Sole Diesel 10 GSC Marine Diesel Gensets User Manual

Sole Diesel 10 GSC Marine Diesel Gensets

Product Information

The Marine generator sets are diesel gensets that are used in marine environments. The following models are Type Approved by DNV: 10 GSC, 12 GSAC, 11 GTC, 14 GTAC, 14 GSC, 17 GSAC, 17 GTC, and 20 GTAC. This operator’s manual provides information and instructions for the safe installation, operation, and maintenance of the Marine Diesel gensets.

Product Usage Instructions

Before using the Marine Diesel gensets, it is important to follow the safety precautions and instructions listed in this manual to prevent personal injury or property damage. The following are some of the key safety precautions to keep in mind:

• Handle engine fuels, fuel vapours, and combustible materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. In case of fire do not open sound shield compartment and follow these instructions: – Shut down engine(s) – Continuously discharge entire contents of a halon or CO2 portable fire extinguisher (or other provision) immediately.
• Do not operate the engine with the air cleaner/silencer removed. Servicing the air cleaner can cause a sudden backfire that can result in severe injury or death.
• Before working on the engine or connected equipment, disable the engine by disconnecting the power input from the battery and disconnecting the battery cables. Follow these precautions to prevent the starting of the engine by engine controller, remote start/stop switch, or engine start command from a remote computer.
• Carbon monoxide (CO) is an odourless, colourless, tasteless, no irritating gas that can cause death if inhaled for even a short time. Engine exhaust gases contain carbon monoxide gas. Get fresh air and do not sit, lie down, or fall asleep if anyone shows signs of carbon monoxide poisoning.

It is important to follow all safety precautions and instructions listed in this manual to ensure safe usage of the Marine Diesel gensets. For more information on the safe installation, operation, and maintenance of the gensets, please refer to the operator’s manual.

Introduction

Marine generator sets
Operator’s manual
TYPE APPROVAL (DNV)
10 GSC 12 GSAC 11 GTC 14 GTAC 14 GSC 17 GSAC 17 GTC 20 GTAC

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Operator’s Manual Marine Diesel Gensets

Introduction

Introduction
Presentation
Dear Customer,
First, we would like to thank you for choosing a Solé Diesel product. We recommend that you read this manual carefully before carrying out any 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 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.

Marine Diesel gensets. Operator’s Manual.

Safety precautions and instructions
Safety precautions and instructions
Solé Diesel is concerned for your safety and your machine’s condition. Safety Precautions and Instructions are one of the primary ways to call your attention to the potential hazards associated with our engine operation. Follow the precautions listed throughout the manual before and during operation and maintenance procedures for your safety, the safety of others and the performance of your engine.
Types of Safety Precautions:
Indicates the presence of a hazard that can cause severe personal injuries, death or substantial property damages.
Indicates the presence of a hazard that will or can cause minor personal injury or property damages.
Communicates installation, operation and maintenance information that is safety related but not hazard related.
Servicing the fuel system and combustible materials. A flash 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 fuel system. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines and use flexible sections to avoid fuel line breakage caused by vibrations. Keep the compartment and the engine clean and free of debris to minimize the risk of fire.
Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the engine with the air cleaner/silencer removed.
Combustible materials. A fire can cause severe injury or death. Engine fuels, fuel vapours and combustible materials are flammable and explosive. Handle these
materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. In case of fire do not open sound shield compartment and follow these instructions: – Shut down engine(s) – Continuously discharge entire contents of a halon or CO2 portable fire extinguisher (or other provision) immediately.

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Marine Diesel gensets. Operator’s Manual.

Safety precautions and instructions
Carbon monoxide (CO) can cause severe nausea, fainting or death. Engine exhaust gases contains carbon monoxide gas. Carbon monoxide is an odourless, colourless, tasteless, no irritating gas that can cause death if inhaled for even a short time. Get fresh air and do not sit, lie down or fall asleep if anyone shows signs of carbon monoxide poisoning:
– Light-headedness, dizziness – Physical fatigue, weakness in joints and muscles. Sleepiness, 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 protective clothing when servicing the battery. If battery fluid contacts the eyes and/or skin, immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment.
Before working on the engine or connected equipment, disable the engine as follows: (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 start/stop switch, or engine start command from a remote computer.
Never remove the cooler cap if the engine is hot. Steam and hot engine coolant will spurt out and seriously burn you. Allow the engine to cool down before you attempt to remove the cooler cap.

Read the engine operator’s manual and understand it before operation and maintenance of the engine, to ensure that it continues operating practices and maintenance procedures. Hearing protection. Use to avoid hearing loss when handling the motor.
1. The installer / operator of 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 working has to be kept tidy and free of oil and other liquid spillages and solid waste (metal chips, etc.).

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Marine Diesel gensets. Operator’s Manual.

Safety precautions and instructions

Engine labels

If the engine does not start after several attempts to crank may cause water entering the engine. In this situation it is recommended:

1. Close the seacock. 2) Drain the water from the exhaust system in the water
   trap. 3) Do not try to restart the engine until the cause of the
   start fail is identified.

The engine and the gearbox are supplied without any fluid inside. Consult the manual to follow the installation procedure and commissioning as well as the fluid capacity – coolant, oil and oil of gearbox

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.
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 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 heavy element, use the right tools for transportation and handling. Do not use the motor as a step. Use it as a step can cause engine damage plus cause undesired operation.
Connection point of the battery cables to the engine. Red cable (positive) and black cable (negative).

Engine exhaust line installation label, above and below the waterline. See 6.7. Intake and exhaust system.

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Marine Diesel gensets. Operator’s Manual.

Transport, handling and storage

Solé Diesel warranty

Read the manual and documents delivered with each engine before carrying out any of the operations or presenting any queries. The engine is supplied without any liquids. Ensure that the liquids used match the specifications contained in Solé Diesel manuals.
The application of the conditions described in this document shall only be effective for engines or generator sets that have been invoiced after November 4, 2011.
Solé Diesel limited warranty

Solé Diesel guarantees that at the time of shipment all its engines and generator sets comply with the provided specifications and do not have any manufacturing defects.

The limited warranty provided by Solé Diesel 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 warranty periods are applied according to the time elapsed in months from the date of purchase or the limit of hours of operation (whichever occurs first) listed in the following table:

Product
Propulsion Engines Generator Sets

Limited Warranty Coverage Periods

Pleasure

Comercial

Months 36 36

Hours 1000 1000

Months 2 2

Hours 2000 1000

Solé Diesel extended warranty

Solé Diesel an extended period of coverage for the following components: engine block, cylinder head, crankshaft, camshaft, flywheel housing, timing gear housing, timing gear, conrod.

Product
Propulsion Engines Generator Sets

Extended Coverage Periods

Pleasure

Months

Hours

24

1500

24

1000

Comercial

Months

Hours

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Restrictions
Coverage:
a) To validate the warranty is necessary fill and send the inspection prior to the delivery of propulsion engines or genset to Solé Diesel through an official installer. See SECTION 14.
b) The warranty covers any failure of the product under normal opera- ting conditions caused by a defect in manufacturing.
c) The warranty covers the labour costs necessary to replace and/or repair the defective original components, according to Solé Diesel standards of excellence. The period covered for these operations is limited to 4 hours.
d) The warranty covers reasonable costs of travel required to carry out the necessary operations. The travel distance is limited to 300 kilometres in conjunction to a travel time of 3 hours.
Excluded from coverage:
a) If Solé Diesel products are installed and used alongside other products not designed or manufactured by Solé Diesel that affect their operation, the warranty shall apply exclusively to the Solé Diesel products and shall not apply if the products from another manufacturer are inappropriate for use alongside Solé Diesel products or are the cause of the failure or poor operation of our products.
b) The warranty doesn’t will be effective if don’t filled correctly and send the inspection prior to the delivery of propulsion engines and genset to Solé through an official installer. SECTION 14.
c) The warranty shall not apply if the revisions 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 with the procedures described in the User and Maintenance Manuals.
e) Deterioration resulting from not complying with the procedure for winter storage while the engine is not in service, as described in the User and Maintenance Manuals.
f) Faults due to negligence, lack of service, accidents, abnormal use and inadequate service or installation.
g) Faults due to the use of components not manufactured or sold by Solé Diesel. h) Faults due to electrical installations that do not comply with Solé Diesel design specifications
or are not expressly approved by Solé Diesel. i) Faults due to the use of and operation with fuels, oils or lubricants that are not authorised by
Solé Diesel. j) Faults due to water entering the cylinder(s) through the exhaust system. k) Faults in propulsion engines due to the use of a propeller that is inadequate for the load or
application. We recommend contacting Solé Diesel to consult the choice of the correct propeller(s). l) Failure for general omission of the procedures described in the User and Maintenance Manuals. m) Components subjected to normal operating wear and tear. n) n) Costs due to phone communications, loss of time or money, discomfort, launching, grounding, removal or replacement of vessel parts or materials because the design of the vessel makes it necessary to do so to access the engine, and damage and/or accidents caused because of a failure.

