Sole Diesel 20 GSC DNV Operator's Manual
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Sole Diesel 20 GSC DNV Operator's Manual

Sole Diesel 20 GSC DNV Operator's Manual

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Introduction
Marine
generator sets
Operator's manual
TYPE APPROVAL (DNV)
20 GSC 25 GSAC
25 GTC 30 GTAC
35 GTC 40 GTAC
29 GSC 32 GSAC
45 GTC 54 GTAC
50 GTC 60 GTAC
68 GTC 84 GTAC
U_CTGR6381T_EN
Revision 1
Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.soleDiesel.com · info@soleDiesel.com
Operator's Manual Marine Diesel Gensets
U_XXXX_EN
Revision 2
2

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  • Page 1 Introduction Marine generator sets Operator’s manual TYPE APPROVAL (DNV) 20 GSC 25 GSAC 25 GTC 30 GTAC 35 GTC 40 GTAC 29 GSC 32 GSAC 45 GTC 54 GTAC 50 GTC 60 GTAC 68 GTC 84 GTAC U_CTGR6381T_EN Revision 1 Solé, S.A.

  • Page 3: Introduction

    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.

  • Page 4: Table Of Contents

    Table of contents Table of contents Introduction ............................2 Table of contents ..........................3 Safety precautions and instructions ..................... 6 Engine labels ............................8 Solé Diesel warranty ..........................9 Section 1 – Genset Information ......................12 1.1. Genset Identification....................... 12 1.2.
  • Page 5 Table of contents Circuit description ..........................30 Fuel specifications ..........................31 Maintenance task. Fuel level inspection..................31 Maintenance task. Fuel tank clean ....................31 Maintenance task. Water separator filter purge ................31 Maintenance task. Fuel filter change ....................31 Maintenance task. Injection pump inspection................32 Maintenance task.
  • Page 6 Table of contents Operation ............................63 8.2. Magnetic speed sensor (Pickup) ....................63 Installation ............................64 8.3. Electronic control unit (ECU)......................64 Connections ............................64 Adjustments before engine startup ....................65 Start the engine ..........................65 8.4. Electrical actuator ......................... 66 8.5.

  • Page 7: Safety Precautions And Instructions

    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.
  • Page 8 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.

  • Page 9: Engine Labels

    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.

  • Page 10: Solé Diesel Warranty

    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.
  • Page 11 Transport, handling and storage 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.
  • Page 12 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.

  • Page 13: Section 1 - Genset Information

    Genset information 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...

  • Page 14: Genset Parts Identification

    Genset information 1.2. Genset parts identification Gensets: 20 GSC / 25 GSAC / 25 GTC / 30 GTAC PIECE ELEMENT Oil filter Oil level stick Oil fill cap Oil drain tuve Fuel filter Manual priming Fuel regulator Fuel feed pump Nozzles Air inlet elbow Wet exhaust elbow...
  • Page 15 Genset information Gensets: 29 GSC / 32 GSAC / 35 GTC / 40 GTAC DNV: PIECE ELEMENT Oil filter Oil level dipstick Oil fill cap Oil drain tuve Fuel filter Manual priming Fuel regulator Fuel feed pump Nozzles Air inlet elbow Wet exhaust elbow Relay Air filter...
  • Page 16 Genset information Gensets: 45 GTC / 54 GTAC DNV: PIECE ELEMENT Oil filter Oil level stick Oil fill cap Oil drain tuve Fuel filter Manual priming Fuel regulator Fuel feed pump Nozzles Air inlet elbow Wet exhaust elbow Turbocharger Air filter Sea water pump Fresh water pump Heat exchanger...
  • Page 17 Genset information Gensets: 50 GTC / 60 GTAC DNV: PIECE ELEMENT Oil filter Oil level dipstick Oil fill cap Oil drain tuve Fuel filter Manual priming Fuel regulator Fuel feed pump Nozzles Air inlet elbow Wet exhaust elbow Relay Air filter Sea water pump Fresh water pump Heat exchanger...
  • Page 18 Genset information Gensets: 68 GTC / 84 GTAC DNV: PIECE ELEMENT Oil filter Oil level stick Oil fill cap Oil drain tuve Fuel filter Manual priming Fuel regulator Fuel feed pump Nozzles Air inlet elbow Wet exhaust elbow Turbocharger Air filter Sea water pump Fresh water pump Heat exchanger...

