CURSOR
C78 ENS M20
C78 ENT M30-M50-M55
6 CYLINDER IN LINE
DIESEL CYCLE
FOR MARINE APPLICATIONS
INSTALLATION DIRECTIVE
T E C H N O L O G I C A L
E X C E L L E N C E
MAY 2006 EDITION
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
FOREWORD
We strongly recommend that you carefully read the indications contained in this document: compliance with them
protects the engine against irregular operation and assures
its reliability, safeguarding sea-going and maintenance personnel against accident hazards.
The indications contained in this directive pertain to the C78
ENS M20, C78 ENT M30, C78 ENT M50 and C78 ENT M55
engines and complement the IVECO MOTORS publication
“Guide to the Installation of Marine Engines”, the reader
should refer to for anything that is not explained herein.
For more complete information about the engine, please
refer to the appropriate technical brochure.
Use of fuels and oils with different characteristics from
those set out in the operation and maintenance manual may
compromise the regular operation of the engine, limiting its
performance, reliability and working life.
Exclusive use of IVECO Original Parts is a necessary condition to maintain the engine in its original integrity.
Tampering, making modifications and using non original parts
can jeopardize the safety of boat engineers and users.
To obtain spare parts, you must indicate:
-
-
Commercial code, serial number and indications shown
on the engine tag;
Part number of the spare as per spare part catalog.
The information provided below refer to engine characteristics that are current as of the publication date. IVECO
MOTORS reserves the right to make modifications at any
time and without advance notice, to meet technical or
commercial requirements or to comply with local legal and
regulatory requirements.
We refuse all liability for any errors and omissions.
The reader is reminded that the IVECO MOTORS Technical
Assistance Network is always at the Customer’s side with its
competence and professionalism.
Publication IVECO MOTORS edited by:
IVECO PowerTrain
Advertising & Promotion
Pregnana Milanese (MI)
www.ivecomotors.com
Printed P3D64C001 E - May 2006 Edition
MAY 2006
MAY 2006
INSTALLATION DIRECTIVE
C78 ENS M20
C78 ENT M30-M50-M55
CONTENTS
Page
1. WARNINGS AND CAUTIONS
4
2. ENGINE PARTS AND COMPONENTS
6
3. INSTALLATION OVERVIEW 8
4. GENERAL INSTALLATION CRITERIA
9
5. TECHNICAL DATA FOR INSTALLATION 10
6. IDENTIFICATION DATA
12
7. FUEL LINE
13
8. ELECTRICAL EQUIPMENT
15
9. MAIN ANALOG INSTRUMENT PANEL 22
10. SECONDARY ANALOG INSTRUMENT PANEL 26
11. DRILLING PLANS FOR ANALOG PANELS
27
12. MAIN DIGITAL INSTRUMENT PANEL
28
13. SECONDARY DIGITAL INSTRUMENT PANEL
34
14. DRILLING Plan FOR DIGITAL PANELS
35
15. CUSTOMIZED INSTRUMENT PANEL
36
16. SENSORS FOR DETECTION AND PANEL SIGNALING
38
17. PREPARING THE ENGINE FOR FIRST START-UP 41
18. TESTS BEFORE THE FIRST START-UP
41
19. FIRST ENGINE START
42
20. EDC ANOMALIES INDICATION
44
21. BLINK CODE TABLE 45
22. UNDERWAY CHECKS
46
23. PREPARING THE ENGINE FOR LONG IDLE PERIODS
47
24. ELECTRIC DIAGRAMS
48
25. C78 ENS M20 ENGINE
59
26. APPENDIX
63
Indications for consultation
The different versions of the motors are generally hown
using the same pictures and descriptions, however important
differences are shown separately.
The specific characteristics of the C78 ENS M20 engine
electric system are described in Chapter 25.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
1. WARNINGS AND CAUTIONS
To obtain the best engine performance, it is essential not to
deviate from the mission profile for which it was produced
and set up. The engine must not be used for purposes other
than those stated by the manufacturer. IVECO MOTORS
is willing to examine any need for particular installations
beforehand. Use of an electronically controlled injection
system, in providing the engine with performance benefits,
requires that the installer and maintenance specialist comply
with some fundamental rules, which will become more and
more commonplace as use of such equipment becomes
progressively more widespread. Boat outfitters and maintenance specialists are invited to closely follow the instructions
contained herein. No modifications to the engine, its accessories and components, are allowed.
o Do not connect any extraneous user device to the
engine electrical equipment.
Failure to comply with the instructions that follow shall
void the warranty and relieve IVECO MOTORS of all
liabilities.
o Do not subject electronic units to temperatures exceeding 80°C.
For personnel safety
o Do not alter the data contained in the engine control
electronic unit.
Specialists and installers are cautioned to comply with
workplace safety rules and to adopt prescribed individual
protection devices when working.
o Comply with prescribed procedures and torque values
when tightening threaded elements.
o Do not place voltage across the boat’s on-board electrical system without first verifying that there are no short
circuits.
o Do not branch pipes off to draw fuel from the engine
supply lines.
o Do not make any change to the engine’s hydraulic circuits and components.
o Do not execute arc welding operations before removing
the electronic units from their seating, placing them at an
adequate safety distance.
o Do not paint electrical components and their connections.
o Drain the cooling, lubrication and fuel lines only after
the fluids have duly cooled. The pressurized cap of the
coolant line may be opened only after the engine has
duly cooled.
Start-up
o Batteries contain a highly corrosive sulfuric acid solution:
must never be upset and must be handled with the
utmost caution to prevent spillage. Ensure that the battery compartment is adequately ventilated.
o When starting the engine the first time, have suitable
means available to cut off air intake in case of a runaway
condition.
Handling
The engine must be handled by experienced personnel,
using the prescribed tool or a rocker arm that keeps the
lifting lines parallel and with adequate equipment in terms
of capacity and size. The two eyebolts provided for lifting the
engine alone must always be used simultaneously.
Installation
o Knife switches or battery breakers may be used on the
power supply line of the engine electronic unit, provided
they are not used to shut the engine off.
o Do not modify the wiring harnesses; their length may
not be modified: use only available extensions.
o Do not use electronic device wiring harnesses not compliant with the IVECO MOTORS directive, in terms of
length, type of conductor, location, clamping, connection
of the shielding and earth braids.
o To avoid any interference, the wiring harnesses of the
different on-board electronic devices must follow different paths from those of the engine electronic systems.
o Ready the engine following the procedure set out in
Chapter 17.
o Start the engine after ensuring that it is complete with
every part specified by the manufacturer and required
by the installation, without attempting to start it with
caps and occlusions to the lubrication, cooling and fuel
feed lines.
o Check that the fluid lines are perfectly sealed, especially
lines for fuels and lubricants, which may cause fires and
consequent harm to persons and equipment.
o Make sure that the various pipelines are not in contact
with warm surfaces or moving parts.
o The installing yard is required to carry out tests to verify
the functional compatibility between the electrical-electronic equipment of the engine and the other electronic
equipment present on the boat.
Tests and tuning up
o Never disconnect the batteries when the engine is running.
o Remove the electrical connections from the batteries
before any operation on the electrical system.
o Ensure that the battery terminals comply with the exact
polarity, are properly tightened and protected against
accidental short circuits and corrosion phenomena.
MAY 2006
INSTALLATION DIRECTIVE
o Do not connect or disconnect electrical connections
when electrical power supply is present.
o Do not cause sparks in the attempt to verify the presence of electrical voltage.
o Do not draw fuel through unfiltered lines.
o Do not clean the engine and its parts with corrosive or
abrasive detergent substances, to avoid compromising
the integrity of electrical connections.
o The engine fluids and air, coolant, and oil filters discarded
after use must be properly stored and delivered to
appropriate collection centers.
Long engine inactivity periods
Before long periods of inactivity, ready the engine following
the procedure set out in Chapter 23.
C78 ENS M20
C78 ENT M30-M50-M55
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
2. ENGINE PARTS AND COMPONENTS
Figure 1
3
2
1
4
5
6
7
4
8
9
25
24
23
22
10
21
11
20
19
12
18
13
17
16
15
14
80819
1. Intake air filter - 2. Location of intake air pressure and temperature sensors - 3. Lubricating oil refill cap - 4. Lifting padeyes 5. Coolant level sensor - 6. Engine coolant tank - 7. Coolant refill cap - 8. Injector solenoid valve connector - 9. Location of
thermostatic valve - 10. Cap for engine coolant outlet to sanitary water heating system - 11. Alternator location - 12. Coolant/sea
water tube bundle heat exchanger - 13. Auxiliary pulley - 14. Oil drain sump plug - 15. Sacrificial anodes - 16. Sea water intake 17. Sea water drain plug - 18. Air/sea water heat exchanger (not present on the C78 ENS M20 engine) - 19. Sea water pump 20. Electrical starter motor - 21. Sea water pump gear - 22. Fuel transfer pump - 23. Fuel filter - 24. Filter clogging sensor 25. Fuel temperature sensor.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
Figure 2
3
4
5
6
7
8
9
2
1
10
11
12
20
13
14
19
18
17
16
15
04_001_C
1. Coolant feed to exhaust manifold - 2. Lubricating oil filters - 3. Lubricating oil dipstick - 4. Insulated support - 5. Electronic Central
Unit - 6. Cooled exhaust manifold - 7. Turbocharger inlet pipe-fitting - 8.Timing mechanism and oil vapor filter cover - 9. Location
of timing phase sensor - 10. Oil filter clogging indicator - 11. Cooled turbo-charger - 12. Exhaust gas outlet flange - 13. Phase and
engine shaft rotation sensor location - 14. Waste-gate actuator - 15.Timing phase inspection port - 16.Throttle position sensor
potentiometer - 17. Electrical equipement wiring connectors - 18. Oil fill-in fill-out / pre-lubrication electrical pump (optional) 19. Oil fill-in fill-out / pre-lubrication electrical pump solenoid valve (optional) - 20. Cap for engine coolant discharge and
recyrculation from sanitary water heating system
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
3. INSTALLATION OVERVIEW
Figure 3
1
11
12
2
3
4
10
5
9
8
6
04_016_C
7
1. Exhaust gas and sea water discharge - 2. Electrical system cabinet - 3. Secondary instrument panell - 4. Fuel tank with suction/
return assembly - 5. Fuel suction pipe - 6. Fuel return pipe to tank - 7. Pre-filter - 8. Fuel feed pipe to the fuel transfer pump 9. Sea water decanter filter - 10. To the filtered sea water intake - 11. Main instrument panel - 12. Throttle actuator.