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Transport, handling and storage

Responsibilities
Responsibilities of the manufacturer: The obligations of Solé Diesel are restricted to repairing the defective parts or, IF DEEMED
APPROPRIATE BY Solé Diesel, returning the amount of the purchase or replacing the parts to prevent poor operation resulting from defective materials or faults in the manufacture covered by the warranty.
Solé Diesel reserves the right to modify the design of any of its products without taking on any obligation to modify a product that has been manufactured previously.
This manual, as well as technical documentation, manuals or pamphlets may undergo modifications without prior notice.
Responsibilities of the purchaser: The purchaser shall be responsible for the care, operation and maintenance of the product in
compliance with the contents of the User and Maintenance Manuals. The purchaser shall provide proof of all the maintenance services performed on the product. The costs of said services and that of the components and liquids replaced during said services shall be at the expense of the purchaser.
The maintenance operations described in this manual shall be performed during the Warranty Contract Periods (Limited and Extended Coverage) by an AUTHORISED Solé Diesel DEALER. Noncompliance with 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.
All shipments of products or components sent by the purchaser for inspection and repair shall be paid in advance by the purchaser.
After-sales service contact
Claims shall be presented during the warranty period to the nearest authorised Solé Diesel dealer (see chart of Solé Diesel Dealers), who shall take care the service covered by the warranty.
The purchaser must provide a proof of purchase and date of purchase by presenting the invoice to the authorized dealer for the purchase of the product served or a copy of it. Claims under warranty shall not be dealt with by the dealer until the date of purchase has been verified.
The following information must also be provided by the purchaser: a) Owner’s name, address, and contact telephone number. b) Product model and serial number. c) Number of service hours of the product. d) Detailed description of the problem. e) Information regarding any repair or installation performed by a service not included in the
Solé Diesel distribution network, as well as the services performed. For an updated list of our distribution network, visit Dealers section in our web page www.soleDiesel.com.
e-mail: info@soleDiesel.com Or request this information by contacting Solé Diesel at: Phone: +34 93 775 14 00

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Marine Diesel gensets. Operator’s Manual.

Transport, handling and storage
Section 1 ­ Genset Information
1.1. Genset Identification
Identification label The nameplate is located above the rocker cover. The characteristics plate of genset it’s located above the alternator case.

Serial number marked
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 between -18 °C and + 45 °C.

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1.2. Genset parts identification
Gensets: 7 GSC / 8 GSAC / 8 GTC / 10 GTAC / 10 GSC / 12 GSAC / 11 GTC / 14 GTAC / 14 GSC / 17 GSAC / 17 GTC / 20 GTAC DNV
PIECE ELEMENT 1 Oil filter 2 Oil level stick 3 Oil fill cap 4 Oil drain tuve 5 Fuel filter 6 Manual priming 7 Fuel regulator 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 pressure control 32 Thermostat 34 Oil thermostat 35 Pick up 36 Fuel leak alarm 37 Anti- vibration mounts

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Marine Diesel gensets. Operator’s Manual.

Transport, handling and storage
Section 2 ­ Transport, Handling and Storage
2.1. Reception
When the genset is delivered make sure that the packing has not been damaged during transport and that it has not been tampered with or that components inside the packing have been removed (see information marked on covers, bases and cartons).
Place the packed genset as close as possible to the place of installation and remove the packing material, checking that the goods supplied correspond to the order specifications.
If you notice damage or missing parts, inform Solé DieselS.A. after-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 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 lifting the load.
The use of any other system automatically invalidates the insurance guarantee against possible damage to the genset.
To unpack the genset, you must follow these steps: 1. Remove the cardboard crate. 2. Lift the genset using a forklift and suitable chains, which hook to the genset eyebolts. 3. Transfer the genset to the intended position of installation. 4. Remove the wooden base. 5. Begin installation operations.

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Marine Diesel gensets. Operator’s Manual.

Transport, handling and storage

2.3. Transporting and Handling the Unpacked Genset
When the genset is unpacked and ready for transport, use EXCLUSIVELY the appropriate lifting eyebolts.

Gensets: 7 GSC / 8 GSAC / 8 GTC / 10 GTAC DNV:

Gensets: 10 GSC / 12 GSAC / 11 GTC / 14 GTAC / 14 GSC / 17 GSAC / 17 GTC / 20 GTAC /

2.4. Storage 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 decides to start the genset after a long-time period, this must be done in the presence of an authorized technic.

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Marine Diesel gensets. Operator’s Manual.

Installation
Section 3 ­ Installation
3.1. Genset installation
Follow these steps to install the genset:
1. FIX GENSET. 2. CONNECT EXHAUST OUTLET.
1. WET EXHAUST 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 necessary to install a waterlock (supplied as accessory) in the exhaust system to avoid water ingestion.

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Marine Diesel gensets. Operator’s Manual.

Operation
Section 4 ­ Operation
4.1. Prestart checklist
Follow these checks and inspections to ensure the correct genset operation. In addition, some checks require verification after unit starts.
AIR CLEANER: Check for a clean and installed air cleaner element to prevent unfiltered air from entering the genset. AIR INLETS: Check for clean and unobstructed air inlets. BATTERY: Check for tight battery connections. COOLANT LEVEL: Check the coolant level according to coolant circuit capacity. DRIVE BELTS: Check the belt condition and tension of the coolant pump and battery charging alternator belt. EXHAUST SYSTEM: Check for exhaust leaks and blockages. Check the silencer and piping condition and check for 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-up. 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 start-up as indicated by water discharge from the exhaust outlet.
4.2. Genset Operation at Low Temperatures
Whenever the atmospheric temperature drops below zero, the following series of circumstances occur:
The cooling liquids may freeze. The oil becomes thicker. There is a drop in the voltage at the battery terminals. The inlet air temperature is low and the genset has difficulty in starting. The fuel loses fluidity.
To prevent the damage caused by low temperature operation, the genset should be prepared:
1. Use special low temperature coolant or suitable anti-freezing agent concentration. 2. Close the seawater cock, when the genset is stopped. Open the seawater filter cover and start
the genset adding a mixture of freshwater and suitable anti-freezing agent concentration (see package labels) until the seawater circuit is filled completely. Stop the genset and replace the seawater filter cover. Before starting the genset again, open the seawater cock. Repeat this operation whenever the genset is used at temperatures below 0ºC. 3. Use oil with suitable quality and viscosity. SAE 15W40 is recommended. Under extreme conditions contact with technical support.

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Marine Diesel gensets. Operator’s Manual.

Operation
4. Cover battery with an adequate material to protect it against the cold. Check that the battery is fully charged. It is also advisable to use a dielectric spray on the electrical connections.
5. When starting the genset, make sure that the glow plugs become hot enough. 6. If necessary, replace the Diesel oil by a specified Diesel oil type for low temperatures. The
accumulation of impurities in the fuel tank could cause faulty firing.
All gensets not in use are subject to rusting and corrosion of machined surfaces that are not protected with a paint coating. 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. Winterization 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 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 must 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 from the seawater pump, clean it with fresh water and store it in place
protected from moisture and sunlight. 4. Renew and refill the heat exchanger to the maximum level with a mixture of fresh water and
anti-freezing agent. 5. Renew the oil and oil filter in the genset. 6. Cover the air intake. 7. If the fuel tank is small, empty it completely and clean it; fill it up again with a mixture of Diesel
and anti-corrosion additive. Solé S.A. recommends DIECYL PLUS. Add one measure of this additive for every 25 litres of Diesel. On the other hand, if the fuel tank is large, add 1 litre of this additive for every 500 litres of Diesel. 8. Clean and dry the area where the genset is installed. 9. Loosen the belts. 10. Apply dielectric spray on the electrical connection, disassemble the battery and charge it several times during the time it is not being used. 11. Apply moisture repellent spray on the motor.

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Marine Diesel gensets. Operator’s Manual.

Operation
4.4. Maintenance during the storage
During the long genset storage, it has to be stored inside a ventilated area and free of humidity.
When the genset stay stopped for 3 months or more, inside parts can be oxidize and lost the oil film. As a result, the genset could size up after the storage. To avoid this, the genset must work periodically during the storage.
Realize the following steps at least once per month: 1. In case that has a battery next to the genset, check the electrolyte level and fill it. 2. Start the genset during approximately 10 seconds. 3. Stop the genset for 1 minute. Repeat this action two or three times. 4. Be sure that oil pressure 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 the genset.
2. Get the genset work during 5 or 10 minutes without load, as maintenance operation. 3. Check the fuel filter. If the filter is clogged, replace the filter. 4. Renew the oil in the genset. 5. Check the condition of coolant circuit’s rubber hoses. 6. Reconnect the battery and apply a layer of neutral Vaseline to the battery terminals. 7. Remove the nozzle supports and clean them. If possible, verify the setting of the nozzles at a
workshop. Then install the clean nozzles. 8. Connect the cooling and exhaust system. Open the seawater cock. 9. 9. Verify whether there are any leaks in the fuel, coolant and oil systems.