  • Page 19: Section 2 - Transport, Handling And Storage

    Genset information 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).

  • Page 20: Storage Of Packed And Unpacked Genset

    Genset information Gensets: 29 GSC / 32 GSAC / 35 GTC / 40 GTAC DNV 20 GSC / 25 GSAC / 25 GTC / 30 GTAC DNV: Gensets: 45 GTC / 54 GTAC / 50 GTC / 60 GTAC DNV Gensets: 68 GTC / 84 GTAC DNV 2.4.

  • Page 21: Section 3 - Installation

    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.

  • Page 22: Section 4 - Operation

    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.

  • Page 23: Winterzation And Preservation

    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.

  • Page 24: Maintenance During The Storage

    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.

  • Page 25: Section 5 - Systems And Scheduled Maintenance

    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.
  • Page 26 Systems and scheduled maintenance Intervals 1st 20h- Every Every Every Every Every 2 Inspection Item Daily Winter storage and Preservation 200h 400h 800h year years Screw tightening, fastening. Genset block. General Valve clearance. Exhaust gas, noise and vibrations. Compression pressure. Genset oil.

  • Page 27: General

    Systems and scheduled maintenance 5.3. General Solé Diesel offers, for these genset models, a maintenance kit: • Welcome pack. • On board pack. • 50 hours Maintenance pack • 1600 hours Maintenance pack • 3000 hours Maintenance pack Maintenance task. Screw tightening, fastening For details of tightening torques see Section 9 Torques.

  • Page 28: Maintenance Task. Compression Pressure Inspection

    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.

  • Page 29: Lubrication System

    Systems and scheduled maintenance 5.4. Lubrication System Circuit description The lubrication circuit is forced by the trochoid gear pump, and it is composed of the following elements. Gensets 20 GSC / 25 GSAC / 25 GTC / 30 GTAC / 29 GSC / 32 GSAC / 35 GTC / 40 GTAC / 50 GTC / 60 GTAC DNV: PIECE ELEMENT Main gallery...

  • Page 30: Oil Specifications

    Systems and scheduled maintenance The minimum oil pressure in all lubrication system is 0,1 kg/cm². 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.

  • Page 31: Fuel System

    Systems and scheduled maintenance 1. Drain the oil (follow steps below) a. Stop the genset. b. Disconnect the battery negative (-) terminal. 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.

  • Page 32: Fuel Specifications

    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.

  • Page 33: Maintenance Task. Injection Pump Inspection

    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.

  • Page 34: Maintenance Task. Bleeding Air From The Fuel System

    Systems and scheduled maintenance 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. Maintenance task.

  • Page 35: Gensets 45 Gtc / 54 Gtac /68 Gtc / 84 Gtac Dnv

    Systems and scheduled maintenance Gensets 45 GTC / 54 GTAC /68 GTC / 84 GTAC DNV: Coolant circuit description Seawater circuit description PIECE ELEMENT PIECE ELEMENT Seacock (accessory) Coolant fill cap Sea water filter (accessory) Water cooler body Sea water pump Fresh coolant water Heat exchanger Heat exchanger...

  • Page 36: Maintenance Task. Coolant Check

    Systems and scheduled maintenance 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.

  • Page 37: Maintenance Task. Seawater Filter Inspection

    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.

  • Page 38: Inlet And Exhaust System

    Systems and scheduled maintenance 4. Clean the threaded hole of the heat exchanger and coat the threads of anticorrosion zinc anode. Install the anticorrosion zinc anode into the heat exchanger. 5. Close the coolant drain plug and open the seacock. Refill the coolant circuit. 6.

  • Page 39: Maintenance Task. Air Filter Inspection

    Systems and scheduled maintenance 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.

  • Page 40: Maintenance Task. Exhaust Gas, Noise And Vibrations Inspection

    Systems and scheduled maintenance 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.

  • Page 41: Maintenance Task. Incandescent Glow Plug Inspection

    Systems and scheduled maintenance Maintenance task. Incandescent glow plug inspection 1. Loosen nuts, and then remove 2. If the glow plug glows red when the connection plate and glow plug. positive (+) wire is connected to the portion A with the portion B grounded, the plug can be used.

  • Page 42: Maintenance Task. Control Of Windings And Electrical Insulation

    Systems and scheduled maintenance 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.