The figure shows the set of components of an installation,
including those supplied with the engine equipment, standard
or optional, and those supplied or produced by the yard.
It provides a comprehensive picture of the operations
required to install the engine.
Components arrangement and illustrations are not binding
but merely indicative, subject to the choices made by yard
engineers according to their skills, available spaces and the
prescriptions set out herein.
MAY 2006
INSTALLATION DIRECTIVE
C78 ENS M20
C78 ENT M30-M50-M55
4. GENERAL INSTALLATION CRITERIA
Accessibility
Exhaust gas discharge
The engine must be located in such a way as to allow filling
and draining engine liquids when doing servicing operations.
Moreover, the relay box and the diagnostic push-button
present on it must be accessible, also when underway.
The exhaust gas discharge conduit shall be compliant with
the guidelines contained in the IVECO MOTORS publication
“Guide to the installation of marine engines”; it also provides
indications to compute the dimensions of the exhaust pipelines, which is the Yard’s responsibility.
Anchoring
Engine installations to which the inverter has been directly
coupled, must be carried out in compliance with the number
of supports, as specified here below:
o C78 ENS M20 for commercial or heavy duty supports:
6 supports: 4 for the engine - 2 for the inverter;
NOTE: with the inverter weighting < 200 kg and gearing-down ratio < 3, please contact IVECO MOTORS in
order to assess the installation of the 4 engine supports
alone.
o C78 ENT M30 for commercial or heavy duty supports:
6 supports: 4 for the engine - 2 for the inverter.
o C78 ENT M50/M55 for commercial use 6 suppor ts:
4 for the engine - 2 for the inver ter.
o C78 ENT M50/M55 for recreational use 4 supports for
the engine.
In case spring inserts are used, they have to be capable of
supporting the engine mass, the dynamic force, the force
resulting from the torque reaction generated by the transmission and the longitudinal thurst performed by the propeller axis during navigation.
If rigid mounting is adopted, particular care must be given to
support alignment and co-planarity.
Information on dimensions and fastening values are provided
in the “Installation Diagram”.
Combustion and ventilation air
Compliance with prescriptions on the quantity of air
required for combustion and ventilation assures a regular
operation of the engine even in adverse conditions and it
enables to deliver its maximum design power (1).
Sea water line
It must be provided with an intake capable of preventing
the entry of foreign bodies into the suction pipes. Between
the intake and the pump, it is best to interpose a gate to be
closed in emergencies or for extended idle periods and a
filter to stop the smaller impurities; it is also recommended
to install a suitably dimensioned and easily replaced zinc
anode.
The engine sea water line was provided by the manufacturer
with protection anodes to be replaced periodically.
The rubber hoses positioned along the pipeline shall be sufficiently rigid not to create choked areas caused by crushing (1).
Engine pre-heating
If the engine usage profile requires immediate delivery of
power at the highest rpm’s, it is recommended to install an
auxiliary pre-heater on the closed cooling loop.
Electric - electronic equipment
Provide a suitable arrangement of the relay box, and of the
optional electronic unit referring to the dimensions and position of the wire harnesses and the relative connectors.
Both units must be anchored in such a way as to dampen the
vibrations and stresses undergone by the hull while underway and/or induced by the engine’s operation.
NOTE: Information about optional equipment are described
in the Chapter 26.
(1) The EDC engine electronic control is programmed to
reduce maximum deliverable power if the operating
parameters measured by the sensors show that critical conditions have been reached, and if exceeded the
engine could be damaged.
10
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
5. TECHNICAL DATA FOR INSTALLATION
C78
ENS
M20
C78
ENT
M30
C78
ENT
M50
C78
ENT
M55
Engine intake and ventilation air when underway
Static vacuum allowed downstream of the air filter
kPa
mm H2O
≤ 3,5
≤ 350
≤ 3,5
≤ 350
≤ 3,5
≤ 350
≤ 3,5
≤ 350
Engine air intake flow rate
m3/h
≥ 870
≥ 1000
≥ 1560
≥ 1800
Engine room ventilation air flow rate (excluding engine air intake)
m /h
≥ 3100
≥ 3600
≥ 6000
≥ 6600
Static vacuum allowed in the engine room
kPa
mm H2O
≤ 0,1
≤ 10
≤ 0,1
≤ 10
≤ 0,1
≤ 10
≤ 0,1
≤ 10
Temperature allowed in the engine room
°C
≤ 50
≤ 50
≤ 50
≤ 45
Maximum engine room temperature exceed outside temperature
°C
≤ 15
≤ 15
≤ 15
≤ 15
≤ 10
≤ 1000
680
± 25
1980
≤ 10
≤ 1000
690
± 25
2320
3
Exhaust gas discharge
Allowed static back pressure
kPa
mm H2O
Temperature at maximum power (turbocharger inlet)
°C
≤ 10
≤ 1000
540
± 25
Flow rate at maximum power
kg/h
950
≤ 10
≤ 1000
560
± 25
1160
mm
inches
mm
inches
mm
inches
153
6
114
4,5
150
5,9
153
6
114
4,5
150
5,9
153
6
114
4,5
150
5,9
153
6
114
4,5
150
5,9
Transfer pump delivery at maximum rpm
l/h
160
160
160
160
Fuel temperature to allow maximum power
°C
≤ 50
≤ 50
≤ 50
≤ 50
Inner diameter, intake pipe
mm
≥8
≥8
≥8
≥8
Inner diameter, return pipe
mm
≥8
≥8
≥8
≥8
Thread on pre-filter junctions
M
14 x
1,5
Thread on engine junctions
inches UIC
1/2
1/2
1/2
1/2
Allowed intake vacuum
kPa
mm H2O
≤ 20
≤ 2000
≤ 20
≤ 2000
≤ 20
≤ 2000
≤ 20
≤ 2000
mm
inches
l/h
kPa
mm H2O
60
2,36
16500
60
2,36
16500
60
2,36
17500
60
2,36
20000
≤ 20
≤ 2000
50
2
≤ 20
≤ 2000
50
2
≤ 20
≤ 2000
50
2
≤ 20
≤ 2000
50
2
1/2
1/2
1/2
1/2
Riser outer diameter
Dry exhaust outer diameter
Diameter of circumference of distance between 6 locking holes
Fuel supply
14 x 1,5 14 x 1,5 14 x 1,5
Open sea water cooling line
Intake pipeline diameter
Pump delivery at maximum rpm
Allowed intake vacuum
Discharge pipeline diameter
mm
inches
Gear box oil heat exchanger
Thread on engine junctions
inches UIC
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
11
C78
ENS
M20
C78
ENT
M30
C78
ENT
M50
C78
ENT
M55
+20°
+20°
+20°
+20°
Allowed engine inclination angles
Maximum longitudinal in continuous operation (static + dynamic) degrees/360
Maximum transvers in continuous operation(static + dynamic)
degrees/360
± 22°30’
± 22°30’ ± 22°30’ ± 22°30’
Longitudinal for oil level check with standard dipstick
degrees/360
0 ÷ 10°
0 ÷ 10°
0 ÷ 10°
0 ÷ 10°
Power takeoffs (optional)
2-race front pulley for “V” belts
Reference diameter
mm
207
207
207
207
Race dimension
mm
12.7
12.7
12.7
12.7
Power available per belt at 650 rpm
kW
CV
≤ 3,7
≤5
≤ 3,7
≤5
≤ 3,7
≤5
≤ 3,7
≤5
Power available per belt at 1300 rpm
kW
CV
≤ 7,4
≤ 10
≤ 7,4
≤ 10
≤ 7,4
≤ 10
≤ 7,4
≤ 10
Nm
kgm
≤ 400
≤ 41
≤ 400
≤ 41
≤ 400
≤ 41
≤ 400
≤ 41
Torque available in engine axis
Nm
kgm
≤ 400
≤ 41
≤ 400
≤ 41
≤ 400
≤ 41
≤ 400
≤ 41
Radial force resulting from belt tension (*)
N
≤ 1600
≤ 1600
≤ 1600
≤ 1600
2-race front pulley + elastic joint for flange
Torque available in engine axis
2-race front pulley + elastic joint for crankshaft
(*) For direction of the resulting radial force between 60° and 300° with reference to the cylinder axis (piston at top dead
center = 0°)
Moment of inertia of rigidly added masses (*)
kgm2
≤ 0,015
≤ 0,015 ≤ 0,015 ≤ 0,015
Dimensions
Figure 4
¬
¬
¬
¬
¬
¬
¬
¬ ¬
¬
¬
¬
¬
Centre of gravity
MM¬INCHES
04_017_C
12
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
6. IDENTIFICATION DATA
Figure 5
S. p. A.
Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY
ENGINE TYPE
ENGINE FAMILY
ENGINE DWG
POWER (KW)
AND SPEED (RPM)
POWER SET CODE
ENGINE S/N
YEAR OF BUILD
HOMOLOGATION
N°
COMMERC. TYPE / VERSION
04_039_C
Figure 6
80818
The engine identification data are stenciled on a tag positioned over the engine coolant tank
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
13
7. FUEL LINE
Figure 7
5
6
7
8
9
4
10
3
2
1
80839
Fuel inlet
Fuel return
1. Return and suction flows from the tank - 2. Pre-filter - 3. Low pressure supply pump - 4. Return loop pressurization valve 5. Inlet and outlet fittings from cylinder head - 6. Fuel filter - 7. Injector pump - 8. Fuel return line - 9. Cylinder head channel
venting point - 10. Low pression injector feeding line
For the installation, the following connections are required:
-
-
-
from the tank to the pre-filter
from the pre-filter to the pump inlet
from the fuel discharge outlet to the tank
Pre-filter
The pre-filter with priming pump, supplied separately from
the engine, must be fastened near the tank, in a relatively low
point of the line to allow for easy replacement the filtering
cartridge and/or the operation of the hand pump. Avoid the
use of additional mesh or paper filters along the feed lines
between pre-filter and engine. To avoid introducing impurities in the feeding lines inside the engine, do not place filter
cartridges pre-filled with fuel in the system.