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance
Section 5 ­ Systems and Scheduled Maintenance
5.1. Operating Description
Information of special tools required and basic safety precautions.
Disassembly: Use the correct tools and instruments. Serious injury or damage to the genset can result from using the wrong tools and instruments. Use an overhaul stand or work bench if necessary. Also, use assembly bins to keep the genset parts in order of removal. Lay down disassembled or cleaned parts in the order in which they were removed. This will save you time at reassembly. Pay attention to the marks on assemblies, components and parts for positions or directions. Put on your own marks, if necessary, to aid reassembly. Carefully check each part for faults during removal or cleaning. Signs of abnormal wear will tell if parts or assemblies are functioning improperly. When lifting or carrying heavy parts, get someone to help you if the part is too awkward for one person to handle. Use jacks and chain blocks when necessary.
Reassembly: Wash all genset parts, except oil seals, 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 required.
Increase the frequency of maintenance in harsh duty conditions (frequent stops and starts, dusty surrounding, prolonged winter season, no-load running).
Risk of burns during maintenance operations carried out when the genset is hot. Wear suitable safety clothing.
It is strictly forbidden to clean the genset with compressed air. It is strictly forbidden to perform maintenance/cleaning operations in the presence of moving
parts. Use gloves, overalls, etc. to protect the body from burns.
5.2. Periodic Maintenance Schedule
The maintenance and fault diagnostic procedures involve risks that may cause severe injury or even death. These procedures should therefore be carried out solely by qualified electrical and mechanical specialists. Before any maintenance and cleaning work, make sure that there are no moving parts, that the generator housing has cooled to ambient temperature, that the electricity generating set cannot be accidentally started up and that all procedures are strictly observed.

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

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General Lubrication system*
Fuel system Intake system Cooling system Electrical system

Inspection Item
Screw tightening, fastening. Genset block. Valve clearance. Exhaust gas, noise and vibrations. Compression pressure. Genset oil. Oil filter. Fuel level. Fuel tank. Fuel filter. Water separator filter (if applicable). Injection pump. Injector. Air filter. Turbocharger Coolant. Salt water circuit. Anode Water filter. Sea water cock. Salt water pump impeller. Incandescent glow plug. Starter motor and alternator 12/24V. Alternator 12/24V belt and tension. Battery level.

Daily
I I I

1st 20h50h
I

Every 200h

Intervals
Every 400h
I

I

C

C

C

C

C

E

C

I

C

I

I/C

I

CL

CL

I

I/C

I

I

I

I

I

I

I

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

Every 800h

Every year

Every 2 years

Winter storage and Preservation

CL

I

C

C

CL

E/L/I

I

I

C

I

I

C

C

I/CL

I/CL

C

I

C

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

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5.3. General
Solé Diesel offers, for these engine models, the several Pack, consult on the web.
· Welcome pack. · On board pack. · Maintenance pack 50 hours. · Maintenance pack 1600 hours. · Maintenance pack 3000 hours.

Maintenance task. Screw tightening, fastening

For details of tightening torques see Section 9 Torques.

Maintenance task. Valve clearance inspection

The rocker cover must be dismounted to check the valve clearance. This operation must be carried out when the genset is cold.

Item Valve clearance (cold setting)

Inlet Exhaust

Assembly standard 0,25 mm

Inspection

Insert the appropriate thickness gauge between the

rocker arm and valve cap to check the clearance.

Loosen the rocker nut (1).

Tighten or loosen adjusting screw (2) to adjust valve

clearance by checking thickness with thickness gauge (3).

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 similarly as with the other cylinders. The position of the BTDC can be confirmed with the aligning signs of the distribution or timing cover and the crankshaft pulley.

The adjustment of the valve play must be made after the cylinder head screws are again tightened. (Strictly comply with the operation sequence indicated in the heading 4.1)

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance
Maintenance task. Compression pressure inspection
Start by:
1. Make sure the genset oil level, air cleaner, starting motor and battery are well-conditioned.
2. Start the genset and allow it to warm up thoroughly, until 50ºC or more coolant temperature.

Measure the compression pressure on all cylinders:

1. Remove the injection nozzle from the cylinder head where the compression pressure is to be measured.
2. Attach 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. 4. If the compression pressure is lower than repair limit, check the genset parts affected.

Model
8 GTC / 10 GTAC / 7GSC / 8 GSAC DNV
12 GSAC / 11 GTC / 14 GTAC / 14 GSC / 17 GSAC / 17 GTC / 20 GTAC DNV

Genset speed 250 to 280 rpm
290 rpm

Compression pressure 3,14 MPa (29 – 32 kgf/cm2) 3,14 MPa (29 – 32 kgf/cm2)

Repair limit 2,45 MPa (25 kgf/cm2) 2,45 MPa (25 kgf/cm2)

– 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 speed. Check genset speed when measuring the compression pressure.
– The compression pressure will be slightly higher in a new or overhauled genset due to new piston rings, valve seats, etc.

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Marine Diesel gensets. Operator’s Manual.

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5.4. Lubrication System Circuit description

The lubrication circuit is forced by the trochoid gear pump, and it is composed of the following elements.
PIECE ELEMENT 1 Main gallery 2 Oil pump 3 Oil strainer 4 Oil pan 5 Oil filter 6 Pressure relief valve

Model 8 GTC / 10 GTAC / 7 GSC / 8 GSAC DNV 11 GTC / 14 GTAC / 10 GSC / 12 GSAC DNV 17 GTC / 20 GTAC / 14 GSC / 17 GSAC DNV *Including filter change (0,5l)

*Oil circuit capacity (L) 4,1 4,2 6,0

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 going to be operated. On the other hand, use oil quality no less than ACEA E5/E3 or API CH-4/SJ. Other genset oils may affect warranty coverage, cause internal genset components to seize and/or shorten genset life.

Never mix different types of genset oil. This may adversely affect the lubricating properties of the genset oil.

Maintenance task. Oil filter change

The oil filter is located under inlet manifold of the engine. When fitting a fresh oil filter, smear a small quantity of oil into the annular seal and firmly tighten it with the hand. When this operation is finished, start the genset and check oil is not leaking.

Maintenance task. 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 of aspiration by the oil pump. Follow next steps to perform the modification:

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Marine Diesel gensets. Operator’s Manual.

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1. With the engine in horizontal position, 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 and minimum quantity, and mark the new minimum.
Do not operate the genset if the oil level is below the Min mark or above the Max mark.
Maintenance task. Oil fill / change
Oil must be changed with hot genset so as to be sure the oil is fully drained. The procedure is the following:
1. Drain the oil (follow steps below) a. Stop the genset. b. Disconnect the battery negative (-) terminal. c. Remove the oil drain plug. d. Connect the external oil pump to the end of the oil drain hose. Place the outlet of the pump into an oil collection container. e. Allow time for the genset oil to drain completely.
2. Replace the oil filter. 3. Remove dipstick 4. Fill with oil according to oil capacity circuit. 5. Check for leaks. 6. Check oil level according 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.

PIECE ELEMENT

1 Fuel injection nozzle

2 Fuel injection pipe

3 Fuel leak-off pipe

4 Injection pump

5 Priming pump

6 Fuel filter

7 Tank (supplied as accessory)

8

Fuel decanting filter (supplied as accessory)

9

Fuel intake pipe (supplied accessory)

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance
Fuel specifications
Use 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 inspection
Periodically, it is necessary to check the fuel level to assure the operation of the genset. On top of that, if fuel pump sucks air when the fuel level is lower than pump suction, it could break.
Whenever possible, keep the fuel tank full. The temperature changes may cause condensation of the damp air present in the tank and this water accumulates 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 separator filter purge
The fuel system has to have a water separator filter (supplied as accessory) to avoid the inlet of water in the fuel circuit. According to the maintenance plan it is necessary to purge the filter to eliminate water periodically. This is the procedure:
1. Loosen the bottom nut to eliminate water. 2. Shut it off again. 3. Check for any leakage.
Maintenance task. Fuel filter change
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.

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance

Maintenance task. Injection pump inspection

The injection pump is adjusted at factory and should never be adjusted carelessly. Such adjustment, whenever is required, shall be made by a Solé Diesel licensed service shop, since a precision pump monitor and skill knowledge are required.
You must check: – The presence of exhaust smoke colour. – Procedure: quickly accelerate genset.
Criteria: no remarkably black smoke exhaust, and correct function of fuel cut- off solenoid – Any leaks at the body injection pump or fuel lines
Maintenance task. Injector inspection

To check the injection pressure of injectors (opening pressure) you have to follow these steps: 1. Remove nozzle and washer. 2. Install the injection nozzle on the tester. Slowly
operate the tester handle full strokes to bleed (remove) air from the pipe and nozzle. 3. Make a slow increase in 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.

Injection pressure

13 MPa (140 kgf/cm2)

5. To adjust the injection pressure, increase or decrease the amount of shims fitted to the nozzle holder.
6. Look at the orifice discharge pattern (shape of discharge) when fluid begins to flow through the injection nozzle. The discharge must be finely and uniformly atomized. Any change is an indication of a bad nozzle.

7. If the nozzle is bad, remove the tip from the nozzle and wash needle valve and body in clean washing solution. And if the nozzle is still bad after the tip has been washed, replace the tip.
8. When installing the new tip, remove synthetic resin film from the tip and slide the needle valve in the body in clean Diesel fuel to wash off inhibitor completely
9. The washer shown on figure must be replaced.
When testing the injection nozzle, keep its tip pointed away from the operator. Fuel from the orifices in the tip of the nozzle is under high pressure and can cause injury to the operator.