  • Page 43: 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.
  • Page 44 Troubleshooting GENSET FAILURE PROBABLE CAUSES RECOMMENDED ACTIONS Battery discharged or dead Recharge or replace the battery. Battery connections loose, corroded FAILURE TO Verify that the battery connections are correct, clean and tight. or incorrect ELECTRICAL SYSTEM (DC) CRANK Faulty cranking relay/stop solenoid Check the cranking relay and the stop solenoid.
  • Page 45 Troubleshooting GENSET FAILURE PROBABLE CAUSES RECOMMENDED ACTIONS GENERAL Governor inoperative Contact with our dealer Fuel pump faulty or clogged Check inlet of fuel pump. Fuel filter clogged Replace fuel filter. STARTS THEN FUEL SYSTEM Air in fuel system Bleed fuel system. STOPS Injection pump incorrectly set Contact with our dealer...
  • Page 46 Troubleshooting GENSET FAILURE PROBABLE CAUSES RECOMMENDED ACTIONS Calibrate the voltage. UNDER LOAD Current too high, cosφ very low, speed below 4% of nominal. VOLTAGE BELOW ALTERNATOR (AC) Change the regulator. NOMINAL Check the diodes, unhooking the cables. UNDER LOAD Calibrate the voltage. VOLTAGE ABOVE ALTERNATOR (AC) Change the regulator.
  • Page 47 Troubleshooting GENSET FAILURE PROBABLE CAUSES RECOMMENDED ACTIONS Faulty oil pump Contact with our dealer Oil pressure relief valve sticking Oil pressure too low Check oil level. LOW OIL LUBRICATION SYSTEM Oil level too low Restore the oil level. Inspect the genset for oil leaks. PRESSURE Faulty oil pressure valve Contact with our dealer...

