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Sole Diesel 29 GSC, Operator'S Manual

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Sole Diesel 29 GSC Operator'S Manual Download Page 25

Systems and scheduled 

maintenance 

 

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

24 

Marine Diesel gensets. Operator’s Manual.

 

 

 

 

 

Intervals 

 

 

 
 

General 

Inspection Item 

Daily 

1st 20h-

50h 

Every 
200h 

Every 
400h 

Every 
800h 

Every 

year 

Every 2 

years 

Winter storage and Preservation 

Screw tightening, fastening. 

 

I 

 

I 

 

 

 

 

 

Genset block. 

 

 

 

 

 

 

 

 

CL 

Valve clearance. 

 

 

 

I 

 

 

 

 

 

Exhaust gas, noise and vibrations. 

I 

 

 

 

 

 

 

 

 

Compression pressure. 

 

 

 

 

I 

 

 

 

 

Lubrication system* 

Genset oil. 

I 

C 

C 

 

 

C 

 

 

C 

Oil filter. 

 

C 

C 

 

 

 

 

 

 

Fuel system  

Fuel level. 

I 

 

 

 

 

 

 

 

 

Fuel tank. 

 

 

 

 

 

 

CL 

 

E/L/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 

Incandescent glow plug. 

 

 

 

I 

 

 

 

 

 

Starter motor and alternator 12/24V. 

 

 

 

I 

 

 

 

 

 

Alternator 12/24V belt and tension. 

 

I 

 

I 

C 

 

 

 

I 

Battery level. 

 

I 

I 

 

C 

 

 

 

 

* Use oil with 15W40 viscosity and no less than ACEA E5 or API CH-4/SJ quality. 
. 

I: Inspect, adjust or fill.  E: Empty. C: Change.  CL: Clean. 
. 

Summary of Contents for 29 GSC

Page 1: ...3 775 14 00 www soleDiesel com info soleDiesel com 2 Operator s Manual Marine Diesel Gensets Marine generator sets Operator s manual TYPE APPROVAL DNV 35 GTC 40 GTAC 29 GSC 32 GSAC 45 GTC 54 GTAC 50 GTC 60 GTAC 68 GTC 84 GTAC U_XXXX_EN Revision 2 U_DNV0_EN Rev 0 02 2020 ...

Page 2: ......

Page 3: ...ny of the operations and keep it close at hand near the genset as it can be of great use in the future Our goal as a manufacturing company is that you enjoy our product regardless of the use you make of it The equipment manufactured in Solé Diesel facilities is designed to offer the highest performance in the most demanding operating conditions The images text and information contained in this man...

Page 4: ...of Packed and Unpacked Genset 18 Section 3 Installation 19 3 1 Genset installation 19 Section 4 Operation 20 4 1 Prestart checklist 20 4 2 Genset Operation at Low Temperatures 20 4 3 Winterzation and Preservation 21 4 4 Maintenance during the storage 22 4 5 Restoration of Operational Conditions 22 Section 5 Systems and Scheduled Maintenance 23 5 1 Operating Description 23 5 2 Periodic Maintenance ...

Page 5: ...e 34 Maintenance task Seawater filter inspection 35 Maintenance task Seawater pump impeller inspection 35 Maintenance task Zinc anode inspection 35 5 7 Inlet and Exhaust System 36 Exhaust circuit description 36 Maintenance task Air filter inspection 37 Maintenance task Exhaust gas noise and vibrations inspection 38 5 8 Electrical System 39 Battery 39 Circuit protection 39 Maintenance task Incandes...

Page 6: ... 53 8 4 Electrical actuator 54 8 5 Parallel operation troubleshooting 54 Magnetic speed sensor 54 Electronic control unit and governor ECU 54 Section 9 Control Panel 56 Section 10 Alternator connections 86 Connection s type 1 86 Connection type 2 88 10 1 Regulator connections 89 Connection s type 1 89 Connection s type 2 91 Section 11 Wiring diagrams 92 Section 12 Overall dimensions 97 Section 13 ...

Page 7: ...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 fuel system Keep the fuel lines and connections tight and ...

Page 8: ... on the engine or connected equipment disable the engine as follows Set the engine controller to OFF Mode 1 Disconnect the power input from battery 2 Disconnect the battery cables Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the engine by engine controller remote star...

Page 9: ...ce guards screens and covers before operating the engine Read the engine operator s manual and understand it before any operation and maintenance of the engine to ensure that it continues operating practices and maintenance procedures insurance Dangerous 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 ...