Materials Characteristics
The fuel tank and the suction and return assembly must
withstand the continuous abrasion caused by a flow of fuel
oil of 160 l/h at a temperature of 90°C without noticeable
deformation or wear or release of material. Use of metal
tanks, preferably made of iron alloys, is allowed, provided
they are connected to the negative terminal of the battery
to prevent the accumulation of electrostatic charges.
Tanks must be provided with vents to avoid exceeding an
internal pressure of ± 5kPa (± 0.5 m of H2O column); their
shape and the suction assembly must be such as to assure a
suction at the maximum longitudinal and transverse inclination allowed for the boat, with a residual quantity of fuel oil
considered “reserve”.
The suction inlet should be positioned in such a way as to
avoid taking in sludge. The return flow must be in such a way
as to facilitate the mixing of the returning fuel with the fuel
in the tank. If the tank is lower than the filter, then the return
pipe must always be submerged. The pipes and union fittings
of the fuel line must withstand a fuel oil flow rate of 160
l/h at a temperature of 90°C and a pressure of 3 bar (300
kPa) without noticeable deformation, wear or release of
material. Metal tubes, preferably made of iron alloys, are recommended, taking care to connect each individual segment
to engine ground to avoid the accumulation of electrostatic
charges and inserting a vibration damper elastic joint on each
segment. The pipes used must be certified according to the
relevant Countries’ rules or to the standards issued by classification Bodies.
14
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
Fuel supply system scheme
Figure 8
3
4
5
6
2
1
7
22
21
8
9
10
11
12
20
19
18
17
16
15
14
13
80840
1. EUI injector - 2. EUI pumper - 3. Rocker arm - 4. Actuating cam - 5. EUI solenoid valve - 6. Vent fitting on cylinder head 7. Calibrated hole - 8 Vent fitting on pre-filter - 9. One-way valve - 10. Hand pump - 11. Fuel pre-filter - 12. One-way valve 13. Fuel tank - 14. Gear pump assembly - 15. Fuel supply gear pump - 16. Pressure limiter valve (initial opening pressure 5 bar) 17. One-way valve - 18. One-way valve - 19. Calibrated hole - 20. Pressure regulating valve (initial opening pressure 3.5 bar) 21. Fuel filter - 22. Vent fitting on fuel filter support.
Hydraulic connections
Figure 9
1
2
10
9
3
4
5
8
6
7
04_019_C
1. Outlet fitting from cylinder head - 2. Inlet fitting to cylinder head - 3. Pressure regolating valves location 4. Outlet fitting for fuel outflow to the tank - 5. Inlet fitting from pre-filter - 6. Pre-filter - 7. Inlet pipe from the tank 8. Outlet pipe to the tank - 9. Low pressure feed pump - 10. Fuel filter.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
15
8. ELECTRICAL EQUIPMENT
Figure 10
1
2
3
15
4
14
5
13
6
12
7
11
10
8
04_004_C
9
1. Indicator and control panel - 2. Engine wiring - 3. Electronic Central Unit - 4. M Connector - 5. Relay box 6. JF and JF1 connectors - 7. Sedimenting pre-filter - 8. Sensor for the presence of water in the fuel 9.Wiring harness to be manufactured by the yard -10. Power supply and interface wire harness - 11. JG Connector 12. JE Connector - 13. JA Connection - 14. JB Connection - 15. Power line for electric starter motor and alternator.
The electrical equipment of the engine comprises a series of
components provided separately from the engine to enable
an easy and diversified installation, according to the Yard’s
design choices.The need to make accessible, at sea or underway, the controls to the electrical components and to the
connector for diagnostics contained in the relay box may be
met through different installation arrangements.
Along with the coupling of all connectors provided in the
wire harnesses, completing the installation also requires the
connecting wire harness (9) for the sensor for the presence
of water in the fuel (8), to complete the power line and to
connect the accumulator to the engine wire harness.
C78 ENS M20
C78 ENT M30-M50-M55
16
INSTALLATION DIRECTIVE
MAY 2006
Synoptic
Figure 11
GEAR BOX
INDICATIONS AND
ALARMS SENSORS
INDICATIONS AND
ALARMS SENSORS
THROTTLE POSITION
SENSOR
EDC COMPONENTS
EUI SOLENOID
VALVES
!
ALTERNATOR
EDC
"
ELECTRIC STARTER
MOTOR
*'
*"
*%
#¬%.3¬-
#¬%.4¬-
*!
*&
*&
RELAY
BOX
1
2
3
BATTERY
4
5
6
04_005_C
1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Connector for pre-lubricating system 4. Connector for certified installations by classification Bodies - 5. Interface wire harness - 6. Power line.
The wire harnesses provided with the engine include the connectors for all optional components which may ordered and their
connections to the JB connector for the indication and control panel.
Engine wire harness
– BATT
+ BATT

Interface wire harness
A EDC
B EDC
JB
JA
JA
JG
PA
V
JF
U
V
W
E
S
W
EC
PO
M
S
WI
WI
B
SI
VI
T
SI
F
VI
X
X
T
K
K
I
O
Z
A
H
MM
C
J
GG
GG
GH
INSTALLATION DIRECTIVE
Figure 12
*
A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - E.
EUI solenoid valves - F. Engine coolant temperature sensor for EDC - H. Combustion air pressure/
temperature sensor for EDC - I. High coolant temperature - J. Low coolant level sensor (for alarm) - K. Air filter clogging sensor (for alarm) - M. Sensor for detecting the
presence of water in the fuel pre-filter (for alarm) - O. Exhaust gas temperature sensor (for gauge) - S. Oil temperature sensor (for gauge) - T. Coolant temperature sensor (for
gauge) - U. Clogged oil filter sensor (for alarm) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - X. Clogged blow-by filter sensor (for alarm) - Z.
Clogged fuel filter sensor (for alarm) - EC. Switching solenoid valve for oil charge/discharge - GG. Alternator - GH. Pre-heating power relay - JB. Instrument panel connection
wire harness - JE. Alarms control unit (for Certification Bodies) - JF,JF1. Relay box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle position sensor
- PO. Pre-lubrication electrical pump - SI. Gear box oil temperature sensor - VI. High gear box oil pressure sensor (25 bar) - WI. Low gear box oil pressure sensor (7 bar) - *
Sensor H wiring harness.
05_116_C
JE
JF1
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
17
Wire harness
C78 ENS M20
C78 ENT M30-M50-M55
18
INSTALLATION DIRECTIVE
Power supply line
Supplementary services battery
To assure that the engine can be started with a sufficient
quantity of energy, it is advisable to provide for the installation of a supplementary battery, dedicated to supplying
power to the on-board electrical services. The power line to
recharge it may be constructed according to the indications
provided in Chapter 20.
Figure 13
2
Equipment power supply
30
50
+B
S
L
If one engine is installed
The battery used for services may be recharged interposing
on the power supply line a relay actuated by the recharge
signal of the alternator’s electronic regulator (L).
IG
M
1
05_040_C
MAY 2006
4
3
1. Electric starter motor - 2. Engine wire harness 3. Batteries - 4. Alternator.
The connection of the +B terminal of the alternator to the
positive +30 terminal of the electric starter motor must be
achieved with a conductor having a cross section of at least
40 mm2. The connection of the positive +30 terminal of the
electric starter motor to the positive pole of the battery,
achieved with a conductor having a cross section of at least
95 mm2, allows to obtain, as shown in the figure, the simultaneous connection of the alternator to the battery. The connection between the engine ground and the negative pole
of the battery must be achieved according to the guidelines
provided in the Engine electrical ground paragraph.
caution
If magneto-thermal protecting breakers are inserted, they
must not be used to stop the engine and in any case they
must be activated only a few seconds after shut-down.
If two engines are installed
The presence of two generators allows to keep the recharging functions separated: the generator (G1) recharges the
battery (AC1) dedicated to starting both engines and powering both electrical/electronic control circuits, whilst the
generator (G2) recharges the battery (AC2) used to power
the services.
In two-engine applications, it is essential to connect the
engine grounds to a common potential; the solution proposed in Chapter 20 fully complies with this need, assuring
the full functionality and independence of the two circuits.
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
Engine electrical ground
19
Battery recharging
Figure 15A
Figure 14
B+
Connect to positive
pole terminal of the
starter motor
S
1
04_038_C
1. Point of connection of the engine electrical ground.
The connection of the engine electrical ground is achieved
by connecting with a cable of at least 95 mm2 cross section
to the negative pole of the battery to the tightening point of
the electric starter motor as shown in Figure 14.
To anchor the grounding terminal to the engine, proceed as
follows:
o completely remove the paint from both parts constituting the connection, using mechanical means or suitable
chemical product;if the anchoring operation is to take
place on superficially treated parts, completely remove
the anaphoretic paint with mechanical means, obtaining
a smooth support surface;
L
IG
05_038_C
This is accomplished through the power supply line of
the electric starter motor and connection to the +B of
the alternator. The electronic regulator of the alternator
that equips the engine allows an effective control over the
battery recharging operation.