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance

Maintenance task. Bleeding air from the fuel system
Prime the fuel system to bleed the air from the circuit. Trapped air in the fuel system can cause difficult starting and erratic engine operation. It is necessary to prime the system:
Before starting the engine for the first time. After running out of fuel and adding fuel to the tank. After fuel system maintenance such as changing the fuel
filter, draining the fuel/water separator, or replacing a fuel system component.
Fuel filter: 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 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 flows without fizzing.

When fuel overflows from the injection pipes, wipe thoroughly with a cloth. Spilled fuel is a fire hazard.
5.6. Cooling system

The genset cooling system is based on coolant circulation controlled by centrifugal pump with thermostatic control and heat exchanger, where the coolant is refrigerated by sea water. Moreover, the exhaust manifold is cooled also by sea water.

Coolant circuit description

Seawater circuit description

PIECE ELEMENT 1 Coolant fill cap 2 Water cooler body 3 Fresh coolant water

PIECE ELEMENT 1 Seacock (accessory) 2 Sea water filter (accessory) 3 Sea water pump 4 Heat exchanger 5 Wet exhaust elbow

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance

Model 8 GTC / 10 GTAC / 7 GSC / 8 GSAC DNV 11 GTC / 14 GTAC / 10 GSC / 12 GSAC DNV 17 GTC / 20 GTAC / 14 GSC / 17 GSAC DNV

Coolant circuit capacity (L) 3,5 6,25 8,0

Coolant specifications
It is recommended use Solé Diesel 50% coolant or another coolant with similar specifications. On the other hand, distilled water with an anti-freezing agent is also suitable. The anti-freezing agent concentration 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.
Other genset coolants may affect warranty coverage, cause an internal build-up of rust and scale and/or shorten genset life.
Never mix different types of coolants. This may adversely affect the properties of the genset coolant.
Maintenance task. Coolant check
Allow the genset to cool. Release pressure from the 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 two drain plugs, one in the heat exchanger and the other in the cylinder block.
2. Close the drain plugs. 3. Remove bleeding bolt of thermostat holder 4. Refill to the hole in the tank cap with coolant

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance

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 care that the cover is well seated on the o-ring. 4. Start the genset to check seawater leakages.

Maintenance task. Seawater pump impeller inspection

Seawater pump impeller is neoprene and cannot rotate dried. If operated without water, the impeller can be broken. It is important therefore that a spare impeller is always available. Impeller inspection and replacement procedure:

1. Close the seawater cock. 2. Remove the seawater pump cover plate. 3. Remove the impeller from the shaft. 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 in the impeller housing. 8. Inspect the cover plate and gasket for corrosion and/or damage. Replace components as necessary. 9. Lubricate the gasket with silicon grease and attach the gasket and cover plate to the seawater pump housing. 10. Open the seacock. 11. Start the genset and check for leaks.

5.7. Inlet and Exhaust System

Exhaust circuit description

There are two possible installations of the exhaust system. You need to check the distance 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 following formula:

=

4

2

0.5

1000000

C = collector capacity (L) D = Inside diameter of the tube (mm) L = Tube length (mm)

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Marine Diesel gensets. Operator’s Manual.

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– Goose neck (supplied as accessory) – Siphon breaker (supplied as accessory) ­ needed in case there is less than 150 mm between
the water injection point of wet exhaust and the waterline, or if the point of injection is below waterline. Type 1 installation. When between water injection point of wet exhaust and waterline is minimum 150 mm.
Type 2 installation. When between water injection point of wet exhaust and waterline there is less than 150 mm or 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.

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance
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 and freely expelled from the area.
Maintenance task. Exhaust gas, noise and vibrations inspection
Inspect the exhaust system components for cranks, leaks and corrosion.
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 carbon or soot residue on
exhaust components. Carbon and soot residue indicate an exhaust leak. Seal leaks as needed.

5.8. Battery

Electrical System

The minimum recommended capacity is from 60 – 80 Ah. 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 the battery for an earth isolated engine. · Positive battery is connected to the starter.
Genset model
8 GTC / 10 GTAC / 7 GSC / 8 GSAC DNV 11 GTC / 14 GTAC / 10 GSC / 12 GSAC / 17 GTC / 20
GTAC / 14 GSC / 17 GSAC DNV · Negative battery is connected to the bipolar relay.

Battery capacity (Ah)

12V

24V

60

PD

80

PD

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance

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.

Genset model

Current (A)

8 GTC / 10 GTAC DNV

10

7 GSC / 8 GSAC DNV

25

11 GTC / 14 GTAC DNV

16

10 GSC / 12 GSAC DNV

40

17 GTC / 20 GTAC DNV

20

14 GSC / 17 GSAC DNV

63

Maintenance task. Incandescent glow plug inspection

1. Loosen nuts, and then remove connection plate and glow plug.

2. If the glow plug glows red when the positive (+) wire is connected to the portion A with the portion B grounded, the plug can be used.
Rated voltage – Current 12 V 9,7-10,5 A

Maintenance task. Starter motor inspection

1. Check if there is any impurity in pinion teeth. 2. Make sure that the pinion shaft turns freely when turned in the direction of driving (clockwise)
and it is locked when turned in the opposite direction. If not, replace the overrunning clutch.

Maintenance task. Alternator belt tension inspection

Push the belt inward with thumb pressure exerted midway between the pulleys, as shown, to check the belt tension (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

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 with genset running or battery connected.

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Marine Diesel gensets. Operator’s Manual.

Systems and scheduled maintenance
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 neutral grease layer. 3. Metal objects must not be placed over the battery. 4. Add distilled water if the level is out of range.
5.9. Alternator
The maintenance and fault diagnostic procedures involve risks that may cause severe injury or even death. These procedures should therefore be carried out solely by qualified electrical and mechanical specialists. Before any maintenance and cleaning work make sure that there are no live parts that the generator housing has cooled to ambient temperature, that the genset cannot be accidentally started up and that all procedures are strictly observed.
Maintenance task. control of windings and electrical insulation
The condition of the windings can be checked by measuring their electrical resistance to earth. While running this test, disconnect the voltage regulator. It is usually sufficient to control the main winding.
The readings should give a measurement of the least 1MOhms. If the insulation resistance is below this threshold, the alternator alone should be oven dried at 60 ­ 80ºC for 3 hours. Before carrying out this operation remove the voltage regulator. As an alternative to oven drying hot air at 60 ­ 80ºC can be blown through the alternator for at least 1 hour.
Maintenance task. Control of bearings
During 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 to a worn bearing that, if damaged, has to be replaced. No maintenance is required for the total operating time:
Operating time 20.000 hours
A bearing lifespan is closely linked to the working conditions and environment.
Long periods of sustained vibrations can damage the bearing balls and their seat. Too high humidity can emulsify the grease and encourage corrosion.

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Marine Diesel gensets. Operator’s Manual.

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Intense vibrations caused by the motor or bad alignment of the components in the genset put the bearing under stresses that will reduce its lifespan.
Maintenance task. Cleaning and lubrication
Any kind of cleaning work must be carried out with the genset shutdown and the mains power shut off for the risk of severe hazard for persons and objects. Moreover, prior to approaching or touching the alternator, ensure that it is at room temperature.
Make sure that the genset is shutdown and the mains power is shut off before cleaning the outside of the genset with compressed air.
Never and for no reason whatsoever use fluids or water. Do not use compressed air to clean internal electrical parts since this could cause short circuits or related problems.

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Marine Diesel gensets. Operator’s Manual.

Troubleshooting
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.

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Marine Diesel gensets. Operator’s Manual.

Troubleshooting

GENSET FAILURE
FAILURE TO CRANK

PROBABLE CAUSES Battery discharged or dead Battery connections loose, corroded
ELECTRICAL SYSTEM (DC) or incorrect Faulty cranking relay/stop solenoid
Faulty starter motor

RECOMMENDED ACTIONS Recharge or replace the battery.
Verify that the battery connections are correct, clean and tight.
Check the cranking relay and the stop solenoid. If necessary, replace. Replace if it is inoperative.

FAILURE TO START

ELECTRICAL SYSTEM GENSET
GENERAL LUBRICATION SYSTEM
FUEL SYSTEM
INLET AND EXHAUST SYSTEM

Blown fuse
Battery discharged or dead Battery connections loose, corroded or incorrect Faulty cranking relay/stop solenoid Faulty starter motor Compression weak Oil viscosity too high Fuel pump faulty or clogged Fuel lines obstructed Fuel filter clogged Faulty injection pump Air in fuel system Fuel injectors dirty or faulty Fuel injection timing out of adjustment Fuel tank empty or fuel valve shut off

Replace the controller fuse. If the fuse blows again, troubleshoot the controller. Recharge or replace the battery.
Verify that the battery connections are correct, clean and tight.
Check the cranking relay and the stop solenoid. If necessary, replace. Replace if it is inoperative. Check the compression. Check the oil viscosity (according to technical specifications). Check fuel pump inlet. Check fuel lines. Replace fuel filter. Contact with our dealer Bleed fuel system. Clean, test and/or replace the inoperative fuel injector.
Adjust the fuel injection timing.
Add fuel and move the fuel valve to opened position.