Page 10: ... enters 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 war...

Page 11: ...sions 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 comp...

Page 12: ... this 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 Al...

Page 13: ...n 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 temperatures betw...

Page 14: ... regulator 8 Fuel feed pump 9 Nozzles 10 Air inlet elbow 11 Wet exhaust elbow 12 Relay 13 Air filter 14 Sea water pump 15 Fresh water pump 16 Heat exchanger 17 Anode 18 Coolant drain plug 19 Coolant drain plug 20 Starter 21 CA Alternator engine 22 Belt guard 23 CA alternator 24 Stop solenoid 25 Glow plug 26 ECU parallel version 27 Double wall pipes 28 Pressure control 29 Temperature switch 30 Oil ...

Page 15: ...lator 8 Fuel feed pump 9 Nozzles 10 Air inlet elbow 11 Wet exhaust elbow 12 Turbocharger 13 Air filter 14 Sea water pump 15 Fresh water pump 16 Heat exchanger 17 Anode 18 Coolant drain plug 19 Coolant fill plug 20 Starter 21 Alternator AC 22 Belt guard 23 AC alternator 24 Stop solenoid 25 Glow plug 26 ECU parallel version 28 Pressure control 29 Temperature switch 30 Oil pressure transmitter 31 Oil...

Page 16: ...pump 9 Nozzles 10 Air inlet elbow 11 Wet exhaust elbow 12 Relay 13 Air filter 14 Sea water pump 15 Fresh water pump 16 Heat exchanger 17 Anode 18 Coolant drain plug 19 Coolant drain plug 20 Starter 21 CA Alternator engine 22 Belt guard 23 CA alternator 24 Stop solenoid 25 Glow plug 26 ECU parallel version 27 Double wall pipes 28 Pressure control 29 Temperature switch 30 Oil pressure transmitter 31...

Page 17: ...lator 8 Fuel feed pump 9 Nozzles 10 Air inlet elbow 11 Wet exhaust elbow 12 Turbocharger 13 Air filter 14 Sea water pump 15 Fresh water pump 16 Heat exchanger 17 Anode 18 Coolant drain plug 19 Coolant fill plug 20 Starter 21 Alternator AC 22 Belt guard 23 AC alternator 24 Stop solenoid 25 Glow plug 26 ECU parallel version 28 Pressure control 29 Temperature switch 30 Oil pressure transmitter 31 Oil...

Page 18: ...nspecting the goods if you notice damage write a reservation on the delivery note Have the carrier countersign the note and advise Solé DieselS A preferably by mail info soleDiesel com 2 2 Transporting and Handling the Packed Genset When lifting and transporting the genset use EXCLUSIVELY a forklift or bridge crane of appropriate load capacity with chains equipped with safety hooks suitable for li...

Page 19: ...nset 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 decides to start the genset after a...

Page 20: ...ST 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 CONTROL PANEL 13 CONNECT TO BATTERY Follow label battery connection into the genset It is ...

Page 21: ...awater pump before initial startup To prime the pump Close the seacock Remove the hose from the seawater filter outlet Fill the hose and seawater pump with clean water Reconnect the hose to the water filter outlet Open the seacock Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet 4 2 Genset Operation at Low Temperatures Whenever the atmospheric temp...

Page 22: ... to keep it in perfect operating condition If there is no care the inside parts can oxidize and cause damage on the genset When the genset is stored steps indicated below have to been follow 1 Clean the outer surface of the genset 2 Bleed the seawater circuit by filling it with fresh water Fill the seawater circuit again with a mixture of fresh water and anti freezing agent 3 Remove the impeller f...

Page 23: ... 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 operate...

Page 24: ...als 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 when...

Page 25: ...ure I Lubrication system Genset oil I C C C C Oil filter C C Fuel system Fuel level I Fuel tank CL E L 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 Incandesc...

Page 26: ... 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 nº1 in the top dead centre of the compression cycle adjust the play of the intake and exhaust valves of cylinder nº 1 Proceed simil...

Page 27: ... the genset by means of the starter and read the compression pressure gauge indication when the genset is running at specified speed 4 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 few cylinders and presume the compression on the remaining cylinders Compression pressure varies with genset...