If, due to installation requirements, the batteries need to be
positioned at a distance from the engine, we recommend
increasing the cross section of the power line conductors
and verifying recharging effectiveness by measuring voltage
across the battery poles.
For the best control of the battery recharge cabling the line
relating to the S terminal of the alternator directly to the
positive pole terminal of the battery (see figure 15B).
Figure 15B
o apply a uniform layer of BH44D paint (IVECO standard
18-1705) with a brush or spray gun;
o join the parts constituting the grounding note within 5
minutes from the time the paint was applied.
+B
S
L
IG
05_039_C
B+
Connect to positive
pole terminal of the
starter motor
Connect to positive
pole terminal of the
batteries
S
81790
L
IG
C78 ENS M20
C78 ENT M30-M50-M55
20
INSTALLATION DIRECTIVE
Connections of the central electronic unit
(ECU) EDC MS 6.2
Figure 16
Relay Box
Figure 17
ENGINE
ROOM
ENGINE
STOP
BRIDGE
ENGINE
START
1
A
B
80852
A. Engine component wiring connector
B.Vessel side wiring connector
The connection of the central electronic unit, ECU, to the
EDC system, takes place by means of two 35 way connectors
mechanically polarized in the latching system to prevent
switching. The presence of the two connectors provides for
a subdivision of the wiring harnesses to distribute the large
quantity of conductors and at the same favor a more rapid
identification of the lines during testing operations conducted
by technical assistance personnel.
MAY 2006
2
PTO –
PTO +
3
PTO
ON
PTO
OFF
4
CHECK
04_002_C
5
6
7
1. Bridge or engine room engine control selector - 2. Start and
stop push button - 3. Manual accelerator throttle control in
engine room - 4. PTO ON / PTO OFF selector - 5. EDC fault
indicator and blink code LED - 6. Blink code emission request
push-button - 7. Connector for external diagnostic tool.
This shall be installed and anchored in such a way as to
dampen the vibrations and stresses occurring when underway, and they shall be accessible during servicing operations
and when underway. The electrical commands positioned on
the panel allow to control engine starting and stopping (2)
directly from the engine room, while excluding any possibility that anyone may involuntarily start the engine from the
bridge (1), during servicing operations. Engine rpm control
could be obtained directly from engine room by the pushbutton (3) after positioning the switch (4) ON.
Among the controls present on the panel are also the pushbutton (6) and the “blink code” light indicator (5), useful
to obtain, also while underway, indications that will lead to
identify failures or improper engine operating conditions (see
Chapter 20).
On the relay box is located the multipolar connector (7),
protected by a screw-on lid, for connection with the computerized diagnostic tools prescribed by IVECO MOTORS
(see Chapter 20).
Inside the box, anchored to a printed circuit board, are
present the power management relays of some components
and the elements that protect the electrical lines against
short circuits or excessive current absorption. These components perform a similar function to that of fuses, almost
totally avoiding the need to restore the electrical continuity
of circuits subjected to an anomaly condition. These components are able to limit and eliminate short circuit currents
without melting, restoring their own and the circuit’s electrical continuity, once the cause of the anomaly is removed.
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
Throttle lever position sensor
21
Water presence in the pre-filter sensor
Figure 17A
Figure 17B
2
05_078_C
1
After testing the working condition of the linkage, adjust the
run of the servo components (see Chapter 18).
o With the throttle at idle setting, the potentiometer rod
has to be in the resting position;
o With the throttle at the stop, the potentiometer rod has
to be in the position of maximum run out.
05_018_V
3
1. Pre - filter - 2. Conductor to be connected
with the negative battery terminal 3. Sensor to detect water in the fuel.
CAUTION
In order to enable the proper working of the sensor to
detect water in the fuel, it is necessary that the pre-filter
support is connected electrically to the negative battery
terminal. In the engine models which use parts with insulated poles
it is necessary to electrically insulate the pre-filter support
from the boat mass and then connect the support with the
negative battery terminal.
C78 ENS M20
C78 ENT M30-M50-M55
22
INSTALLATION DIRECTIVE
MAY 2006
9. MAIN ANALOG INSTRUMENT PANEL
Figure 18
3
4
5
electronic
RPMx100
2
HOURS
V
oC
bar
oF
6
1
12
11
10
9
8
7
13
14
04_020_C
1. Coolant temperature gauge (TA) - 2. Revolution counter and hour counter (CG) - 3.Voltmeter (V) - 4. Buzzer (SA) - 5. Indication
and alarm module (MS) - 6. Engine oil pressure gauge (MO) - 7. Connector for secondary instrument panel (JE)- 8. On board panel
instrument light switch (L) - 9. Engine start/stop key switch (CA) -10. Engine stop push-button (usable only with electric harness
versions with excitation engine stop) - 11. Sound alarm inhibition push-button (P1) -12. SIFC Alarm abilitation connector 13. Connector for main panel wiring (JC) - 14. Cap with electrical continuity connection.
Installation of the IVECO MOTORS onboard panel with
analog indicators entails connecting the panel’s JC connector to the JB connector on engine wire harness, interposing
the appropriate extension wire harness available in 3, 5 and
7 meter-long versions. The JC-JB wire harness comprises 47
lines, each connected to the terminal identified on both connectors by the same number.
To the main panel is connected the JE connector, provided
for connection to the secondary panel; in installations with
no secondary panel, do not remove the cap of the JE connector to avoid compromising the electrical continuity of the
systems’ power supply circuit.
To allow the work of the fuel filter clogging alarm (SIFC), in
the indication alarm module, it has to disconnect the connector (12) fitted close to JC.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
23
Synoptic of the connections of the analog panels
Figure 19
2
MAIN
INSTRUMENT
PANEL
JE
JH
JE
SECONDARY
INSTRUMENT
PANEL
JH
JC
JC
ENGINE
EQUIPMENT
1
A
EDC
B
JA
JB
JF
JF1
BATTERY
RELAY
BOX
04_021_C
1. JB-JC Extension wire harness - 2. JE-JH Extension wire harness.
Figure 20
46
34
47
32
45
16
43
28
42
7 1
6
5
37
11
24
27
26
37
11 4
38
39
39
40
41
46
32
19
31
18
30
7
1
17
45
6
24
38
12
25
9
3 2
10
47
33
8
22
23
23
4
15 14 13
20
21
22
10
3
17
29
44
9
2
18
34
35
36
36
21
8
19
31
30
35
20
33
5
12 13
14
25
40
29
15
26
16
28
27
44
43
42
41
04_250_N
JC
JB
Connectors of the extension wire harness JB - JC, seen from the coupling side
The JC-JB wire harness comprises 47 lines, each connected
to the terminal identified on both connectors by the same
number.
To identify the functions served by the individual lines, refer
to the electrical diagrams in Chapter 24.
24
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
Installation
MAY 2006
Indications and Alarms Module
In order to drill holes on the area where the panel is to be
mounted, refer to the dimensions indicated in Chapter 11.
Figure 21
Operation of the panel
7
After completing the electrical connections and engine
preparation, perform the tests required for the first start, as
described in Chapter 18.
Verify the proper operation of the panel, proceeding as follows:
6
8
5
9
o Make sure that the “ENGINE ROOM / BRIDGE” switch
of the Relay Box is in the “BRIDGE” position, then
turn the key switch to the first position and verify that
the instruments are powered and the Indications and
Alarms Module runs the alarm test for about 5 seconds
according to the procedures set out below.
4
o Once the test is complete, only the indications prescribed
for the engine not running must remain lighted: e.g.
“alternator charge” and “low oil pressure”; the analog
instruments must provide values consistent with the
relevant physical parameters.
Testing the engine start function
Turn the key switch to the second position and keep it in it
until the engine has started, then release the switch, which
will stably return to the first position; after releasing the key,
the switch may be brought back to the starting position only
after the switch is returned to the resting or zero position.
Checking indications
After starting the engine, verify whether the operating
modes of the Indications and Alarms Module are similar to
those set out below.
Using appropriate measuring instruments, verify the consistency of the indications provided by the analog instruments.
Verify the indication of the panel revolution counter, comparing it with the one measured by a reference instrument; if the
indication is different, proceed as described below.
Testing the engine stop function
The engine is stopped and the panel is disabled by returning
the key switch to the resting or zero position.
The panel has an engine stop push-button whose function is
only enabled in versions where the engine stops as a result
of the excitation of an actuator, i.e. engine versions requiring
certification by Certification Bodies.
3
10
11
12
2
1
13
04_234_N
1. Engine overspeed (SSV) - 2. Presence of water in the fuel
pre-filter (SAC) - 3. Low coolant level (SBLA) - 4. Alternator
anomaly (SS) - 5. Clogged oil filter (SIFO)- 6. Clogged blow-by
filter (SIFB) - 7. Pre-lubrication in progress (SP) - 8. Clogged
air filter (SIFA) - 9. Clogged fuel filter (SIFC)- 10. High coolant
temperature (SATA) - 11. Low oil pressure (SBPO) - 12. Pre/
post heating (SCP) - 13. EDC Malfunction (EDC).
The Indications and Alarm Module comprises the indicator
lights and the electronic alarm interface, timing and storage circuit. It is programmed in such a way that when it is
powered, all indicator lights are lighted, with the exception
of those for “pre-lubrication”, “pre-post heating” and “EDC”
failure and a sound signal is emitted by the buzzer.
The buzzer may be silenced before the end of the test, acting
on the appropriate control.
During the starting phase and for the subsequent 15 seconds, needed to stabilize the low oil pressure signal, all the
module’s functions are inhibited; once this time interval has
elapsed, every alarm state detected by the sensors will cause
the associated indicator to be lighted and the buzzer to be
powered; the exceptions are the “pre-lubrication” and “prepost heating” indicators, given only visually.
When a new alarm state is detected, the indicator light will
flash to highlight the occurrence with respect to any others
which may be ongoing at the time. When the sound alarm is
shut off, the light indicator will remain lighted and the alarm
will be stored until the engine is stopped.