  • Page 48: Section 7 - Technical Specifications

    Technical 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 Marine Diesel gensets. Operator’s Manual.
  • Page 49 MARINE GENERATORS 20 GS/GSC DNV Single-Phase General data Active rated power*: 17,5 kW Voltage: 230 V Apparent rated power*: 17,5 kVA Amperage: 87,4 A Frequency: 50 Hz Phases: Dimensions and weights Total lenght without canopy: 1140 mm Total lenght with canopy: 1310 mm Total width without canopy: 610 mm...
  • Page 50 MARINE GENERATORS 20 GTA/GTAC DNV Three-Phase General data Active rated power*: 13,6 kW Voltage: 480/277 V Apparent rated power*: 17 kVA Amperage: 20,4 A Frequency: 60 Hz Phases: Dimensions and weights Total lenght without canopy: 1036 mm Total lenght with canopy: 1181 mm Total width without canopy: 580 mm...
  • Page 51 MARINE GENERATORS 25 GT/GTC DNV Three-Phase General data Active rated power*: 17,6 kW Voltage: 400/230 V Apparent rated power*: 22 kVA Amperage: 31,8 A Frequency: 50 Hz Phases: Dimensions and weights Total lenght without canopy: 1140 mm Total lenght with canopy: 1310 mm Total width without canopy: 610 mm...
  • Page 52 MARINE GENERATORS 25 GSA/GSAC DNV Single-Phase General data Active rated power*: 21,5 kW Voltage: 240 V Apparent rated power*: 21,5 kVA Amperage: 104,6 A Frequency: 60 Hz Phases: Dimensions and weights Total lenght without canopy: 1140 mm Total lenght with canopy: 1310 mm Total width without canopy: 610 mm...
  • Page 53 MARINE GENERATORS 30 GTA/GTAC DNV Three-Phase General data Active rated power*: 21,6 kW Voltage: 480/277 V Apparent rated power*: 27 kVA Amperage: 39 A Frequency: 60 Hz Phases: Dimensions and weights Total lenght without canopy: 1140 mm Total lenght with canopy: 1310 mm Total width without canopy: 610 mm...
  • Page 54 MARINE GENERATORS 29 GS/GSC DNV Single-Phase General data Active rated power*: 25 kW Voltage: 230 V Apparent rated power*: 29 kVA Amperage: 123,5 A Frequency: 50 Hz Phases: Dimensions and weights Total lenght without canopy: 1437 mm Total lenght with canopy: 1600 mm Total width without canopy: 740 mm...
  • Page 55 MARINE GENERATORS 35 GT/GTC DNV Three-Phase General data Active rated power*: 25,6 kW Voltage: 400/230 V Apparent rated power*: 22 kVA Amperage: 46,2 A Frequency: 50 Hz Phases: Dimensions and weights Total lenght without canopy: 1308 mm Total lenght with canopy: 1445 mm Total width without canopy: 630 mm...
  • Page 56 MARINE GENERATORS 32 GSA/GSAC DNV Single-Phase General data Active rated power*: 28 kW Voltage: 240 V Apparent rated power*: 28 kVA Amperage: 131,7 A Frequency: 60 Hz Phases: Dimensions and weights Total lenght without canopy: 1437 mm Total lenght with canopy: 1600 mm Total width without canopy: 740 mm...
  • Page 57 MARINE GENERATORS 40 GTA/GTAC DNV Three-Phase General data Active rated power*: 31,2 kW (39 kVA) Voltage: 480/277 V Apparent rated power*: 28,4 kW Amperage: 50,5 A Frequency: 60 Hz Phases: Dimensions and weights Total lenght without canopy: 1308 mm Total lenght with canopy: 1445 mm Total width without canopy: 630 mm...
  • Page 58 MARINE GENERATORS 50 GT/GTC DNV Three-Phase General data Active rated power*: 36 kW Voltage: 400/230 V Apparent rated power*: 45 kVA Amperage: 65,5 A Frequency: 50 Hz Phases: Dimensions and weights Total lenght without canopy: 1680 mm Total lenght with canopy: 1875 mm Total width without canopy: 841 mm...
  • Page 59 MARINE GENERATORS 60 GTA/GTAC DNV Three-Phase General data Active rated power*: 42,4 kW Voltage: 480/277 V Apparent rated power*: 53 kVA Amperage: 76,5 A Frequency: 60 Hz Phases: Dimensions and weights Total lenght without canopy: 1675 mm Total lenght with canopy: 1875 mm Total width without canopy: 840 mm...
  • Page 60 MARINE GENERATORS 68 GT/GTC DNV Three-Phase General data Active rated power*: 49,6 kW Voltage: 400/230 V Apparent rated power*: 62 kVA Amperage: 89,5 A Frequency: 50 Hz Phases: Dimensions and weights Total lenght without canopy: 1723 mm Total lenght with canopy: 1903 mm Total width without canopy: 700 mm...
  • Page 61 MARINE GENERATORS 84 GTA/GTAC DNV Three-Phase General data Active rated power*: 60 kW Voltage: 480/277 V Apparent rated power*: 75 kVA Amperage: 108,3 A Frequency: 60 Hz Phases: Dimensions and weights Total lenght without canopy: 1723 mm Total lenght with canopy: 1903 mm Total width without canopy: 700 mm...
  • Page 62 MARINE GENERATORS 45 GT/GTC DNV Three-Phase General data Active rated power*: 32 kW Voltage: 400/230 V Apparent rated power*: 40 kW Amperage: 57,7 A Frequency: 50 Hz Phases: Dimensions and weights Total lenght without canopy: 1428 mm Total lenght with canopy: 1605 mm Total width without canopy: 740 mm...
  • Page 63 MARINE GENERATORS 54 GTA/GTAC DNV Three-Phase General data Active rated power*: 38,4 kW Voltage: 480/277 V Apparent rated power*: 48 kVA Amperage: 69,3 A Frequency: 60 Hz Phases: Dimensions and weights Total lenght without canopy: 1428 mm Total lenght with canopy: 1605 mm Total width without canopy: 740 mm...

  • Page 64: Section 8 - Parallel Operation Elements

    Blue Voltaje control signal (Controller or potentiometer 5 kΩ) 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.

  • Page 65: Installation

    Parallel operation elements 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. • 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).

  • Page 66: Adjustments Before Engine Startup

    Parallel operation elements Adjustments before engine startup COMPONENT POSITION GAIN Middle position STABILITY Middle position SPEED TRIM CONTROL Middle position STARTING FUEL Full CW (Maximum fuel) SPEED RAMPING 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.

  • Page 67: 8.4. Electrical Actuator

    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.
  • Page 68 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 Value 4,0 A (12 V DC) Nominal current 2,0 A (24 V DC) 5,8 A (12 V DC)

  • Page 69: Section 9 - Control Panel

    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 ID- RPU.
  • Page 70 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 pick- up relay.
  • Page 71 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. ComAp a.s. Written by Ladislav Kadanik, Vladimir Sebian and Kundratka 2359/17, 180 00 Praha 8, Czech Republic Pavel Doubek...