Page 28: ...TAC DNV Gensets 45 GTC 54 GTAC 68 GTC 84 GTAC DNV Including filter change 0 5l PIECE ELEMENT 1 Main gallery 2 Oil pump 3 Oil strainer 4 Oil pan 5 Oil filter 6 Pressure relief valve PIECE ELEMENT 1 Oil pan 2 Oil strainer 3 Oil pump 4 Oil cooler 5 Oil filter 6 Intermediate gear 7 Fuel injection pump 8 Oil main gallery 9 Camshaft 10 Tappet 11 Pushrod 12 Piston 13 Crankshaft 14 Turbocharger 15 Valve m...

Page 29: ... Oil level check Check the oil level in the crankcase daily or before each start up to ensure that the level is between the upper Max mark and lower Min mark lines on the dipstick To check the oil level 1 Remove the dipstick 2 Wipe the dipstick end 3 Reinsert inside the guide 4 Remove it again to see the oil level If the genset is fitted inclined the oil dipstick must be modified to avoid problems...

Page 30: ...rding to the oil level check procedure Never overfill Overfilling may result in white exhaust smoke genset overspeed or internal damage 5 5 Fuel System Circuit description The fuel system is based on a fuel feed pump and an in line mechanical injection pump Gensets 29 GSC 32 GSAC 35 GTC 40 GTAC Gensets 50 GTC 60 GTAC 68 GTC 84 GTAC PIECE ELEMENT 1 Fuel injection nozzle 2 Fuel injection pipe 3 Fuel...

Page 31: ...tes at the bottom It can cause an increase of corrosion or an impossibility of starting the genset if this water is aspired by the fuel pump Maintenance task Fuel tank clean The fuel impurities could obstruct the suction pump For this reason drain out the content of the fuel tank to remove condensate and any foreign material Then wash the tank with fuel and refill it Maintenance task Water separat...

Page 32: ...pressure by operating the tester handle at a speed of more than one stroke per second while observing the pressure gauge 4 The pressure gauge reading will slowly increase and when the nozzle starts discharging fuel it will go down fast Take the gauge reading right then as the injection pressure 5 To adjust the injection pressure increase or decrease the amount of shims fitted to the nozzle holder ...

Page 33: ...l filter turning it approximately 1 5 laps 2 Unlock the fuel pump plunger turning it in anticlockwise and actuate the pump 3 Taut the air drain plug when fuel flows without fizzing Fuel injection pump 1 Loose the air drain plug on the fuel filter turning it approximately 1 5 laps 2 Unlock the fuel pump plunger turning it in anticlockwise and actuate the pump 3 Taut the air drain plug when fuel flo...

Page 34: ...tion according to operating conditions is specified 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 PIECE ELEMENT 1 Seacock accessory 2 Sea water filter accessory 3 Sea water pump 4 Heat exchanger 5 Turbocharger 6 Wet exhaust elbow Model Coolant circuit capacity L 29 GSC 32...

Page 35: ...cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise Remove the cap after pressure has been completely released and the genset has cooled Check the coolant level at the tank the level must be approximately 3 4 full Maintenance task Coolant fill change 1 Drain off all the coolant by opening the tw...

Page 36: ...4 Clean the housing 5 Inspect the impeller for damaged cranked broken missing or flattened vanes The impeller vanes should be straight and flexible 1 If it is damaged replace with a new one 6 Lubricate the impeller with soapy water before installation 7 Install the impeller During installation push and rotate the impeller in the same direction as the genset rotation until it is thoroughly seated i...

Page 37: ...nce between water injection point and waterline to decide which type of installation you need This information is specified in the following drawings The elements included in the drawing are essential for the correct genset operation Waterlock supplied as accessory to prevent seawater from entering inside the engine when it stops To calculate the required collector capacity we must follow the foll...

Page 38: ...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 freely supplied...

Page 39: ...n Exhaust system inspection points 1 Check the hoses for softness cranks or dents Replace the hoses as needed 2 Check for corroded or broken metal parts and replace them as needed 3 Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed 4 Check that the exhaust outlet is unobstructed 5 Visually inspect the exhaust system for exhaust leaks Check for c...

Page 40: ...ated engine Positive battery is connected to the starter Negative battery is connected to the bipolar relay Circuit protection AC Breaker interrupts the genset output in the event of an overload or short circuit It is located in front panel as is showed in the section 10 Maintenance task Incandescent glow plug inspection 1 Loosen nuts and then remove connection plate and glow plug 2 If the glow pl...

Page 41: ...oose or has oil and insufficient load it can cause the belt to skid Never adjust the belt tension with genset running or battery connected Maintenance task battery level Battery requires a very careful handling and frequent checking Proceed as shown below 1 Keep battery dry and cleaned 2 Check terminal cleanliness regularly If dust is settled terminals should be loosened cleaned and smeared with a...