The standard set-up of the C78 ENS M20, C78 ENT M30,
C78 ENT M50 and C78 ENT M55 provides for use of the
indicators: SBLA, SIFA, SIFC, SIFO, EDC, SS.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
Revolution-counter calibration
25
Revolution-counter calibration
Figure 22B
Figure 22A
2
1
2
1
06_113_V
04_255_N
1. Adjustment screw - 2. Panel lighting lamp.
1. Calibration increasing button 2.Calibration decreasing button.
Verify the indication of the panel revolution counter by
comparing it with the one measured with a reference
instrument; if it differs, operate the adjustment screw (1),
located in the rear part of the revolution counter, until
consistency is achieved; repeat the operation for different
engine rpms.
Verify the indication of the panel revolution counter by comparing it with the one measured with a reference instrument;
if it differs, press the button 1 and 2 situated on the rear
of the tachometer, until consistency is achieved; repeat the
operation for different engine rpms.
Maintenance
Maintenance
Should it become necessary to replace a panel light, remove
the lamp holder from the rear part of the instrument (see
Figure 22A).
The board is illuminated by not-replaceable internal LEDs.
C78 ENS M20
C78 ENT M30-M50-M55
26
INSTALLATION DIRECTIVE
MAY 2006
10.SECONDARY ANALOG INSTRUMENT PANEL
Figure 23
4
5
electronic
RPMx100
3
2
6
7
1
04_240_N
1.Connector for secondary panel wire harness (JH) - 2. Engine start push-button (CS) - 3. Revolution-counter (CG) 4. Buzzer (SA) - 5. Indications and alarms module (MS) - 6. Engine stop push-button (AS) 7. Sound alarm inhibition push-button (P1).
The connection is achieved by removing the cap on the JE
connector of the main panel, and connecting the JE connector to the JH connector on the secondary panel, interposing
the extension wire harness, available in 3, 5 and 7 meter-long
versions (see Fig. 19). The JE-JH wire harness comprises 12
lines, each connected to the terminal identified on both connectors by the same number (see fig. 24).
Figure 24
1
6
6
1
Operation of the secondary panel
After completing the electrical connection to the main panel
and engine preparation, and performing the tests required
for the first start (as described in Chapter 18), verify the
proper operation of the panel, proceeding as follows:
o Make sure that the “ENGINE ROOM / BRIDGE” switch
of the Relay Box is in the “BRIDGE” position, then turn
the key switch to the first position, thus enabling the
operation of both panels.
o Carry out the same tests for the secondary panel as
were carried out for the main panel.
o Disable the secondary panel by bringing the key switch
on the main panel to the resting or zero position.
Testing the engine start and stop function.
04_251_N
7
*%
12
12
*(
7
CONNECTORS OF THE JE-JH EXTENSION WIRE
HARNESS, SEEN FROM THE COUPLING SIDE
Installation
In order to drill holes on the area where the panel is to be
mounted, refer to the dimensions indicated in Chapter 11.
With the panel enabled, press the green push-button until
the engine starts, then release it; wait for engine rpm to stabilize before stopping it by pressing the red push-button.
The starting and stopping operations can be performed several times and consecutively from the secondary panel
Checking indications
Proceed in the same way as for the main panel.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
27
11.DRILLING PLANS FOR ANALOG PANELS
Ø
Ø
4
26
4
Figure 25
4
=
200
140
=
Main panel
Ø4
Ø
4
26
4
4
26
=
=
26
4
225
285
04_022_C
Dimension in millimeters.
28
2
Figure 26
Ø
Ø
4
4
140
=
80
=
Secondary Panel
4
2
28
=
=
28
2
28
4
Ø
Ø
180
240
04_023_C
C78 ENS M20
C78 ENT M30-M50-M55
28
INSTALLATION DIRECTIVE
MAY 2006
12.MAIN DIGITAL INSTRUMENT PANEL
Figure 27
3
4
20
– +
2
3
25
15
8
1
10
0
10
2
3
30
BAR
BAR
50
5
90
120
40
1
2
0
RPM
X100
5
MIN
35
RPM
C
MAX
– +
V
6
h
P
ROG.
7
16
15
14
13
12
11
10
8
9
04_256_N
1. Engine coolant temperature indicator - 2. Lubrication loop pressure indicator - 3. Service and alarm indicators - 4. Revolution
counter - 5. Supercharger air pressure indicator - 6. Voltmeter - 7. Engine start/stop key switch - 8. JE connector for secondary
panel - 9. Cap with electrical continuity connection - 10. Accessory function programming push-button - 11. Push-button for
selecting accessory information - 12. Digital display - 13. Push-button for zeroing the “programmed maintenance” indication 14. Sound alarm inhibition push-botton - 15. JH connector for panel wiring - 16. Buzzer.
Installing the panel provided with digital displays requires
connecting the JH-D connector of the panel to the JE connector of the interface wire harness, itself connected to the
“Converter Module”, interposing the JE extension wire harness, available in 3, 5 and 7 meter-long versions (Figure 24).
To the main panel is connected the JE connector, set for
connection to the secondary panel; in installations lacking the
secondary panel, do not remove the cap of the JE connector
in order not to compromise the electrical continuity of the
system power supply circuit.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
Synoptic of digital panel connections
Figure 28
SECONDARY
INSTRUMENT
PANEL
MAIN
INSTRUMENT
PANEL
JE
JH
JE
JA
JH
JH
2
JE
JE
JE1
CAN - BUS
CONVERTER
MODULE
JD
JO
ENGINE
EQUIPMENT
1
A
EDC
B
JB
JA
JF1
JF
RELAY
BOX
04_024_C
1. Interface wire harness for converter module - 2. JE-JH extension wire harness.
The JE1 connector provides connection to a second main
onboard panel. Its installation is subject to IVECO MOTORS
approval.
BATTERY
29
30
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
CAN-BUS CONVERTER MODULE
Functions of the JO terminals
Figure 29
04_259_N
Rear view of the module with JO connector
The presence of the “Converter Module” is necessary to
translate the information of some sensor, provided in analog
form, into information suited to be decoded by the digital
converters of the panel.
The interface wire harness is set up to connect the main
panel (JE) from which the secondary panel is to be branched
off, and it is provided with a branch (JD) for connecting an
electronic engine rpm managing system or an electronic
throttle.
The JE1 connector is branched from the interface cable. The
connector provides connection to an optional second main
onboard panel. Its installation is subject to IVECO MOTORS
approval (see figure 28).
Figure 30
04_218_N
JO CONNECTOR
VIEW OF THE WIRE HARNESS TERMINAL,
COUPLING SIDE
1
Gear box oil pressure signal
2
CAN L
3
CAN H
4
Power supply positive (+ B)
5
Power supply positive (+ B)
6
Battery positive with key in ON position
7
Battery positive with key in ON position
8
Power supply negative (ground)
9
Optional output
10
Engine rpm signal
11
Pre-lubrication signal
12
Not connected
13
Exhaust gas temperature signal (-)
14
Exhaust gas temperature signal (+)
15
Gear box oil temperature signal
16
Engine oil temperature signal
17
Engine oil pressure signal
18
Air filter clogging signal 2
19
Power supply negative (ground)
20
Not connected
21
Alternator anomaly signal
22
Pre-heating signal
23
EDC failure signal
24
Low coolant level signal
25
Exhaust gas temperature signal (-)
26
Exhaust gas temperature signal (+)
27
External throttle input signal
28
Coolant temperature signal
29
Air filter clogging signal 1
30
Not connected
31
Power supply negative (ground)
32
Not connected
33
Runaway engine signal
34
Water in fuel signal
35
Oil filter clogging signal
36
Fuel filter clogging signal
MAY 2006
INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
31
Connector JD
Figure 31
04_263_N
PIN 1
PIN 4
The JD connector enables to use an electronic engine rpm
management instead of the system provided on the engine.
If this solution is used, the throttle position sensor, situated
on the engine, will remain electrically connected but not
used and the EDC Central Unit will manage engine rpm
according to the voltage signal applied to the terminals of
the JD connector.
In case of a fault in the electronic throttling system, the engine
rpm may be managed in emergency condition, mechanically
operating the sensor lever positioned on the engine.
The connection requires a METRI PACK 150 four-way connector with male terminals.
PIN
Wire code
(U) Voltage
Interpreted function
Imax
1
7731
+B with key in ON position
Electronic throttle enabling
0,5 A
2
0000
0 V - (Ground)
Common reference terminal
-
0 to 0,2 V
Poor value. EDC recognises a fault
-
0,2 to 0,5 V
Accelerator at minimum level
0,5 to 4,5 V
Accelerator min. to max., U function
-
4,5 to 4,8 V
Accelerator at maximum level
-
4,8 to 5 V
Excessive value. EDC recognises a fault
3
4
5584
5551
Ground, with engine in overspeed Overspeed engine indication
0,1 A
NOTE: The voltage values for the rotation of the motor must be between 0.2 and 4.8 V. Values below 0.2 V or above 4.8 V
generate the recognition of a fault and consequent deactivation of the function.
32
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
Installation
Programming accessory functions
In order to drill holes on the area where the panel is to be
mounted, refer to the dimensions indicated in Chapter 14.
The following programming operations are required when
the panel is first operated:
Operation of the panel
o The hours of the maintenance interval relevant to the
characteristics of the engine in use.
After completing the electrical connections and engine
preparation, perform the tests required for the first start, as
described in Chapter 18.
Verify the proper operation of the panel, proceeding as follows:
o Make sure that the “ENGINE ROOM / BRIDGE” switch
of the Relay Box is in the “BRIDGE” position, then
turn the key switch to the first position and verify that
the instruments are powered and the Indications and
Alarms Module runs the alarm test for about 5 seconds.