  • Page 72: Table Of Contents

    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?........................

  • Page 73: Abbreviations

    Abbreviations Archive file extension for InteliDrive controller 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. Controller All Speed mode ECU Alarm list Controller or PC DriveMonitor screen with list of active and unaccepted alarms detected from engine ECU.
  • Page 74 I-RB16 Inteli Relay board = interface board with 16 free contact relays. I-RD Inteli Remote Display (Remote Panel) = the same panel like on controller, all data received via CAN2 bus. I-RD-CAN Inteli Remote Display (Remote Panel) = the same panel like on controller, all data received via CAN2 bus.

  • Page 75: Conformity Declaration

    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...

  • Page 76: General Description

    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).

  • Page 77: Manuals

    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 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.

  • Page 78: Operator Interface

    Operator Interface Pushbuttons and LEDs Pushbuttons and LED’s: MODE ► Cycle forward through engine operation modes OFF -> RUN (AUX, EME, HRB and PRP in case of Marine version). MODE ◄ Cycle backward through engine operation modes OFF <- RUN (AUX, EME, HRB and PRP in case of Marine version).

  • Page 79: How To Select Engine Mode

    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.

  • Page 80: How To Check The Serial Number And Software Revision

    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.

  • Page 81: Controller Screens

    Main screen indication LOC R L ! Running Oil press 3,5 Bar Cool temp 1500 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.
  • Page 82 Alarm, ECU Alarm list screen See the Alarm management chapter Info screen Info Comment InteliDrive Product type ComAp 2003 – 2013 Company name ID-DCU-Industrial Controller name Serial: 0200FFFF Controller serial number Sw ver: 3.0 Software version Appl: SS Application Branch: DCU Industrial Customer branch Statistic values It is calculated:...
  • Page 83 Engine events Note Starts Button start Start from ID panel CAN control + Button start Start from ID RD RS232 control + Button start Start from DriveMonitor Remote start Start from BI Stops Engine stop Stop from ID panel or BI CAN control + Engine stop Stop from ID RD RS232 control + Engine stop...

  • Page 84: Functions Available From Id-Dcu Front Panel Keys

    Corresponding Sd BINx, Sd BOUTx or Sd AINx is indicated in Alarm list and history record when communication with any extension units (IS-BIN, IS-AIN, IGS-PTM) interrupted. Example: When IS-BIN16/8 is configured for addresses: Binary inputs = BIN1, BIN2 and Binary outputs = BOUT1, then three messages Sd BIN1, Sd BIN2, Sd BOUT1 are indicated after communication is interrupted.

  • Page 85: Alarm Management

    Alarm management Following alarms are available in InteliDrive-DCU: Binary alarms Analog alarms No protection None Warning Warning Shutdown Sensor fail Cool down Wrn+shut down Sensor fail Wrn+cool down Warning + BW Alarm only Shutdown + BW HisRecOnly Warning + Fls A new record containing selected values is written to the history file in the moment of any alarm comes up.
  • Page 86 Alarms indication There can be following actions when Alarm is active (depends on Alarm type and configuration):  Alarm list record  History list record  Active call (when is enabled and modem is installed)  Controller front panel LED indication ...

  • Page 87: Controller Monitoring

    Controller monitoring InteliDrive sw pack contains separate PC software tools: DriveConfig (DC) and DriveMonitor (DM). Drive Monitor is meant to be monitoring tool for remote controller connection. DriveMonitor is based on Windows 95/98/NT/ME/2000/XP or higher platform and requires 50 MB of hard disc free space.
  • Page 88 Connection type Direct connection via RS232 (up to 10m). For longer distance use RS232/RS485 converters (e.g. ADVANTECH – ADAM 4520). Modem connection via Analog, ISDN or GSM modem. Internet via IG-IB (InteliGen internet interface unit). IG-IB Internet - Ethernet or Dial-up connection is available.

  • Page 89: Drivemonitor Screen Example (Id-Dcu-Industrial, Ss)

    DriveMonitor screen example (ID-DCU-Industrial, SS) Description: 1. Buttons to deactivate Fault and Horn reset. 2. Buttons to switch-over the engine operation modes OFF and RUN (in ID-DCU-Industrial). 3. Buttons for Start or Stop of the engine. 4. Engine operation state indication. 5.