Air filter clogged

Replace air filter element.

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Marine Diesel gensets. Operator’s Manual.

Troubleshooting

GENSET FAILURE STARTS THEN STOPS
NO OR LOW OUTPUT VOLTAGE

GENERAL FUEL SYSTEM COOLING SYSTEM GENERAL
ALTERNATOR (AC)

PROBABLE CAUSES Governor inoperative Fuel pump faulty or clogged Fuel filter clogged Air in fuel system Injection pump incorrectly set Fuel outlet cock closed Coolant level low Engine overload Governor inoperative AC output circuit breaker open Wiring, terminals or pin in the exciter field open Main field (rotor) inoperative (open or grounded) Stator inoperative (open or grounded)

The genset will not excite

NO LOAD VOLTAGE TOO
LOW
NO LOAD VOLTAGE TOO
HIGH

ALTERNATOR (AC) ALTERNATOR (AC)

After the genset is excited it deactivates

RECOMMENDED ACTIONS Contact with our dealer Check inlet of fuel pump. Replace fuel filter. Bleed fuel system. Contact with our dealer Open fuel outlet cock. Restore the coolant to normal operating level. Reduce the electrical load. Contact with our dealer Close AC circuit breaker.
Check for continuity.
Test and/or replace the rotor.
Test and/or replace the stator.
Check the fuse. Increase speed by 15%. Apply a 12V voltage for an instant across the electronic regulator terminals using a battery with a 30 Ohm resistance in series and remember to respect the polarities.
Check the wiring against the diagrams in appendix.
Calibrate the voltage. Check the rpms. Check the windings. Calibrate the voltage.
Change the regulator.

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

31

Marine Diesel gensets. Operator’s Manual.

Troubleshooting

GENSET FAILURE UNDER LOAD
VOLTAGE BELOW NOMINAL
UNDER LOAD VOLTAGE ABOVE
NOMINAL UNSTABLE VOLTAGE
BLACK SMOKE
BLUE SMOKE
GENSET OVERHEATING

PROBABLE CAUSES ALTERNATOR (AC) ALTERNATOR (AC)

RECOMMENDED ACTIONS Calibrate the voltage. Current too high, cos very low, speed below 4% of nominal. Change the regulator. Check the diodes, unhooking the cables. Calibrate the voltage.
Change the regulator.

ALTERNATOR (AC) FUEL SYSTEM INLET AND EXHAUST SYSTEM LOAD GENSET GENERAL LUBRICATION SYSTEM GENERAL
LUBRICATION SYSTEM
COOLING SYSTEM
INLET AND EXHAUST SYSTEM

Fuel filter clogged Fuel injectors dirty or faulty Injection pump incorrectly set Air filter clogged Propeller to large (not enough rpm) Valve clearance incorrect Oil level too high Compression weak Overload Incorrect injection time Faulty oil pump
Oil viscosity too high
Oil level too low Faulty coolant pump Seawater cock clogged or restricted Faulty seawater pump
Water cooler clogged
Coolant level low Thermostat inoperative Air filter clogged

Check for uniform rotation. Control regulator stability by adjusting potentiometer. Change fuel filter. Clean, test and/or replace the inoperative fuel injector. Contact with our dealer Replace air filter element. The power curve of the genset is not adequate. Carry out a propulsive power study. Adjust the valves. Restore the oil to normal operating level. Check the compression. Propeller too large, replace. Adjust the injection time of the injection pump. Contact with our dealer Check oil specifications (oil used must be chosen according to Technical Specifications). Restore the oil level. Inspect the genset for oil leaks. Check coolant pump (impeller, pump sealing).
Clean the cock, check the seawater pump impeller for damage.
Check seawater pump (impeller, pump sealing). Clean the water cooler and the tube stack fitted in the heat exchanger. Restore the coolant to normal operating level. Replace the thermostat. Replace air filter.

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

32

Marine Diesel gensets. Operator’s Manual.

Troubleshooting

GENSET FAILURE LOW OIL
PRESSURE
NOISY GENSET OIL PRESSURE
TOO HIGH
LOW POWER
HIGH FUEL CONSUMPTION
BATTERY CHARGE DEFECTIVE

PROBABLE CAUSES

Faulty oil pump

Oil pressure relief valve sticking

LUBRICATION SYSTEM

Oil pressure too low Oil level too low

Faulty oil pressure valve

Faulty oil pressure gauge or switch

Compression weak

Overload

GENERAL

Exhaust system leak

LUBRICATION SYSTEM GENERAL
FUEL SYSTEM
INLET AND EXHAUST SYSTEM

Vibration excessive Valve clearance incorrect Oil pressure relief valve sticking Faulty oil pressure valve Valve clearance incorrect Fuel filter clogged Fuel injectors dirty or faulty Water in fuel system Fuel injection timing out of adjustment Air filter clogged
Exhaust backfires

GENERAL
FUEL SYSTEM INLET AND EXHAUST SYSTEM COOLING SYSTEM
ELECTRICAL SYSTEM (DC)

Compression weak Overload Governor inoperative Fuel injection timing out of adjustment
Air filter clogged
Thermostat blocked at open position Battery discharged or dead Battery connections loose, corroded or incorrect Governor inoperative Alternator belt tension

RECOMMENDED ACTIONS
Contact with our dealer
Check oil level. Restore the oil level. Inspect the genset for oil leaks. Contact with our dealer Check and/or replace oil pressure switch. Check the compression. Reduce the electrical load. Inspect the exhaust system. Replace the inoperative exhaust system components. Tighten all loose nuts and bolts. Adjust the valves. Contact with our dealer Contact with our dealer Contact with our dealer Contact with our dealer Contact with our dealer Contact with our dealer Contact with our dealer Replace air filter element. Inspect the exhaust system. Replace the inoperative exhaust system components. Check the compression. Reduce the electrical load. Contact with our dealer Adjust the fuel injection timing.
Replace air filter.
Replace thermostat and check the coolant state. Recharge or replace the battery.
Verify that the battery connections are correct, clean and tight.
Contact with our dealer Check belt tension and change it if necessary.

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

33

Marine Diesel gensets. Operator’s Manual.

Techincal specifications
Section 7 ­ Technical specifications

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

34

Marine Diesel gensets. Operator’s Manual.

MARINE GENERATORS
10 GS/GSC’19
Single-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

885 mm 580 mm 609 mm 271 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-33 4 No. of Strokes 1500 3 1318 cc SAE 15W40 4 L (1,06 gal) 10,7 kW (14,55 CV) 16,5 l/min (4,36 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

1,3 L/H (0,34 Gal/H) 1,8 L/H (0,48 Gal/H) 2,4 L/H (0,63 Gal/H) 3,1 L/H (0,82 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 1,7 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

50 mm (1,97 in) 20 mm (0,79 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 65 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160CA1 BL4 4 H 23

7KHUHLVDRIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1032 mm 580 mm 668 mm 308 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

78 mm (3,07 in) 92 mm (3,62 in) 22:1 Mechanical and indirect Naturally aspirated SAE 5 5,7 L (1,51 gal) SAE 7 1/2 40 l/min (10,57 gal/m) 0,85 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,3 m (0,98 ft)

Maximum raw water lift height: 1,3 m (51,18 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 25 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

1 S Brushless 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

MARINE GENERATORS
11 GT/GTC’19
Three-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

885 mm 580 mm 609 mm 264 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-33 4 No. of Strokes 1500 3 1318 cc SAE 15W40 4 L (1,06 gal) 10,7 kW (14,55 CV) 16,5 l/min (4,36 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

1,3 L/H (0,34 Gal/H) 1,8 L/H (0,48 Gal/H) 2,4 L/H (0,63 Gal/H) 3,1 L/H (0,82 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 1,7 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

50 mm (1,97 in) 20 mm (0,79 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 65 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160CA BL4 4 H 23

7 KHUHLV D RIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1032 mm 580 mm 668 mm 300 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

78 mm (3,07 in) 92 mm (3,62 in) 22:1 Mechanical and indirect Naturally aspirated SAE 5 5,7 L (1,51 gal) SAE 7 1/2 40 l/min (10,57 gal/m) 0,85 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,3 m (0,98 ft)

Maximum raw water lift height: 1,3 m (51,18 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 25 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

0,8 S Brushless 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

MARINE GENERATORS
12 GSA/GSAC’19
Single-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

885 mm 580 mm 609 mm 271 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-33 4 No. of Strokes 1800 3 1318 cc SAE 15W40 4 L (1,06 gal) 13,8 kW (18,77 CV) 19,8 l/min (5,23 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

1,7 L/H (0,45 Gal/H) 2,2 L/H (0,58 Gal/H) 3 L/H (0,79 Gal/H) 3,8 L/H (1 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 1,7 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

50 mm (1,97 in) 20 mm (0,79 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 65 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160CA1 BL4 4 H 23

7 KHUHLV D RIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1032 mm 580 mm 668 mm 308 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