Page 42: ... 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 to a worn bearing that if damaged has to be replaced No maintenance is required for the total operating time A bearing lifespan is closely linked to the working conditions and environment Long periods of sustained vibrations can damag...

Page 43: ...Manual 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 44: ...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 45: ...ad 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 The genset will not excite Check the fuse...

Page 46: ...er curve of the genset is not adequate Carry out a propulsive power study BLUE SMOKE GENERAL Valve clearance incorrect Adjust the valves LUBRICATION SYSTEM Oil level too high Restore the oil to normal operating level GENSET OVER HEATING GENERAL Compression weak Check the compression Overload Propeller too large replace Incorrect injection time Adjust the injection time of the injection pump LUBRIC...

Page 47: ...h our dealer LOW POWER GENERAL Valve clearance incorrect Contact with our dealer FUEL SYSTEM Fuel filter clogged Contact with our dealer Fuel injectors dirty or faulty Contact with our dealer Water in fuel system Contact with our dealer Fuel injection timing out of adjustment Contact with our dealer INLET AND EXHAUST SYSTEM Air filter clogged Replace air filter element Exhaust backfires Inspect th...

Page 48: ...e clearance cold genset mm 0 25 RPM rpm 1500 29 GSC 35 GTC 45 GTC 50 GTC DNV 1800 32 GSAC 40 GTAC 54 GTAC 60 GTAC DNV Starting system Glow plugs Lubrication System System description Forced lubrication by trochoid gear pump Oil specification Use oil with 15W40 viscosity and no less than ACEA E5 E3 or API CH 4 SJ quality Oil pump Trochoid gear type Oil circuit capacity l 10 10 12 Min oil pressure h...

Page 49: ...system Brushless Power Factor cos φ 0 8 0 8 0 8 Insulation system H Voltage variation V 1 Speed variation rpm 5 3 GENSET General Information Active rated power kW 25 0 29 GSC 28 0 32 GSAC 25 6 35 GTC 28 0 40 GTAC 32 0 45 GTC 38 4 54 GTAC 36 0 50 GTC 42 4 60 GTAC Apparent rated power kVA 29 0 29 GSC 28 0 32 GSAC 32 0 35 GTC 35 0 40 GTAC 40 0 45 GTC 48 0 54 GTAC 45 0 50 GTC 53 0 60 GTAC Voltage Υ V ...

Page 50: ...4996 Compression ratio 17 1 Secuencia de encendido 1 5 3 6 4 2 4 Valve timing Inlet valve Open 18º BTDC Close 54º ABDC Exhaust valve Open 66º BBDC Close 22º ATDC Inlet and exhaust valve clearance cold genset mm 0 25 RPM rpm 1500 68 GTC 1800 84 GTAC Starting system Electric starter Starting aid Glow plugs Lubrication System System description Forced lubrication by gear pump Oil specifications Use o...

Page 51: ...RNATOR General Information Installation type 3 Phase System cooler Air fresh Type 4 poles Protection degree IP23 Excitation system Brushless Power Factor cos φ 0 8 1 Insulation system H Voltage variation 1 Speed variation rpm 5 3 GENSET General Information Active rated power kW 49 6 68 GTC 60 84 GTAC Apparent rated power kVA 62 68 GTC 75 84 GTAC Voltage Υ V Voltage Δ V 400 230 68 GTC 230 68 GTC 48...

Page 52: ...al kit 8 2 Magnetic speed sensor Pickup The magnetic speed sensor is used for detecting the engine speed This element sends a signal to the controller with the engine speed information Requires no energizing from the ECU Installation Insert the magnetic speed pickup into the hole and turn it until the magnetic speed pickup makes contact with the face of the gear Wire Colour Description 1 Red Batte...

Page 53: ...agnetic speed sensor to the control unit Shielding is required if external interference is present or the leads are longer than 3 m 10 ft 8 3 Electronic control unit ECU The controller ECU is all electronic device designed to control the engine speed quickly and precisely in response to transient load changes This is connected to an electric actuator and magnetic speed sensor pickup Connections TE...

Page 54: ... is increased by clockwise rotation of the SPEED adjustment control Remote speed adjustment can be obtained with an optional 5K Speed Trim Control To do the stability adjustment do the follow steps with the engine running Turn the GAIN potentiometer clockwise until the engine becomes unstable Then turn it slowly counterclockwise until it stabilizes Turn it about 1 8 more turn counterclockwise to e...