  • Page 90: Password Protection

    Password protection Password is a four-digit number. Only setpoints associated with the entered password level can be modified. There are three levels of password protection: 0. User level allows change of non-protected setpoints only 1. Operator level allows change of setpoints protected by Operator level 1. 2.

  • Page 91: Technical Data

    Appendix Recommended wiring according DNV rules There is recommended wiring diagram of InteliDrive DCU Marine controller + ID-RPU module following latest DNV requirements for mutual independency of control, alarm and safety systems. InteliDrive DCU Marine provides features of control and alarm system, ID-RPU provides features of safety system. n.c.
  • Page 92 Technical data ID-DCU MARINE Power supply Nominal power supply 24 VDC 8 – 36 VDC Power supply range Current consumption (depends on supply voltage) 0,34A at 8VDC 0,12A at 24VDC 0,09A at 36VDC Battery voltage measurement tolerance 2 % at 24V RTC battery life-cycle 10 year Hint:...
  • Page 93 Speed pick-up input Type of sensor magnetic pick-up (connection by shielded cable is recommended) Input impedance 10 k Minimum input voltage 2 Vpk-pk (from 4 Hz to 4 kHz) Maximum input voltage 50 Veff Minimum measured frequency 4 Hz Maximum measured frequency 10 kHz (min.
  • Page 94 ID-RPU Power supply Voltage range 8 - 36V DC Binary inputs Number of inputs Sd1 – Sd5 5 (broken wire detection, 10 k required) Input resistance 1 k Input range 0 - 5 VDC Switching voltage level for close contact indication 0 - 1,5 V Max voltage level for open contact indication 3 - 4,5 V...
  • Page 95 ID-RPU Redundancy protection unit Binary information from ID-RPU to ID-DCU MARINE Symbol Meaning SD1 … SD5 State of all binary inputs SD1-SD5 BW1 … BW5 State of all BW protections PRIFAIL Primary A battery fail = switched to B battery ESTOP Binary input Emergency stop state BWSS...
  • Page 96 ID-RPU functions ID-RPU (InteliDrive Redundant Protection Unit) is designed for marine applications. This no microprocessor unit provides redundant engine protection, RPM measuring and back-up power supply switching for the control system. ID-RPU monitors InteliDrive central unit and in the case of fail switches itself to the backup mode or Emergency backup mode and protects the engine using its own binary EMERGENCY STOP and SHUT DOWN inputs and FUEL and STOP SOLENOID outputs.
  • Page 97 Binary output COMM SD Output indicates any shutdown Alarm. Normal mode: the output is controlled from ID-DCU MARINE (Binary output Comm Sd) Backup mode: the output is activated if RPU emergency stop or SD1 – SD5 become active. Binary output COMM WRN Common warning indication.
  • Page 98 ID-RPU will leave all own binary outputs in the last state when ID-DCU MARINE fail is detected (engine stays running after ID-DCU MARINE fail). ID-RPU activates corresponding binary outputs when Emergency stop, Engine over speed protection or some Shutdown input (in AUX mode only), is activated. ID-RPU over speed setting ID-RPU Over speed limit is set via two DIP switches: Prefix and Speed preset.
  • Page 99 Control Panel Sensor Data Coolant temperature sensor Measuring range: -40ºc to 130ºC Shutdown: 93ºC Coolant pressure sensor Measuring range: 0 to 6 bar Shutdown: 0,5 Bar Coolant temperature switch Measuring range: -40ºC to 250ºC Shutdown: 95ºC Differential range: 6ºC Oil pressure sensor Measuring range: 0 to 10 bar Shutdown: 1,6 bar Oil temperature sensor...

  • Page 100: Section 10 - Alternator Connections

    Alternator connections Section 10 – Alternator connections According to genset model, consult the alternator’s connection: • Connection type 1: Meccalte alternator 1 • Connection type 2: Meccalte alternator 2 • Connection type 3: Sincro alternator Connection’s type 1 Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets.

  • Page 101: Connection Type 2

    Alternator connections Connection type 2 Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.

  • Page 102: Connection Type 3

    Alternator connections Connection type 3 Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.