78 mm (3,07 in) 92 mm (3,62 in) 22:1 Mechanical and indirect Naturally aspirated SAE 5 5,7 L (1,51 gal) SAE 7 1/2 47 l/min (12,42 gal/m) 1,1 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,3 m (0,98 ft)

Maximum raw water lift height: 1,5 m (59,06 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 25 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

1 S Brushless 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

MARINE GENERATORS
14 GTA/GTAC’19
Three-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

885 mm 580 mm 609 mm 264 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-33 4 No. of Strokes 1800 3 1318 cc SAE 15W40 4 L (1,06 gal) 13,8 kW (18,77 CV) 19,8 l/min (5,23 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

1,7 L/H (0,45 Gal/H) 2,2 L/H (0,58 Gal/H) 3 L/H (0,79 Gal/H) 3,8 L/H (1 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 1,7 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

50 mm (1,97 in) 20 mm (0,79 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 65 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160CA BL4 4 H 23

7 KHUHLV D RIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1032 mm 580 mm 668 mm 300 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

78 mm (3,07 in) 92 mm (3,62 in) 22:1 Mechanical and indirect Naturally aspirated SAE 5 5,7 L (1,51 gal) SAE 7 1/2 47 l/min (12,42 gal/m) 1,1 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,3 m (0,98 ft)

Maximum raw water lift height: 1,5 m (59,06 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 25 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

0,8 S Brushless 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

MARINE GENERATORS
14 GS/GSC’19
Single-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

1036 mm 580 mm 612 mm 294 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-44 4 No. of Strokes 1500 4 1758 cc SAE 15W40 6 L (1,59 gal) 15 kW (20,4 CV) 16,5 l/min (4,36 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

1,8 L/H (0,48 Gal/H) 2,7 L/H (0,71 Gal/H) 3,5 L/H (0,92 Gal/H) 4,3 L/H (1,14 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 2 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

50 mm (1,97 in) 20 mm (0,79 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 80 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160MA1 BL4 4 H 23

7 KHUHLV D RIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1181 mm 580 mm 668 mm 344 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

78 mm (3,07 in) 92 mm (3,62 in) 22:1 Mechanical and indirect Naturally aspirated SAE 5 8 L (2,11 gal) SAE 7 1/2 55 l/min (14,53 gal/m) 1,2 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,3 m (0,98 ft)

Maximum raw water lift height: 1,5 m (59,06 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 25 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

1 S Brushless 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

MARINE GENERATORS
17 GSA/GSAC’19
Single-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

1036 mm 580 mm 612 mm 294 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-44 4 No. of Strokes 1800 4 1758 cc SAE 15W40 6 L (1,59 gal) 19,5 kW (26,52 CV) 20 l/min (5,28 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

2,2 L/H (0,58 Gal/H) 3,1 L/H (0,82 Gal/H) 4,1 L/H (1,08 Gal/H) 5,4 L/H (1,43 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 2 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

50 mm (1,97 in) 20 mm (0,79 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 80 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160MA1 BL4 4 H 23

7 KHUHLV D RIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1181 mm 580 mm 668 mm 344 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

78 mm (3,07 in) 92 mm (3,62 in) 22:1 Mechanical and indirect Naturally aspirated SAE 5 8 L (2,11 gal) SAE 7 1/2 66 l/min (17,44 gal/m) 1,4 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,3 m (0,98 ft)

Maximum raw water lift height: 2 m (78,74 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 25 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

1 S Brushless 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

MARINE GENERATORS
17 GT/GTC’19
Three-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

1036 mm 580 mm 612 mm 282 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-44 4 No. of Strokes 1500 4 1758 cc SAE 15W40 6 L (1,59 gal) 15 kW (20,4 CV) 16,5 l/min (4,36 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

1,8 L/H (0,48 Gal/H) 2,7 L/H (0,71 Gal/H) 3,5 L/H (0,92 Gal/H) 4,3 L/H (1,14 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 2 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

50 mm (1,97 in) 20 mm (0,79 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 80 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160MA BL4 4 H 23

7 KHUHLV D RIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1181 mm 580 mm 668 mm 344 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

78 mm (3,07 in) 92 mm (3,62 in) 22:1 Mechanical and indirect Naturally aspirated SAE 5 8 L (2,11 gal) SAE 7 1/2 55 l/min (14,53 gal/m) 1,2 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,3 m (0,98 ft)

Maximum raw water lift height: 1,5 m (59,06 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 25 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

0,8 S BRUSHLESS 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

MARINE GENERATORS
20 GS/GSC’19
Single-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

1140 mm 610 mm 662 mm 402 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-63 4 No. of Strokes 1500 4 2505 cc ATF 6,5 L (1,72 gal) 21,5 kW (29,24 CV) 38 l/min (10,04 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

2,4 L/H (0,63 Gal/H) 3,5 L/H (0,92 Gal/H) 4,75 L/H (1,25 Gal/H) 6,4 L/H (1,69 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 2 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

60 mm (2,36 in) 32 mm (1,26 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 95 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160LA1 BL4 4 H 23

7 KHUHLV D RIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1310 mm 610 mm 698 mm 426 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

88 mm (3,46 in) 103 mm (4,06 in) 22:1 Mechanical and indirect Naturally aspirated SAE 4 9,5 L (2,51 gal) SAE 7 1/2 52 l/min (13,74 gal/m) 1,65 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,6 m (1,97 ft)

Maximum raw water lift height: 3 m (118,11 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 15 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

1 S BRUSHLESS 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

MARINE GENERATORS
20 GTA/GTAC’19
Three-Phase

General data $FWLYHUDWHGSRZHU
$SSDUHQWUDWHGSRZHU
)UHTXHQF

N: N9$ +]

Dimensions and weights Total lenght without canopy: Total width without canopy: Total height without canopy: Dry weight without canopy:

1036 mm 580 mm 612 mm 282 Kg

Engine Base engine manufacturer: Model Solé Diesel: Type: Engine RPM: Number of cylinders: Total displacement: Oil type: Oil capacity: Power: Salt water flow rate: Starting aid:

Mitsubishi MINI-44 4 No. of Strokes 1800 4 1758 cc SAE 15W40 6 L (1,59 gal) 19,5 kW (26,52 CV) 20 l/min (5,28 gal/m) Glow plugs

Fuel system details Consumption: Consumption at 50 %: Consumption at 75 %: Consumption at 100 %:

2,2 L/H (0,58 Gal/H) 3 L/H (0,79 Gal/H) 4,1 L/H (1,08 Gal/H) 5,4 L/H (1,43 Gal/H)

Electrical system Battery voltage: Starter motor: Battery cable section:

12 V 2 kW 70 mm2

Installation details Exhaust hose inner diameter: Sea water hose inner diameter: Fuel feeding hose inner diameter: Fuel return hose inner diameter: Minimum battery capacity:

50 mm (1,97 in) 20 mm (0,79 in) 8 mm (0,31 in) 6 mm (0,24 in) 12 V 80 Ah

Alternator details Brand: Model: Regulator type: Number of poles: Isolation type: IP protection:

Sincro SK160MA BL4 4 H 23

7 KHUHLV D RIRYHUORDGSRZHUFDSDFLWIRUWKHLQGLFDWHGSRZHU

9ROWDJH $PSHUDJH 3KDVHV

9 $

Total lenght with canopy: Total width with canopy: Total height with canopy: Dry weight with canopy:

1181 mm 580 mm 668 mm 344 Kg

Diameter: Stroke: Compression ratio: Injection system: Intake system: SAE Flywheel housing: Coolant capacity: Flywheel: Coolant flow rate: Intake air flow rate:

78 mm (3,07 in) 92 mm (3,62 in) 22:1 Mechanical and indirect Naturally aspirated SAE 5 8 L (2,11 gal) SAE 7 1/2 66 l/min (17,44 gal/m) 1,4 m3/m

Fuel type: Fuel standards: Injection pump type: Governor type:

Diesel Fueloil diesel ASTM In line (OHFWURQLF

Stop solenoid type: Alternator: Battery cable length:

ETR 50 A 1,5 m

Maximum fuel lift height:

0,3 m (0,98 ft)

Maximum raw water lift height: 2 m (78,74 in)

Maximum sea water temperature: 32 ºC (32 ºF)

Maximum installation angle***: 25 º

Cos : Tropicalized: Excitation system: Voltage regulation accuracy**: Standards: Alternator type:

0,8 S BRUSHLESS 1% EN 60034-1, IEC 60034-1, ISO 8528-3 Synchronous

Parallel operation elements

Section 8 ­ Parallel operation elements

8.1. Controller Connections

Operation

The genset is delivered with all necessary elements to operate in parallel. However, the controller that regulates the genset is not included in the Scope of Supply.
If the controller has not been installed from the factory, the design the control part of the genset must be carry out. For this reason, it is necessary consider the requirements of the electrical wiring, according to the ECU connector, where the controller must be connected. The following table specifies the function of each wire:

Wire

Colour

1

Red

2

Black

3 Red-White

4

Brown

5

Blue

6

Grey

7

White

8

Pink

9

Yellow

10

Green

11 Green-White

12

Purple

13

Brown

14

Blue

15

–

16

Brown

17

Blue

18

–

Description Battery positive (+) Battery negative (-)
DC alternator excitation
Oil pressure signal Oil pressure alarm Coolant temperature signal Coolant temperature alarm
Cranking signal Fuel solenoid Electric fuel pump Preheating signal Emergency stop signal (not used) External controller RPM regulation AUX (ECU PIN N) External controller RPM regulation AUX (ECU PIN G) Shield (ECU PIN Ground) Voltaje control signal (Controller or potentiometer 5 k) AVR Pot. Voltaje control signal (Controller or potentiometer 5 k) AVR Ext.
Shield

Sole Diesel dispose the complete elements to control the gensets in parallel operation (optional 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.