Page 55: ... to check the output voltage with the genset running the engine doesn t crank but the flywheel rotates Disconnect the wires and measure the voltage AC between wires The voltage value should be 1V If the voltage value is around 1 V 3 V it is correct and the pickup works correctly If the value is less than 1 V Check the distance between sensor and flywheel teeth Wrong wires Check the impedance betwe...

Page 56: ...urrent on the wire of PIN A to actuator at 1500 RPM Increase the load and measure the current it should increase If don t increases the ECU don t operates correctly 3 Check the resistance between PIN C and PIN D Terminals Value Nominal current 4 0 A 12 V DC 2 0 A 24 V DC Max Continuous current 5 8 A 12 V DC 3 1 A 12 V DC Nominal coil resistance 7 2 Ω 2 0 Ω Terminals Value C D 30 Ω to 1200 Ω ...

Page 57: ...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 58: ... 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 59: ...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 60: ...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 61: ... 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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ... 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 70: ... 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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ... 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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ... 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 87: ...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 temperatu...

Page 88: ... com info solediesel com 86 Marine Diesel gensets Operator s Manual Section 10 Alternator connections According to genset model consult the alternator s connection CONNECTION S TYPE 1 35 GTC 40 GTAC DNV CONNECTION S TYPE 2 29 GSC 32 GSAC 45 GTC 54 GTAC 50 GTC 60 GTAC 68 GTC 84 GTAC DNV Connection s type 1 ...

Page 89: ...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 87 Marine Diesel gensets Operator s Manual ...

Page 90: ...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 88 Marine Diesel gensets Operator s Manual Connection type 2 ...

Page 91: ...esel com info solediesel com 89 Marine Diesel gensets Operator s Manual 10 1 Regulator connections According to genset model consult the regulator s connection CONNECTION S TYPE 1 35 GTC 40 GTAC DNV CONNECTION S TYPE 2 29 GSC 32 GSAC 45 GTC 54 GTAC 50 GTC 60 GTAC 68 GTC 84 GTAC DNV Connection s type 1 ...

Page 92: ...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 90 Marine Diesel gensets Operator s Manual ...

Page 93: ...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 91 Marine Diesel gensets Operator s Manual Connection s type 2 ...

Page 94: ...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 92 Marine Diesel gensets Operator s Manual Section 11 Wiring diagrams ...

Page 95: ...6 Black CPC PIN 13 Grey Black Brown Red Orange White CPC PIN 19 PIN 1 PIN 3 PIN 1 PIN 2 PIN 1 PIN 2 PIN 1 PIN 2 PIN 2 PIN 1 PIN 2 PIN 1 DC ALTERNATOR EXCITATION CRANKING SIGNAL EMERGENCY STOP SIGNAL PREHEATING SIGNAL OIL PRESSURE SIGNAL OIL PRESSURE ALARM OIL TEMPERATURE SIGNAL OIL TEMPERATURE NEGATIVE COOLANT PRESSURE SIGNAL COOLANT TEMPERATURE SIGNAL COOLANT TEMPERATURE NEGATIVE COOLANT TEMPERAT...

Page 96: ...ZER 12V Engine rpm pick up Engine rpm pick up GND Coolant temperature sensor Exhaust gas temperature Coolant pressure sensor CPC PIN 2 CPC PIN 7 CPC PIN 5 CPC PIN 3 CPC PIN 4 CPC PIN 21 CPC PIN 22 CPC PIN 17 CPC PIN 10 CPC PIN 12 CPC PIN 11 CPC PIN 20 CPC PIN 23 CPC PIN 24 CPC PIN 15 CPC PIN 18 CPC PIN 14 TO AIN 7 TO CPC PIN 18 CPC PIN 9 CPC PIN 6 Preheating CPC PIN 8 3 A 10 A 10 A Exhaust gas tem...

Page 97: ...TCH CPC PIN 2 CPC PIN 3 CPC PIN 4 CPC PIN 23 MAGNETICK PICK UP 2 CPC PIN 24 MAGNETICK PICK UP 2 OPT STD CANOPY EMERGENCY STOP N C CONTACT BATTERY B BATTERY B BATTERY B Purple Black White MAGNETIC PICK UP SENSOR 1 CPC PIN 21 MAGNETICK PICK UP 1 CPC PIN 22 MAGNETICK PICK UP 1 BATTERY A BATTERY A BATTERY A 10 kΩ 10 kΩ CPC PIN 16 Black CPC PIN 13 Grey Black Brown Red Orange White CPC PIN 19 PIN 1 PIN ...

