary information from ID DCU MARINE to ID RPU Symbol Meaning COMMWRN Binary output Common warning COMMSD Binary output Common shut down FUELSOL Binary output Fuel solenoid STOPSOL Binary output Stop solenoid MODE Controlle...

Page 83: ...wn Sd1 to Sd5 inputs are inactive ID RPU starts to Emergency backup mode after power on without active ID DCU MARINE BI EMERGENCY STOP BI SHUT DOWN or 0 5 sec 30 sec BO FUEL SOLENOID BO STOP SOLENOID RPM 0 Power supply terminals A A B B COM COM The ID RPU module has two independent power input terminals and one power output terminals The power output is supplied from battery A and if this voltage ...

Page 84: ...t used the output must be configured as not used otherwise broken wire protection will be detected Backup mode If no shutdown protection active the output is closed SEC RPM IN SEC RPM GND Terminals for the secondary RPM pickup It is possible to connect two redundancy pickups or one pickup to ID DCU MARINE and to the ID RPU in parallel The ID RPU will detect over speed failure on running engine Bat...

Page 85: ... RPM Basic settings Gear teeth 120 Speed preset formula N RPMover x Gear teeth 60 C 1 1 Step X RPMover x Gear teeth 60 3200 2 Step select coefficient C according table and corresponding DIP Prefix Table 1 X range C Prefix 2016 to 8128 32 1000 504 to 2032 8 0100 126 to 508 2 0010 1 to 127 0 5 0001 X 3200 is in the range 2016 to 8128 C 32 Prefix 1000 3 Step Speed preset 3200 32 1 101 01100101 in bin...

Page 86: ...re sensor Measuring range 0 to 6 bar Shutdown 0 5 Bar Coolant temperature switch Measuring range 40ºC to 250ºC Shutdown 95ºC Differential range 6ºC Oil pressure sensor Measuring range 0 to 10 bar Shutdown 1 6 bar Oil temperature sensor Measuring range 50ºC to 200ºC Shutdown 95ºC Oil pressure switch Measuring range 0 5 to 3 bar Shutdown 1 4 bar delay 4 ms Differential range 0 25 to 0 80 bar Exhaust...

Page 87: ...TC 100 GTAC 115 GTC 120 GTAC DNV N m kgf m Cylinder head 127 5 13 0 Crankshaft pulley 39 0 to 49 0 4 0 to 5 0 Main bearing caps 49 0 5 0 Connecting rod caps 29 5 3 0 Flywheel 30 45 mm Bolts 19 5 to 29 5 2 0 to 3 0 50 85 mm Bolts 29 5 to 39 0 3 0 to 4 0 Oil pan drain plug 49 0 5 0 Oil filter 14 7 1 5 Heat exchanger drain plug 22 5 2 3 Nut for B Terminal of starter 10 8 1 1 General tightening torque...

Page 88: ...Wiring diagrams Solé S A C 243 b km 2 08760 Martorell Barcelona Tel 34 93 775 14 00 www solediesel com info solediesel com 86 Operator s Manual Marine generators sets Section 11 Wiring Diagrams ...

Page 89: ...IN 2 Salida BORNA 9 To Terminal 9 Salida BORNA 8 To terminal 8 CONECTOR ECU 1 ECU1 ECU 1 CONNECTOR ECU1 LADO IZQUIERDO MOTOR LEFT SIDE ENGINE CONECTOR DIAGNOSTICO DIAGNOSTIC CONNECTOR Pulsador de lámpara de fallo PIN 1 Fault lamp test PIN 1 0 Salida BORNA 0 To Terminal 0 Paro emergencia contacto B PIN1 Emergency stop relay PIN87 Emergency stop Contact B PIN2 P test lámpara f allo PIN2 Fault lamp t...

Page 90: ...DULO ID RPU A CAN 2 INTERCONTROLLER ID COM INTERCONTROLADORES COM B L H COM L H COM J1708 CAN1 J1939 MODULE ID COM MODULO ID COM CAN high CAN low D 5 4 3 2 1 11 10 9 8 7 6 19 18 17 16 15 14 13 12 Cranking signal ECU stop signal Battery Battery Screen CPC Conexión control y monitorización CPC Connector Control and monitoring Battery Battery N C CONTACT Emergency stop switch Paro de emergencia White...