  • Page 103: 10.1. Regulator Connections

    Alternator connections 10.1. Regulator connections According to genset model, consult the regulator’s connection: • Connection type 1: Meccalte alternator 1 • Connection type 2: Meccalte alternator 2 • Connection type 3: Sincro alternator Connection type 1 Connection type 2 Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets.

  • Page 104: Connection Type 3

    Alternator connections Connection type 3 Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.

  • Page 105: Section 11 - Wiring Diagrams

    Wiring diagrams Section 11 – Wiring diagrams Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.
  • Page 106 Preheating Cranking Earth disconnecting relay BB0A OPT. STD. CANOPY 27 Sec. 10 mm EMERGENCY STOP 40 Sec. 2,5 mm N.C. CONTACT 36 Sec. 10 mm Diode 25 A 41 Sec. 1 mm CPC 37 PIN Diodes 2,5 A STARTER 34 Sec. 4 mm PIN MALE MAGNETIC PICK-UP SENSOR 1 CPC PIN 7...
  • Page 107 Sec. 1 mm TO CPC PIN 18 Sec. 1 mm TO CPC PIN 19 BINARY OUTPUTS ANALOG INPUTS BINARY INPUTS CO-40 ID-RPU MICRO RELAY 12V MICRO RELAY 12V MICRO RELAY 12V FUEL SOLENOID PREHEATING CRANKING BINARY INPUTS BINARY OUTPUTS POWER 8-36V DC 85 86 BINARY INPUTS...
  • Page 108 Preheating Cranking Earth disconnecting relay BB0A OPT. STD. CANOPY EMERGENCY STOP Sec. 2,5 mm N.C. CONTACT Sec. 10 mm RELAY Diode 25 A Sec. 1 mm Diodes 2,5 A STARTER Sec. 4 mm Sec. 2,5 mm Sec. 2,5 mm CPC 37 PIN Sec.
  • Page 109 Sec. 1 mm TO CPC PIN 18 TO CPC PIN 16 Sec. 1 mm TO CPC PIN 19 TO CPC PIN 13 TWISTED Potentiometer RPM signal 5k Potentiometer RPM signal 5k Idle BINARY OUTPUTS ANALOG INPUTS BINARY INPUTS Isochronous Droop AVR shield AVR Ext CO-40...
  • Page 110 Preheating Cranking Earth disconnecting relay BB0A OPT. STD. CANOPY 27 Sec. 10 mm EMERGENCY STOP N.C. CONTACT 40 Sec. 2,5 mm 36 Sec. 10 mm Diode 25 A 41 Sec. 1 mm CPC 37 PIN Diodes 2,5 A STARTER 34 Sec. 4 mm PIN MALE MAGNETIC PICK-UP SENSOR 1 CPC PIN 7...
  • Page 111 Sec. 1 mm TO CPC PIN 18 Sec. 1 mm TO CPC PIN 19 BINARY OUTPUTS ANALOG INPUTS BINARY INPUTS CO-40 ID-RPU MICRO RELAY 12V MICRO RELAY 12V MICRO RELAY 12V FUEL SOLENOID PREHEATING CRANKING BINARY INPUTS BINARY OUTPUTS POWER 8-36V DC 85 86 BINARY INPUTS...
  • Page 112 Preheating Cranking Earth disconnecting relay BB0A OPT. STD. CANOPY EMERGENCY STOP Sec. 2,5 mm N.C. CONTACT Sec. 10 mm RELAY Diode 25 A Sec. 1 mm Diodes 2,5 A STARTER Sec. 4 mm Sec. 2,5 mm Sec. 2,5 mm CPC 37 PIN Sec.
  • Page 113 Sec. 1 mm TO CPC PIN 18 TO CPC PIN 16 Sec. 1 mm TO CPC PIN 19 TO CPC PIN 13 TWISTED Potentiometer RPM signal 5k Potentiometer RPM signal 5k Idle BINARY OUTPUTS ANALOG INPUTS BINARY INPUTS Isochronous Droop AVR shield AVR Ext CO-40...