Page 98: ...IN 24 CPC PIN 15 CPC PIN 18 CPC PIN 14 TO AIN 7 TO CPC PIN 18 CPC PIN 9 CPC PIN 6 Preheating CPC PIN 8 3 A 10 A 10 A Exhaust gas temperature GND CPC PIN 19 TO AIN 7 TO CPC PIN 19 Coolant temperature GND CPC PIN 16 Oil temperature GND CPC PIN 13 CRANKING 87 85 86 30 PREHEATING 87 85 86 30 White PIN MALE CPC 37 PIN 1 2 3 4 5 6 7 8 9 10 11 Vref ext vel reg CPC PIN 25 GND ext vel reg CPC PIN 26 Shield...

Page 99: ...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 97 Marine Diesel gensets Operator s Manual Section 12 Overall dimensions ...

Page 100: ...nsiones en milimetros AGUJERO EXTINTOR SALIDA AIRE 135 5 CONEXIÓN BATERIA PARO EMERGENCIA CONEXIÓN PANEL DE CONTROL ENTRADA CABLES CONEXIÓN ALTERNADOR CONEXIÓN A TIERRA SALIDA ESCAPE HÚMEDO Ø75 ENTRADA AGUA SALADA Ø32 ENTRADA GAS OIL SALIDA FUGAS REFRIGERANTE ENTRADA AIRE 114 5 161 111 18 788 C VISTA C A VISTA A VISTA E INTERRUPTOR CA CONEXIONES PURGADOR ESCAPE PURGADOR ESCAPE KIT OPCIONAL 48 1370...

Page 101: ...17 A B C D 111 143 840 848 195 5 1800 48 27 630 105 105 213 563 64 175 5 295 379 295 411 244 5 LEAKS COOLANT OUTLET Ø8 SEA WATER INLET Ø32 ONLY DRY EXHAUST SEA WATER INLET Ø32 FUEL INLET Ø10 FIRE EXTINGUISHER ACCES HOLE FAN INSIDE AC BREAKER EMERGENCY STOP CUSTOMER LOAD LEAD ACCESS CUSTOMER PANEL CONNECTION EQUIPMENT GROUND CONNECTION BATTERY CONNECTIONS WET EXHAUST OUTLET Ø88 9 AIR OUTLET VIEW C ...

Page 102: ...IA ENTRADA AIRE ENTRADA GAS OIL Ø8 CONEXIÓN PANEL DE CONTROL INTERRUPTOR MARCHA PARO ENTRADA CABLES CONEXIÓN ALTERNADOR CONEXIÓN A TIERRA A B D E C 181 143 111 195 5 AGUJERO EXTINTOR VENTILADOR INTERIOR SALIDA AIRE 27 1800 48 1875 CONEXIONES PURGADOR ESCAPE PURGADOR ESCAPE KIT OPCINAL SALIDA FUGAS REFRIGERANTE Ø8 SALIDA AGUA SALADA Ø32 SOLO ESCAPE SECO 848 Nota Dimensiones en milimetros USAR SOLO ...

Page 103: ...in controller is supplied without fixing at genset in order to allow their installation on engine room according to installer requirements 2 Dry exhaust available as an option 3 Dimensions in millimeters LEAKS COOLANT OUTLET Ø8 SEA WATER INLET Ø32 ONLY DRY EXHAUST SEA WATER INLET Ø32 FUEL INLET Ø8 FIRE EXTINGUISHER ACCES HOLE AC BREAKER CUSTOMER LOAD LEAD ACCESS CUSTOMER PANEL CONNECTION EQUIPMENT...

Page 104: ...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 105: ...y 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 104 Marine Diesel gensets Operator s Manual Section 14 Inspection prior to the delivery of generator sets ...

Page 106: ...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 105 Marine Diesel gensets Operator s Manual ...

Page 107: ...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 106 Marine Diesel gensets Operator s Manual Maintenance log DATE HOURS DESCRIPTION SERVICE NAME ...

Page 108: ...Maintenance log Solé S A C 243 b km 2 08760 Martorell Barcelona Tel 34 93 775 14 00 www solediesel com info solediesel com 107 Marine Diesel gensets Operator s Manual DATE HOURS DESCRIPTION SERVICE NAME ...

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Page 110: ...U_DNV0_EN Rev 0 02 2020 ...

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