During this phase, all indicator lights must be lighted,
with the exception of those for “pre-lubrication”, “prepost heating” and “EDC failure”. A sound signal must be
emitted by the buzzer; it may be silenced before the end
of the test, pressing the push-button on the panel.
o Once the test is complete, only the indications prescribed for the engine stopped must remain lighted: e.g.
“alternator charge” and “low oil pressure”; the analog
instruments must provide values consistent with the
respective physical parameters.
Testing the engine start function
Turn the key switch to the second position and keep it in it
until the engine has started, then release the switch, which
will stably return to the first position; after releasing the key,
the switch may be brought back to the starting position only
after the switch is returned to the resting or zero position.
Checking indications
After starting the engine, verify whether the operating
modes of the Indications and Alarms Module are similar to
those set out above.
Using appropriate measuring instruments, verify the consistency of the indications provided by the analog instruments.
Testing the engine stop function
The engine is stopped and the panel is disabled by returning
the key switch to the resting or zero position.
The panel has an engine stop push-button whose function is
only enabled in versions where the engine stops as a result
of the excitation of an actuator, i.e. engine versions requiring
certification by Certification Bodies.
o The maximum quantity of introduction, necessary to
compute fuel consumption.
With reference to Figure 27, proceed as follows:
o Holding down the “Programming” (10) and “Slide-down
selection” (11) push-buttons, positioned on the panel,
turn the key switch to the first position and wait for the
display to show the value of the maintenance interval
set previously (e.g., 200 hours).
o Release the push-buttons and set the hours of the
time interval, indicated for oil replacement, provided on
the operation and maintenance manual; the operation
is completed by repeatedly pressing the “Slide-down
Selection” push-button (11) until the number that is
selected and highlighted by flashing is correctly set, then
operating the “Programming” push-button (10) to select
the number to set.
o Press and hold the “Programming” push-button (10)
until the display shows the maximum introduction value,
set by default to the value 10 mg/strk, then release it.
o Set the number for engine calibration, obtaining it from
the table that follows, proceeding as described in item 2.
o Press and hold the “Programming” push-button (10)
until the display shows the engine rpm indication.
If programming operations were not performed correctly,
the display will show the indication “Err.P”; check whether
the electrical connections of the main panel and of the
converter module were performed correctly, then repeat
the procedure.
C78 ENS M20
Maximum power calibration
[HP]
230
200
Fuel introduction
[mg/strk]
118,5
118,5
C78 ENT M30
Maximum power calibration
[HP]
330
300
Fuel introduction
[mg/strk]
153
153
INSTALLATION DIRECTIVE
MAY 2006
Fuel introduction
[mg/strk]
195
450
179
400
170
350
144
330
153
300
153
280
144
260
137
240
129
220
119
190
106
C78 ENT M55
Maximum power calibration
[HP]
550
33
Symbology key
C78 ENT M50
Maximum power calibration
[HP]
500
C78 ENS M20
C78 ENT M30-M50-M55
Clogged air filter
Expired programmed maintenance interval
Clogged oil filter
Pre-lubrication in progress
Pre-post heating
Clogged fuel filter
Fuel introduction
[mg/strk]
218
500
218
450
218
400
210
Presence of water in the
fuel filter
Clogged blow-by filter
Alternator fault
Low oil pressure
High coolant temperature
Runaway engine
Low engine coolant leve
EDC fault
04_264_N
C78 ENS M20
C78 ENT M30-M50-M55
34
INSTALLATION DIRECTIVE
MAY 2006
13.SECONDARY DIGITAL INSTRUMENT PANEL
Figure 32
3
4
20
– +
2
3
25
15
8
1
10
0
10
2
3
30
BAR
BAR
50
5
90
120
40
1
2
0
5
C
RPM
X100
35
RPM
MIN
MAX
– +
V
6
h
12
START
STOP
8
11
10
7
9
04_257_N
1. Engine coolant temperature indicator - 2. Lubrication loop pressure indicator - 3. Service and alarm indicators 4. Revolution counter - 5. Supercharger air pressure indicator - 6. Voltmeter - 7. Push-button for selecting accessory information 8. Engine stop push-button - 9. Digital display - 10. JA connector for panel wire harness - 11. Engine start push-button.
12. Sound alarm inhibition push button.
The secondary panel is branched to the main panel. Remove
the cap from the main panel JE connector and connect the
JE connector to the JA connector on the secondary panel,
placing the special extension JE-JH cable, available 3.5 and
7 meters long (see figure 24). IVECO MOTORS standard
supply is provided for the installation of the main and secondary board and their simultaneous use with no operation
limitations.
o Carry out the same tests for the secondary panel as
were carried out for the main panel.
o Disable the secondary panel by bringing the key switch
on the main panel to the resting or zero position.
Testing the engine start and stop function.
In order to drill holes on the area where the panel is to be
mounted, refer to the dimensions indicated in Chapter 14.
With the panel enabled, press the green push-button until
the engine starts, then release it; wait for engine rpm to stabilize before stopping it by pressing the red push-button.
The starting and stopping operations can be performed several times and consecutively from the secondary panel.
Operation of the secondary panel
Checking indications
After completing the electrical connection to the main panel
and engine preparation, and performing the tests required
for the first start (as described in Chapter 18), verify the
proper operation of the panel, proceeding as follows:
Proceed in the same way as for the main panel.
Installation
o Make sure that the “ENGINE ROOM / BRIDGE” switch
of the Relay Box is in the “BRIDGE” position, then turn
the key switch to the first position, thus enabling the
operation of the main and secondary panels.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
35
14.DRILLING Plan FOR DIGITAL PANELS
16
Figure 33
7
7
Ø
Ø
191
=
159
=
Main panel
and
secondary panel
Ø
7
7
Ø
16
=
=
244
276
Dimensions in millimeters
04_025_C
36
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
15.CUSTOMIZED INSTRUMENT PANEL
Using only the components of the panel that are not wired
to allow for panel customization, they will have to be wired
using the 10 meter long wire harness, set up at one end for
coupling to the JB connector and at the opposite end with
conductors with free terminals with identifying numbering
on each wire. The conductors will have to be connected to
the individual components as indicated in the electrical and
wiring diagrams in Chapter 24.
Figure 35
1
2
3
5
6
7
9
4
8
10 11 12
13 14 15 16
caution
17 18 19 20
To assure the functionality of the safeties pertaining to the
engine start/stop commands from the instrument panel or
engine room, it is mandatory to wire the key switch strictly
as shown in the electrical diagrams in Chapter 24.
The wiring details of the indications and alarms module
alone are provided below; indications for IVECO MOTORS
indicator instruments, are shown in the related wiring diagrams in Chapter 24.
JD Connector for indications and alarms
module
21 22 23 24
04_241_N
VIEW FROM THE TERMINAL SIDE
OF THE COUPLING SIDE WIRING
connector
TRIDENT / ITT CANNON part TST 24PA00
terminal
female
part 192990-0050
lid
rear
part TST24AH0
Figure 34
JD connects the indications and alarms module to the electrical system of the engine (sensors, power supply, etc.).
The terminal part of the wire harness, supplied with the
module, must be completed using female terminals, as
described in the electrical diagram of Chapter 24.
For standard-equipped engines, to have the essential indications available, the following ways must be wired: 1, 2, 3, 7, 8,
9, 10, 11, 13, 14, 15, 16 with the female terminals supplied as
standard equipment.
4
3
2
1
8
7
6
5
12 11 10 9
16 15 14 13
20 19 18 17
24 23 22 21
05_034_C
VIEW FROM THE INTEGRATED SIDE
IN THE REAR PART OF THE MODULE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
37
Functions of the JD terminals
PIN Description
Electric level
OFF Indication
ON Indication
1
Module power supply
2
EDC lamp power supply
3
EDC Fault indication
4
Pre-heating light power supply
5
Pre-heating indication
6
Positive (+B)
Power supply positive (+B)
High (+B)
Low (ground)
Power supply positive (+B)
High (+B)
Low (ground)
Pre-lubrication indication
Open circuit
High (+B)
7
Engine start
Power supply positive (+B) while starting
8
Buzzer inhibition
9
Module power supply
Negative (ground)
10 Sound alarm power supply
Negative (ground) during the emission of sound
Negative (ground) during the request
11 Clogged oil filter indication
Open circuit
Low (ground)
12 Clogged oil vapor filter indication
Open circuit
Low (ground)
13 Clogged air filter indication
Open circuit
Low (ground)
14 Clogged fuel filter indication
Low (ground)
Open circuit
15 Alternator fault indication
High (+B)
Low (1 ÷ 3 V)
16 Low engine coolant level indication
Open circuit
Low (ground)
17 High coolant temperature indication
Open circuit
Low (ground)
18 Low engine oil pressure indication
Open circuit
Low (ground)
19 Presence of water in fuel indication
Open circuit
Low (ground)
20 Overloaded or runaway engine indication
Open circuit
High (+B)
21 Not connected
-
22 Not connected
-
23 Reception of data from main panel NMEA communication protocol (0 ÷ 5 V)
24 Transmission of data to secondary panel
NMEA communication protocol (0 ÷ 5 V)
caution
To assure the utmost reliability and safety while underway, all installations must be provided with the following alarm indications:
(EDC) EDC failure
(SATA) high coolant temperature
(SBPO) low oil pressure
It is also recommended that the following indications be present:
(SAC) presence of water in the fuel pre-filter
(SIFA) clogged air filter
(SS) alternator fault
C78 ENS M20
C78 ENT M30-M50-M55
38
INSTALLATION DIRECTIVE
MAY 2006
16.SENSORS FOR DETECTION AND PANEL SIGNALING
Coolant temperature sensor
Oil pressure sensor
Figure 38
Figure 36
04_026_C
Resistor with negative temperature coefficient, providing the
signal for analog temperature indication.
04_237_N
Rheostat component providing the signal for the analog
indication of pressure.