  • Page 114: Section 12 - Overall Dimensions

    Overall dimensions Section 12 – Overall dimensions Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.
  • Page 115 SIPHON BREAK CONNECTIONS (AIR VENT SYSTEM - OPTIONAL KIT) 1095 23.5 1139.5 (20 GSC / 25 GSAC) (20 GS / 25 GSA) VIEW B VIEW C GENERATOR AIR INLET FIRE EXTINGUISHER ACCESS HOLE AC BREAKER EMERGENCY STOP CUSTOMER LOAD LEAD ACCESS CUSTOMER PANEL CONNECTION EQUIPMENT GROUND...
  • Page 116 SIPHON BREAK CONNECTIONS (AIR VENT SYSTEM - OPTIONAL KIT) 1095 23.5 1139.5 (25 GTC / 30 GTAC) (25 GT / 30 GTA) VIEW B VIEW C GENERATOR AIR INLET FIRE EXTINGUISHER ACCESS HOLE AC BREAKER EMERGENCY STOP CUSTOMER LOAD LEAD ACCESS CUSTOMER PANEL CONNECTION EQUIPMENT GROUND...
  • Page 117 SIPHON BREAK CONNECTIONS (AIR VENT SYSTEM-OPTIONAL KIT) 1385 1422 (29 GSC / 32 GSAC) (29 GS / 32 GSA) VIEW C VIEW B FAN INSIDE FIRE EXTINGUISHER GENERATOR AIR INLET ACCES HOLE AC BREAKER EMERGENCY STOP CUSTOMER LOAD LEAD ACCESS CUSTOMER PANEL CONNECTION EQUIPMENT GROUND...
  • Page 118 WET EXHAUST (G-35T-15) 1230 1382 (35 GT / 40 GTA) 1230 1308 SIPHON BREAK CONNECTIONS VIEW B (AIR VENT SYSTEM - OPTIONAL KIT) 177.5 532.5 (35 GTC / 40 GTAC) VIEW D VIEW A VIEW C GENERATOR AIR INLET FIRE EXTINGUISHER FAN INSIDE ACCESS HOLE AC BREAKER...
  • Page 119 SIPHON BREAK CONNECTIONS (AIR VENT SYSTEM-OPTIONAL KIT) 1638 1680 (50 GTC / 60 GTAC) (50 GT / 60 GTA) VIEW C VIEW B FIRE EXTINGUISHER FAN INSIDE GENERATOR AIR INLET ACCES HOLE AC BREAKER EMERGENCY STOP CUSTOMER LOAD LEAD ACCESS CUSTOMER PANEL CONNECTION EQUIPMENT GROUND...
  • Page 120 SIPHON BREAK CONNECTIONS (AIR VENT SYSTEM-OPTIONAL KIT) 1600 1682 (68 GT / 84 GTA) (68 GTC / 84 GTAC) FAN INSIDE VIEW C VIEW B GENERATOR AIR INLET AC BREAKER EMERGENCY STOP CUSTOMER LOAD LEAD ACCESS CUSTOMER PANEL CONNECTION AIR OUTLET BATTERY CONNECTIONS WET EXHAUST OUTLET (Ø88,9)
  • Page 121 FIRE EXTINGUISHER ACCES HOLE 1395 1428 AIR OUTLET (45 GT / 54 GTA) (45 GTC / 54 GTAC) VIEW B VIEW A FAN INSIDE GENERATOR AIR INLET AC BREAKER EMERGENCY STOP CUSTOMER LOAD LEAD ACCESS CUSTOMER PANEL CONNECTION EQUIPMENT GROUND CONNECTION BATTERY CONNECTIONS WET EXHAUST...

  • Page 122: Section 13 - Instructions To Replace And Remove

    Instructions to replace and remove Section 13 – Instructions to replace and remove When you decide to replace the genset, please contact Solé Diesel S.A.; will provide relevant instructions regarding the laws in force at the time. When disposing of the whole or parts of this genset, meets LAWS IN FORCE IN THE COUNTRY OF INSTALLATION.

  • Page 123: Section 14 - Inspection Prior To The Delivery Of Generator Sets

    Inspection prior to the delivery of generator sets Section 14 – Inspection prior to the delivery of generator sets Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.
  • Page 124 Inspection prior to the delivery of generator sets Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.

  • Page 125: Maintenance Log

    Maintenance log Maintenance log DATE HOURS DESCRIPTION SERVICE NAME Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.
  • Page 126 Maintenance log DATE HOURS DESCRIPTION SERVICE NAME Solé, S.A. C-243 b, km 2 · 08760 Martorell (Barcelona) ·Tel. +34 93 775 14 00 · www.solediesel.com · info@solediesel.com Marine Diesel gensets. Operator’s Manual.
  • Page 128 U_CTGR6381T_EN Revision 1 07/2022...

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