Page 91: ... test lámpara f allo PIN2 Fault lamp test PIN 1 ECU Power Relay PIN 30 Diagnostic connector PIN A Cranking relay PIN 30 Cranking relay PIN 86 ECU2 PIN 18 ECU2 PIN 21 Emergency stop relay PIN 85 Emergency stop relay PIN 30 Emergency stop Contact A PIN 1 ECU Screen connector Cranking relay PIN 85 ECU Power relay PIN 86 ECU Power relay PIN85 Relé de arranque PIN 87 Cranking relay PIN 87 CONECTOR ECU ...

Page 92: ...Battery Batería N S Battery switch Desconectador de baterías N S White Blanco CPC 24 VIAS INSTALACION MOTOR ARMARIO ECU CPC CONNECTOR 24 CONTACTS ENGINE ECU WIRING 21 20 19 18 17 16 14 13 12 11 10 9 8 7 6 5 4 3 2 1 15 22 23 24 3 2 1 CPC 3 VIAS CONECTOR DE POTENCIA CPC CONNECTOR 3 POWER CONTACTS EMR Actuator Coolant temperature sensor Engine speed pick up Engine oil pressure sensor 20 21 22 13 12 9...

Page 93: ...ernator connections Solé S A C 243 b km 2 08760 Martorell Barcelona Tel 34 93 775 14 00 www solediesel com info solediesel com 91 Operator s Manual Marine generators sets Section 12 Alternator connections ...

Page 94: ...Alternator connections Solé S A C 243 b km 2 08760 Martorell Barcelona Tel 34 93 775 14 00 www solediesel com info solediesel com 92 Operator s Manual Marine generators sets 12 1 Regulator connections ...

Page 95: ...Overall dimensions Solé S A C 243 b km 2 08760 Martorell Barcelona Tel 34 93 775 14 00 www solediesel com info solediesel com 93 Operator s Manual Marine generators sets Section 13 Overall dimensions ...

Page 96: ... PRESENTACIÓN ACABADO Basto 0 2 0 5 0 8 SOLÉ S A 1 2 Medio 0 1 0 2 0 3 0 5 Fino 0 05 0 1 0 15 0 2 Grado de Precisión DIN 7168 0 a 6 6 a 30 30 a 100 100 a 300 Medidas Nominales mm 85 GT 100 GTA 115 GT 120 GTA XAVIER S UBACH MEDIO 29 05 2014 957 5 1750 1774 5 865 360 5 105 655 105 147 5 225 327 5 290 480 10x Ø17 mounting holes 280 851 5 B VIEW A Detail A Fuel Inlet Detail B Fuel Outlet Detail C Sea ...

Page 97: ...USTOMER PANEL CONNECTION CUSTOMER LOAD LEAD ACCESS EQUIPMENT GROUND CONNECTION SEA WATER INLET Ø42 GENERATOR AIR INLET AC BREAKER Ø16 x10 MOUNTING HOLES FUEL OUTLET Ø12 1890 42 181 217 5 225 327 5 290 480 350 WET EXHAUST OUTLET Ø90 SIPHON BREAK CONNECTIONS AIR VENT SYSTEM OPTIONAL KIT SEA WATER OUTLET Ø42 ONLY DRY EXHAUST LEAKS COOLANT OUTLET Ø8 DRY EXHAUST ACCESS DRY EXHAUST OPTIONAL KIT 143 865 ...

Page 98: ...ructions to replace and remove When you decide to replace the genset please contact Solé Diesel S A will provide relevant instructions regarding the laws in force at the time When disposing of the whole or parts of this genset meets LAWS IN FORCE IN THE COUNTRY OF INSTALLATION For more information about the materials they are made of the individual components of the generator contact Solé Diesel S...

Page 99: ...ry of generator sets Solé S A C 243 b km 2 08760 Martorell Barcelona Tel 34 93 775 14 00 www solediesel com info solediesel com 98 Operator s manual Marine generator sets Section 12 Inspection prior to the delivery of generator sets ...

Page 100: ...Inspection prior to the delivery of generator sets Solé S A C 243 b km 2 08760 Martorell Barcelona Tel 34 93 775 14 00 www solediesel com info solediesel com 99 Operator s manual Marine generator sets ...

Page 101: ...nce log Solé S A C 243 b km 2 08760 Martorell Barcelona Tel 34 93 775 14 00 www solediesel com info solediesel com 100 Operator s manual Marine generator sets Maintenance log DATE HOURS DESCRIPTION SERVICE NAME ...

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Page 104: ...Safety precautions and instructions U_GNBP_EN Rev 1 02 2020 U_GJBF_EN Revision 4 03 2019 ...

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