Operating voltage from 6V to 24 V
Calibration range from 0°C to 120°C
Resistance value at 90°C
51.2 ± 4.3 Ω
Operating voltage
from 6V to 24 V
Electrical poles
isolated
Calibration range from 0 bar to 10 bar
Resistance value at 0 bar
10 Ω +3/-5 Ω
Resistance value at 2 bar
52 ± 4 Ω
Resistance value at 4 bar
88 ± 4 Ω
Resistance value at 6 bar
124 ± 5 Ω
Maximum value of resistance
184 Ω
Operating temperature
from - 25°C to 100°C
Electrical poles
isolated
High coolant temperature sensor
Figure 37
04_027_C
Switching coolant temperature sensor, providing the signal
for the related indicator.
Operating voltage:
from 6 to 24 V
Condition at ambient temperature
normally open
Closing temperature:
100 ± 3 °C
Electrical poles
isolated
Low oil pressure sensor
Figure 39
04_028_C
Pressure switch, providing the signal for the related indicator.
Operating voltage:
from 6 to 24 V
Condition at ambient pressure
normally closed
Calibration range
0.5 - 0.8 bar
Closing pressure:
0.5 bar
Opening pressure:
0.8 bar
Maximum current
15 A (not inductive)
Electrical poles
isolated
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
Air filter clogging sensor
39
Fuel filter clogging sensor
Figure 40
Figure 42
04_030_C
04_238_N
Vacuum switch, providing the signal for the clogged air filter
alarm indicator.
Pressure switch, providing the signal for the related indicator.
Operating voltage:
from 6 to 24 V
Operating voltage:
from 6 to 24 V
Condition at ambient pressure
normally closed
Condition at ambient pressure
normally open
Opening pressure:
1.5 ± 0.1 bar
Closing vacuum:
≥ -52 mbar
Maximum current
0,1 A (not inductive)
Operating temperature:
-20 / +80 °C
Electrical poles
isolated
Maximum current
0.1 A (not inductive)
Electrical poles
isolated
Exhaust gas temperature sensor
Figure 43
Oil filter clogging sensor
Figure 41
04_260_N
NiCr-Ni thermocouple sensor with insulated poles, providing the signal for the analog indication of exhaust gas
temperature.
04_029_C
Differential pressure switch, providing the signal for the
related indicator when pressure difference between inlet /
outlet oil filter is more then a limit value.
Operating voltage:
from 6 to 24 V
Condition at ambient pressure
normally open
Closing pressure:
2.4 ± 0.3 bar
Opening pressure:
1.8 ± 0.3 bar
Maximum current
3 A (not inductive)
Electrical poles
isolated
Temperature
Voltage
°C
mV
100
4.10
200
8.13
300
12.21
400
16.40
500
20.65
600
24.91
700
29.14
800
33.30
900
37.36
40
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
Sensor to detect the presence of water in fuel
MAY 2006
CAUTION
In order to enable the proper working of the sensor to
detect water in the fuel, it is necessary that the pre-filter
support is connected electrically to the negative battery
terminal. Figure 44
04_031_C
Fuel resistivity sensor, integrated with the control and amplification electronic circuit, providing the signal for the indicatorof the presence of water in the fuel.
Operating voltage
In the engine models which use parts with insulated poles
it is necessary to electrically insulate the pre-filter support
from the boat mass and then connect the support with the
negative battery terminal.
Low level coolant sensor
Figure 46
from 12V to 24 V
Condition in the absence of water open circuit
Closed condition
resistance of the liquid
≤ 1 MΩ
Operating temperature
from -20 °C to +80 °C
Connections of the sensor detecting the presence of water
in fuel
Figure 45
2
1
!
"
#
!
"
#
3
04_032_C
1. M Connector of the engine wire harness 2. Sensor detecting the presence of water in the fuel 3.Wiring harness (outfitter’s responsibility).
The three pole connection between the sensor for detecting the presence of water in the fuel and the engine wire
harness must be produced by the outfitter according to the
position of the fuel pre-filter in the boat.
Connection to the engine wire harness requires a METRIPACK150 three-pole connector with three male terminals;
connection to the sensor requires a JUNIOR TIMER threepole connector with three female terminals
04_033_C
The sensor detect the presence of coolant and is provided
with the control and amplification electronic circuit; it providing the signal for the alarm for low level coolant.
Operating voltage
from 12 to 24 V
Condition for high level
open
Maximum current
0.1 A not inductive
17.PREPARING THE ENGINE FOR FIRST
START-UP
1. Drain the residual 30/M protective oil from the sump.
2. Pour into the lubricating loop only lubricating oil of the
type and in the quantities set out in the Refilling Table.
3. Drain the CFB protective liquid from the fuel loop,
completing the operations as indicated under item 3. of
Chapter 23
4. Remove the caps and/or seals from the engine intake,
exhaust, aeration and venting ports, restoring normal
conditions of use. Connect the inlet of the turbocharger
to the air filter.
5. Connect the fuel loops to the boat tank, completing
the operations set out in item 4. of Chapter 23 During
filling operations, connect the pipe returning fuel to the
tank to a collecting container, to prevent residues of CFB
protective liquid from ending up into the boat tank.
6. Verify and refill engine coolant as prescribed.
7. Engine C78 ENT M55: in order to enable the see
water pump priming it is necessary to input water into
the forcing circuit.
Remove the sacrifical anode (1 of figure 47), introduce 1.5 litres of water into the hole; reassemble the
anode and tighten it as required. C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
41
18.TESTS BEFORE THE FIRST START-UP
Although they are extremely important, “common sense”
checks such as the exposure of sensitive parts (plastics, wire
harness, electronic units, etc. ...) to heat, and those that for
years have characterized the quality of the work performed
in the yard, are not mentioned herein.
Tests of the proper operation of the engine and the components of the electronic control system may be performed
rapidly and with the utmost reliability using specific diagnostic
tools, available from IVECO MOTORS Technical Assistance
Centers.
Fuel tank suction
Verify the fuel suction at the maximum allowed longitudinal
and transverse inclination, with the residual quantity of fuel
considered “RESERVE”, such as to cause the reserve indicator light to be permanently lighted.
Throttle lever position sensor
Figure 48
WARNING
If the engine is activated after a long time, it is necessary
to repeat the operations mentioned in item 7.
8. Remove from the engine the labels with the inscription
“ENGINE WITHOUT OIL”.
Figure 47
04_080.N
In the positions of minimum and maximum travel, verify the
correlation between the position of the throttle control valve
on the bridge and the position of the sensor rod, checking:
o that in the resting position the safety switch inside it is
electrically open. Carry out the test with an ohmmeter
between the points D and E of the potentiometer connector.
1
80819
-
Value read ∞ Ω = optimal adjustment;
- Value read 1 kΩ = a better mechanical adjustment
of the resting position is required, to bring the
value back to ∞ Ω.
o In the position of maximum acceleration, the rod of the
sensor has reached the mechanical end stop.
Instruments and control panel
Verify the efficiency of all light indicators, as described in the
related Chapters.
42
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
19.FIRST ENGINE START
Before starting the engine, please make sure the sea water
gate valve is open, check the levels of the lubricating oil and
of the engine coolant, and complete venting the air from the
fuel feed loop, acting on the hand pump of the pre-filter or
with the aid of a dedicated electrical pump.
The venting air points are fitted on the pre-filter supplied
from IVECO MOTORS, after the main filter, on the cylinder
head near the injectors solenoid valves connector. (see Figure 49).
Loosen the vent fitting on the pre-filter and operate the
pump until only fuel without air flows out.
Tighten the vent fitting and complete the purge operation
on the vent fitting placed on the cylinder head during the
initial start-up phases.
Figure 49
Start-up procedures
Figure 50
ENGINE
ROOM
ENGINE
STOP
BRIDGE
ENGINE
START
PTO+
1
2
3
PTO-
PTO
ON
PTO
OFF
CHECK
4
04_035_C
The electrical equipment of this engine allows to start it from
the “engine room” and from the “bridge”.
NOTE
A few moments after start-up, make sure sea water is correctly drained from the relevant circuit.

Starting the engine from the bridge
This is allowed only if the Relay box switch (1) is in the
“BRIDGE” position.
Start the engine and let it run until the idling rpm has fully
stabilized (see also the Chapters on the instrument panels)
04_034_C
Purge fitting on cylinder head
caution
Make sure that the fuel that flows out of the fitting dont
coming in conctact with the auxiliaries drive belt and is
not dispersed in the environment.
Starting the engine from the “engine room”
Moving the Relay box switch (1) to the “ENGINE ROOM”
position (which must absolutely not be done when the
engine is running), regardless of the position of the key
switch on the indicator and control panel, enables the use of
the adjacent STOP - START push-button (2).
It will thereby be possible to start and stop the engine with
complete independence from the bridge controls.
Moving the switch (1) back to the “BRIDGE” position, inhibits
use of the “START-STOP” push-button positioned on the
Box, allowing the engine to be started only from bridge
controls.
RPM control
To allow easily to control engine RPM from the “engine
room”, a simultaneous acceleration/deceleration function
(PTO+/PTO-), active only when the switch (1) is in the
“ENGINE ROOM” position, and the switch (4) is in PTO
ON position.
Acceleration (PTO +)
If, the engine is running, and PTO+ / PTO- push-button is
held down in the “PTO+ position, then engine rpm are progressively increased (50 rpm per second). The increase ends
when the push-button is released, allowing the engine to run
at the desired rpm.
Deceleration (PTO -)
If the engine is running, and PTO+ / PTO- push-button is
held down in the “PTO-” position, a progressive reduction in
rpm is obtained (50 rpm per second). The reduction ends
when the push-button is released, allowing the engine to run
at the desired rpm.
INSTALLATION DIRECTIVE
MAY 2006
The rpm reached at that point is maintained until the ”
engine is stopped. (function takes priority and always stops
the engine) or switching the PTO ON / PTO OFF push-button in the OFF position.
caution
Never operate the “BRIDGE - ENGINE ROOM” switch
when the engine is running.