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

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Parallel operation elements
· Back out the magnetic pickup by turning it counterclockwise (about a 3/4 turn). The gap between the pickup and gear should be no smaller than 0,64 mm (0.025 in) and 0,89 mm (0.035 in).
· Wire leads should be twisted for their entire length from the magnetic speed sensor to the control unit. Shielding is required if external interference is present or the leads are longer than 3 m (10 ft).

0,64mm (0,025 in) minimium gap

0,89 mm (0,035 in) maximum gap

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

TERMINAL A & B C & D
E & F G
N

DEFINITION Actuator power (+/-) Magnetic speed Pickup signal
(D is ground) Battery power (-/+)
Ground signal Accessory input. Load sharning/synchronizing

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

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Marine Diesel gensets. Operator’s Manual.

Parallel operation elements

Adjustments before engine startup

COMPONENT GAIN
STABILITY SPEED TRIM CONTROL
STARTING FUEL SPEED RAMPING

POSITION Middle position Middle position Middle position Full CW (Maximum fuel) Full CCW (Fastest)

Start the engine
The speed ECU setting is factory set at approximately engine nominal speed. If the engine does not start, adjustment of the Speed potentiometer may be required.
Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum fuel position until the engine starts. The governor system should control the engine at a low idle speed.
Governor speed setting: The governed speed set point 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 ensure stability.
· Turn the STABILITY knob clockwise until the engine becomes unstable. Then, turn it slowly counterclockwise until it stabilizes again. Turn it about 1/8 more turn counterclockwise to ensure stability.
· Apply load to the engine and if any instability is observed, try to correct it by turning the GAIN and STABILITY potentiometers slightly counterclockwise.

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

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Marine Diesel gensets. Operator’s Manual.

Parallel operation elements

8.4. Electrical actuator
Engines managed electronically are controlled by the ECU through the electric actuator. This regulates the fuel flow by acting on the fuel injection pump according to the orders sent by the ECU.
8.5. Parallel operation troubleshooting
To do the following checks, it is necessary to have the engine running.
Magnetic speed sensor
To verify the pickup operation, it is necessary 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 between terminals C and D of the ECU. This should be 30
to 1200 ohms. · Replace the sensor.
Electronic control unit and governor (ECU)

To verify the ECU operation, it is necessary to check the output voltage with the genset running. 1. Check the voltage between following PINS:

Terminals V [A (-) to B (+)] V [C to D] V [E (-) to F (+)] V [P (+) to G (-)] V [F (+) to A (-)]

Value 10 V ­ 14 V
1 V < 3 V 12 V o 24 V
10 V 1 V < 2 V (cranking)

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

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Marine Diesel gensets. Operator’s Manual.

Parallel operation elements

2. Check the current 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.

Terminals Nominal current Max. Continuous current Nominal coil resistance

Value 4,0 A (12 V DC) 2,0 A (24 V DC) 5,8 A (12 V DC) 3,1 A (12 V DC)
7,2 2,0

3. Check the resistance between PIN C and PIN D.

Terminals C & D

Value 30 to 1200

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

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Marine Diesel gensets. Operator’s Manual.

Control Panel

Section 9 ­ Control Panel
The following guide details its function and operation of any DNV Genset Control Panel. All of them are composed by three parts: the main controller CO-40 and two modules, the ID-COM and IDRPU. Together are exchanging information all the time. CO-40 is the main controller, IR-RPU controls all CO-40 parameters and it is his power supply. ID-COM reads all information and translate it to CAN language, also is connected to ECU and exchange all information.
CO-40
POWER TERMINALS · Power supply. Comes from ID-RPU. Connected to buzzer/lamp alarm. · DC Alternator excitation. Connected directly to pin L (or D+) of DC Alternator. · Ground: 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 sensor of engine · Oil Temperature Sensor: Connected directly to sensor of engine · Oil Temperature Sensor: Comes from to analog Oil Temperature Sensor through sensor of engine.

ID-RPU POWER TERMINALS
· Battery A Power Supply: Comes from Positive Terminal of main battery · Battery A Ground: Comes from Negative Terminal of main battery · Battery B Power Supply: Comes from Positive Terminal of auxiliary battery · Battery B Ground: Comes from Negative Terminal of auxiliary battery · Power Supply output (COM+): Power supply of CO-40, connected also to binary output
positive · Ground output (COM-): Ground of CO-40 and its analog inputs

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

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Marine Diesel gensets. Operator’s Manual.

Control Panel
BINARY INPUTS · Oil Pressure Switch: Comes from 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 pickup 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 pick-up relay

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

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Marine Diesel gensets. Operator’s Manual.

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

Operator guide

Copyright © 2004-2013 ComAp a.s. Written by Ladislav Kadanik, Vladimir Sebian and Pavel Doubek Prague, Czech Republic

ComAp a.s. Kundratka 2359/17, 180 00 Praha 8, Czech Republic Tel: +420 246 012 111, Fax: +420 266 316 647 E-mail: info@comap.cz, www.comap.cz

Table of Contents
Table of Contents…………………………………………………………………………………………………………………………… 2 Abbreviations ………………………………………………………………………………………………………………………………… 3 Conformity declaration…………………………………………………………………………………………………………………….. 5 General description…………………………………………………………………………………………………………………………. 6 Manuals………………………………………………………………………………………………………………………………………… 7 Operator Interface ………………………………………………………………………………………………………………………….. 8
Pushbuttons and LEDs………………………………………………………………………………………………………………… 8 How to select engine mode?………………………………………………………………………………………………………… 9 Display menus……………………………………………………………………………………………………………………………. 9 How to view measured data?……………………………………………………………………………………………………….. 9 How to view and edit set points?…………………………………………………………………………………………………… 9 How to view the HISTORY menu?………………………………………………………………………………………………… 9 How to change the display contrast?……………………………………………………………………………………………… 9 How to check the serial number 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-Industrial, SS)…………………………………………………………………….19 Password protection………………………………………………………………………………………………………………….. 20 Modbus protocol……………………………………………………………………………………………………………………….. 20 Technical data……………………………………………………………………………………………………………………………… 21 ID- DCU……………………………………………………………………………………………………………………………………. 21

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Abbreviations

aid

Archive file extension for InteliDrive controller

AIN

Controller or extension module Analog input

Alarm

General term for any active engine protection Warning, Shutdown, … etc.

Alarm list

Controller or PC DriveMonitor screen with list of active and unaccepted alarms

detected from ID controller.

AS

Controller All Speed mode

ECU Alarm list Controller or PC DriveMonitor screen with list of active and unaccepted alarms

detected from engine ECU.

AOUT

Controller Analog OUTput or outputs group.

Archive

Usually aid file that contains all controller data: configuration, setpoints setting and

history records.

AUX

Controller application (archive, operational mode) for Auxiliary engines.

BI

Controller binary input.

BIN

Controller binary inputs group.

BO

Controller binary output.

BOUT

Controller binary outputs group.

CAN

Control Area Network ­ serial data link.

Cd

Cool down protection, cooling period is included before engine stops.

CMB

Controller Combined mode.

D+

Controller function for battery charging function check and/or engine running

indication.

DC

DriveConfig, PC software for InteliDrive configuration.

DM

DriveMonitor, PC software for InteliDrive monitoring.

DriveConfig PC software for InteliDrive configuration.

DriveMonitor PC software for InteliDrive monitoring.

ECU

Engine Electronic (injection) Control Unit.

ECU alarm Alarm detected in engine electronic control unit that is received via 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 listed from the screen or DriveMonitor.

HRB

Controller Harbor mode.

I-CB

Inteli – Communication bridge = controller interface for other electronic engines like

MTU, CAT etc.. that are not supported yet.

ID

InteliDrive controller.

ID-COM

InteliDrive communication module with interface to J1939, J1587 and to other

controllers.

ID-DCU

InteliDrive ­ DieselControlUnit.

ID-MCU

InteliDrive ­ Industrial Controller Unit with Volvo Penta front panel modification.

ID-RPU

InteliDrive ­ Redundancy Protection Unit = ID backup unit for Over speed and

Emergency stop protection in Marine applications.

ID-SCM

InteliDrive – Speed Control Module = interface unit for InteliDrive Industrial.

IG-IB

InteliGen ­ Internet Bridge = controller interface for internet communication.

IGL-RA15 Remote Anunciator = external 15 LED indication panel (three colors, configurable).

IG-MU

InteliGen ­ Modem Unit = controller interface for multiple engines application ­ one

point communication with group or one point modem connection.

IGS-PTM

Controller extension module with 8 binary inputs and outputs and 4 analog inputs.

I-RB

Inteli Relay board = interface board with 16 free contact relays.

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I-RB16 I-RD
I-RD-CAN
I-RP
IS-AIN8 IS-BIN16/8
J1587
J1587/J1708 J1939 KWP2000 LOC mhx MID OFF
PID PPID PRP RPM PCB PSID RS232
Sd SID SPN SS Wrn

Inteli Relay board = interface board with 16 free contact relays. Inteli Remote Display (Remote Panel) = the same panel like on controller, all data received via CAN2 bus. Inteli Remote Display (Remote Panel) = the same panel like on controller, all data received via CAN2 bus. Inteli Remote Display (Remote Panel) = the same panel like on controller, all data received via CAN2 bus. InteliSys ­ Analog input module = extension module with 8 analog inputs. InteliSys ­ Binary input/output module = extension module with 16 binary inputs and 8 binary outputs. The J1587 bus is mainly used for redundant signals; system diagnosis and software download on after market tools. See J1587 The J1939 bus in mainly used for engine controls and engine monitoring. Scania Communication protocol. Controller Local mode Extension for controller firmware (Motorola HeX file). Message Identification Assignments. Controller mode when power supply is switched on, but all binary outputs and start commands are disabled = engine start is blocked. Parameter Identification Assignments. Proprietary Parameter Identification Assignments. Controller application (archive, operational mode) for Propeller engines. Engine Revolution Per Minute ­ engine speed. Printed Circuit Board Proprietary Parameter Identification Assignments. Standard serial data line for PC or Modem connection (controller programming or monitoring). Shut down protection. Subsystem Identification Assignments. Suspect Parameter Number Controller Single Speed mode Warning protection.

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Conformity declaration
Following described machine complies with the appropriate basic safety and health requirement of the EC Low Voltage Directive No: 73/23 / EEC and EC Electromagnetic Compatibility Directive 89/336 / EEC based on its design and type, as brought into circulation by us.
!!! CAUTION !!!
Always properly connect grounding terminals!
Adjust set points
All parameters are preadjusted to their typical values. But the set points in the “Basic settings” settings group !!must!! be adjusted before the first startup of the gen-set.
!!! WRONG ADJUSTMENT OF BASIC PARAMETERS CAN DESTROY THE ENGINE !!!
The following instructions are for qualified personnel only. 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 and Fuel or press EMERGENCY STOP button to avoid unexpected automatic start of genset during any work or maintenance on the engine or switchboard.
Note: ComAp believes that all information provided herein is correct and reliable and reserves the right to update at any time. ComAp does not assume any responsibility for its use unless otherwise expressly undertaken.

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General description

This guide provides general information on how to operate the InteliDrive controller. More detailed information is available in the User guides for ID- DCU Marine or ID-DCU Industrial.

InteliDrive ID-DCU Industrial and ID-DCU Marine engine controllers controls, monitors and protects the engine in single or variable speed operational modes (ID-DCU-Industrial) and propeller, emergency, auxiliary and harbor modes (ID- DCU-Marine). The controllers can communicate with Engine Management System via the CAN serial line using standard J1939 or another (KWP2000) communication protocol.

InteliDrive controllers are equipped with a powerful graphic display with icons, symbols and bar-graphs and panel buttons for intuitive operation.

InteliDrive ID-DCU-Marine central unit together with ID-RPU provides redundant engine control. Switches itself to the backup mode in the case of controller failure, protects engine using its own Shut down and Emergency stop inputs and Fuel, Stop outputs. Monitors power supply, switches to the secondary power and measures also the secondary RPM.

Engine functions

Engine sequencing and control (start/stop, warm-up and cool-down, pre- lubrication etc.)

Different operational 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

Setpoints are adjustable via InteliDrive panel or via PC software

3 level password protection

On screen Alarm and ECU Alarm indication

Event and time driven engine history for back tracing

Two or more languages selectable in controller

Communication

RS232 / Modbus RTU

Analog or GSM modem

Engines with Engine Electronic Control Unit: J1939, J1587, KWP2000

Extension units for more I/O and Remote Display panel

Physical

180×120 mm front panel mounted case

Graphic back-lit LCD display 128×64 pixel resolution with icons and bar graphs

LED status indicators / Lamp test

Available modules ID­RPU Redundant Protection Unit (at ID-DCU-Marine only) ID- SCM Speed control module (at ID-DCU-Industrial only) IS-AIN8 Extension module with 8 analog inputs IS-BIN16/8 Extension module with 16 binary inputs and 8 binary outputs IGS-PTM Extension module with 4 analog inputs and 8/8 binary in/outputs IGL-RA15 Extension module with 15 indicating LED

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Manuals
To download manuals according to the specific controller: 1. Open http://www.comap.cz/ in your browser. To access manuals on ComAp website, please, register in ComAp club 2. Where to find documentation on web
Products / Engine controllers / InteliDrive-DCU (Marine) / Downloads / Manuals
Types of Documents on Web page All the documents are intended for everybody who is concerned with the installation, operation and maintenance of an engine application.
o 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. From this manual you can get information on all available types of communication.
o ComAp Electronic Engines Support describes all supported ECU, wiring and functionality.

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Operator Interface

Pushbuttons and LEDs

3

2

1

4

5

6

7 11

12 8

13

9

10 14

Pushbuttons and LED’s:

1. MODE
2. MODE
3. HORN RESET 4. FAULT RESET 5. START 6. STOP 7. 8.
9.

Cycle forward through engine operation modes OFF -> RUN (AUX, EME, HRB and PRP in case of Marine version). Cycle backward through engine operation modes OFF <- RUN (AUX, EME, HRB and PRP in case of Marine version). Deactivates the HORN. Acknowledges faults and alarms. Starts the engine in SS or AS mode. Stops the engine in SS or AS mode (hold time =1 sec). GREEN = Engine running. Flashing RED = Not acknowledged (new) alarm present in Alarm List. Stable RED = Acknowledged alarm present in Alarm List. GREEN = On/Off output is active.

10. On/Off 11. PAGE
12. 13. 14. ENTER

Button for Close load or Clutch Binary output control. Cycles through the display screens MEASUREMENT -> ADJUSTEMENT ->HISTORY. Select the set point, select the screen or increase set point value. Select the set point, select the screen or decrease set point value. Confirm set point value.

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How to select engine mode?
Use MODE or MODE to select requested engine operation mode.
Hint: Switching to OFF mode is blocked on running engine.
Display menus
There are 4 display menus available: MEASUREMENT, External measurement, ADJUSTMENT and HISTORY. Each menu consists of several screens. Pressing the PAGE button repeatedly will scroll the user through the menu screens.
How to view measured data?
Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the MEASUREMENT screen. Use or to select the screen with requested data.
How to view and edit set points?
1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the ADJUSTMENT screen.
2. Use or to select requested set points group. 3. Press ENTER to confirm. 4. Use or to select requested 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 controller there can occur some PLC logic modules in configuration. Then the user can adjust them from “PLC” set point group.
How to view the HISTORY menu?
1. Pressing the PAGE button repeatedly will scroll the user through the menu screens. Select the HISTORY screen.
2. Use or to select a requested record. 3. Use ENTER to select requested screen (record items) within displayed records.
How to change the display contrast?
Press ENTER and or at the same time to adjust the best display contrast.
Hint: Only in MEASUREMENT menu.

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How to check the serial number and software revision?
Hold down the ENTER and the press PAGE. On the display you can see Controller INFO screen for 10 seconds:

Controller name (see Basic setting group)

Controller serial number (8 character number)

SW version: The firmware version number.

Application: ID

Branch:

InteliDrive

Hint: Only in MEASUREMENT screen.

How to change the display backlight intensity?
Press ENTER and or at the same time to adjust the best display backlight.
Hint: Only in INFO screen.

How to change controller language?
Press PAGE on controller INFO screen to go to Language screen. Select language or and press ENTER 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 alarms in case if Industrial version and accepts just displayed alarms in case of Marine version. Non-active alarms immediately disappear from the list. Active alarm list appears on the screen when a new alarm comes up and Main MEASUREMENT screen is active.
Hint: Alarm list does not activate when you are reviewing the values, parameters or history.

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Main screen indication

1

2

3

4

5

OFF AUX

6
LOC R L !

9

1500

Running

7

Oil press

3,5 Bar

Cool temp

8

75 C

1. Active controller mode (inverse) 2. Available mode 3. Controller Local mode indication 4. R = Remote connection indication (connection to DriveMonitor is opened)
L = Access lock indication 5. Record in Alarm list 6. State machine indication 7. Oil press indication 8. Coolant temperature indication 9. RPM indication

Controller screens
There are three screen groups available on ID-DCU controller: Measuring ­ Setpoints ­ History. Measuring screen will be divided to more groups ­ ID-DCU, BIN/BOUT, AIN

Measuring (instrument) screens

Screen Content

Hidden, but available by Key combination ­ see Function available from ID-DCU front panel keys

Inf

References

• ComAp - ComAp, the heart of smart control
• ComAp - ComAp, the heart of smart control
• PLC, PAC & Dedicated Controllers | Schneider Electric USA
• Solé Diesel: Motores y Grupos Electrógenos para Barcos

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