Once the first start-up phase is complete, verify that:
o There are no liquid leaks from the coolant loop pipeline
junction hoses.
o There are no exhaust gas leaks in the hull.
o In order to carry out the cooling system degassing, do as
follows:
Figure 51
1
2
05_001_C
o keep the engine at minimum rotation speed, slowly
loosen screw (1) positioned on the coolant tank near
the cap and the two screws (2) situated on the exhaust
induction in order to facilitate the exit of possible air
bubbles. When this operation is finished, tighten the
screws as required, stop the engine and verify the level
of the coolant liquid. Fill it up if necessary. Take care not to disperse the exiting liquid in the environment.
o Complete the instrument panel operation tests as
described in the related Chapters.
o Verify that the power supply voltage across the battery,
after about 15 minutes with the engine running, is no
less than about 26 V.
o Stop the engine and delete any “errors” which may have
been stored in the injection system ECU during the
stabilization phases. For the deletion procedure, refer to
Chapter 20.
C78 ENS M20
C78 ENT M30-M50-M55
43
44
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
20.EDC ANOMALIES INDICATION
Anomalies indicator light
The ECU continuously monitors, with complex self-testing
routines, its own operating conditions as well as those of the
components connected to it and of the engine.
When anomalies are detected, the alarm indicator light on
the indicator and control panel is lighted in manners that
provide a first indication on the severity of the problem.
Light off: no anomaly detected or slight anomaly
that does not compromise operating safety
Error deletion procedure
Figure 52
ENGINE
ROOM
ENGINE
STOP
BRIDGE
ENGINE
START
1
PTO-
PTO+
PTO
ON
PTO
OFF
CHECK
2
3
04_035_C
Light on:
significant anomaly, allowing to proceed to
a service center
A. Shut the engine down and keep the key switch in the
“OFF” position for 15 seconds (after run).
Blinking light:
severe anomaly requiring immediate
repairs. If possible, shut the engine down.
B. Approach the relay box. Keeping the “CHECK” diagnostic push-button (3), move the adjacent “BRIDGE
- ENGINE ROOM” switch (1) to the “ENGINE ROOM”,
wait for the luminous indicator (4) to switch off position,
while keeping the diagnostic push-button pressed for 8
more seconds.
Blink code
The emission of the anomaly codes detected during self-testing and stored in the ECU starts after pressing and releasing
the “CHECK” push-button on the relay box panel, when
the “BRIDGE - ENGINE ROOM” switch is in the “ENGINE
ROOM” position
The LED located at the side of the push-button and the
EDC indicator light on the indicator and control panel will
simultaneously signal, with two series of emissions at different
frequencies, the blink codes that indicate the anomaly with
decimal numbering.
Slow blinks identify the area of the anomaly (engine, injectors,
...), fast blinks identify a specific anomaly.
Every time the push-button is pressed and released, only
one of the stored codes is emitted; therefore, the procedure
must be repeated until an error indication identical to the
first one is obtained, which means the entire error memory
has been analyzed.
If no anomalies are stored, the light comes on when the
push-button is pressed and comes off about 1 second after
its release, without any subsequent blinking.
Recovery
The recognition of significant or sever anomalies causes the
adoption of strategies that allow to use the engine with
complete safety, guaranteed by limiting performance within
pre-set thresholds according to the severity of the case.
These strategies cause the reduction of the maximum values
of torque and power delivered by the engine.
In the case of intermittent anomalies, i.e. recognized by the
ECU and subsequently no longer present, performance
reduction will continue until the engine is shut down.
Normal operation will be restored only the next time the
engine is started, while the anomaly data will be “saved” in
the failure memory.
C. Release the push-button and move the “ENGINE
ROOM” switch to the “BRIDGE” position
caution
The mistake deleting procedure is intended to eliminate
the information relating to the mistakes from the ECU
memory, which happened during previous working periods.
The mistakes will not be deleted unless the relating cause
has been removed. Please remember that some anomalies
can be detected by the ECU self-diagnosis only during a
complete engine working cycle.
At the end of this procedure, the codes of any anomalies
detected during the engine installation and first start-up
operations will be deleted in the ECU. To make sure that no
anomaly data remain stored in it, or that there are no other
errors in the system, set the “BRIDGE - ENGINE ROOM”
switch to the “ENGINE ROOM” position and verify that,
when the diagnostic push-button is pressed, the blink code
light (2) does not emit any code.
At the end of these operations, return the switch to the
“BRIDGE” position
If the ECU signals the presence of errors or operating anomalies, the installation will have to be reviewed to remove the
cause of the error or anomaly.
Indications for decoding the codes are provided in Chapter 21.
NOTE: The blink code diagnostic procedure provides indications about current anomalies as well as past anomalies that
are no longer present when the diagnosis is carried out;
therefore, it is absolutely mandatory, at the end of every
repair operation, to erase the error memory to prevent
anomalies whose cause has already been removed from
being signaled in the future.
INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
21.BLINK CODE TABLE
Blinking Code
EDC Indicator light
Indicated Fault
Control area
1.1
(on)
not significant in marine applications
1.2
(on)
not significant in marine applications
1.3
(off)
not significant in marine applications
1.4
on
throttle position sensor
1.5
(off)
not significant in marine applications
1.6
(on)
not significant in marine applications
1.7
(off)
not significant in marine applications
Engine area
2.1
off
coolant temperature sensor
2.2
off
intake air temperature sensor
2.3
off
fuel temperature sensor
2.4
on
supercharge air pressure sensor
2.5
off
ambient pressure sensor (inside the unit)
2.6
(on)
not significant in marine applications
3.5
off
battery voltage
Injectors
5.1
on
cylinder 1 injector fault
5.2
on
cylinder 2 injector fault
5.3
on
cylinder 3 injector fault
5.4
on
cylinder 4 injector fault
5.5
on
cylinder 5 injector fault
5.6
on
cylinder 6 injector fault
Engine rpm sensor
6.1
on
flywheel sensor
6.2
on
timing system sensor
6.4
blinking
runaway engine
Electronic unit
9.1
blinking
defective unit
9.2
on
incorrect EEPROM data
9.3
(blinking)
not significant in marine applications
9.4
on
main relay
9.5
on
erroneous engine shut-down procedure
9.6
on
unit data storage operation not completed
45
46
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
22.UNDERWAY CHECKS
ECU Temperature
Verify that the temperature of the surface of the electronic
engine control unit, after 30 minutes underway at full engine
power, is less than +70°C.
Engine compartment vacuum
Verify that value of ambient air pressure in the engine room
with the engine(s) at full load and maximum power output
complies with the value specified herein.
Combustion air temperature
Verify that the temperature in the engine room, after 30 minutes underway at full engine power, does not exceed 50°C
(C78 ENS M20, C78 ENT M30 and C78 ENT M50) or 45°C
(C78 ENT M55) and, in any case, does not exceed the value
of external temperature by more than 15°C.
Exhaust back-pressure
Verify that the value of back-pressure present at the inlet of
the exhaust gas conduit, with the engine(s) at full load and
maximum power output, complies with the value specified
herein.
Exhaust temperature
Verify that the temperature of the exhaust gases under
maximum engine power output conditions is close to the
prescribed value; to determine the propeller power absorption curve, it will also be possible to obtain from the ECU
parameters the fuel injection values by using the IVECO
MOTORS tool.
Fuel temperature
Verify that the temperature of the fuel in the low pressure
line, while underway at full power and with a stable quantity
of fuel in reserve, does not exceed 50°C. A higher value
would entail a reduction in engine performance. If the tendency to reach the maximum allowed temperature is noted,
install a heat exchanger for the fuel.
Pressure in the fuel supply line
To assure the regular operation of the engine and the reliability of the components of the fuel supply and injection
system, you need to verify that:
o vacuum in the fuel oil supply line to the low pressure
pump is less than 0.2 bar relative (2000 mm H2O);
o pressure in the fuel oil return line to the tank is less than
0.2 bar relative (2000 mm H2O).
Measures are carried out inserting a “T” junction near the
fuel inlet and outlet, taking care to avoid any air suction. Values are read at variable rpm, from idle to maximum, at 200
rpm intervals.
If there are any symptoms indicating the possible presence of
air in the fuel supply line, a check may be made by inserting
a clear tube, arranged as an inverted U, before the engine
inlet junction.
MAY 2006
MAY 2006
INSTALLATION DIRECTIVE
23.PREPARING THE ENGINE FOR LONG IDLE PERIODS
To prevent oxidation to the internal parts of the engine and
to some components of the injection system, if idle periods
exceeding two months are expected, the engine needs to
be prepared with six-months periodicity, proceeding as
follows:
1. Drain the lubricating oil from the sump, after heating the
engine.
2. Pour 30/M protective oil (alternatively, oil conforming
with MIL 2160B Type 2 specifications) into the engine to
the “minimum” level marked on the dipstick.
Start the engine and let it run for about 5 minutes.
3. Drain the fuel from the injection line and from the filter,
taking care to avoid letting the fuel come in contact with
the auxiliaries belt. .To do so, loosen the drain cap in the
front part of the cylinder head and the fuel inlet junction
with the cylinder head, taking care to prevent the fuel
from coming in contact with the auxiliaries belt.
4. Connect the fuel line to a tank containing CFB protective liquid (ISO 4113) and assist the inflow of the liquid
by pressurizing the line and turning the engine over for
about 2 minutes, after excluding the operation of the
injection system. The required operation may be carried
out by directly polarizing the terminal 50 of the electric
starter motor with positive voltage 24 V, using a conductor prepared for the occasion.
5. Nebulize 30/M protective oil at the rate of about 80 g
(10 g per liter of displacement) into the turbocharger
intake, while the engine is turning over as described
above.
6. Close with suitable stoppers or seal with adhesive tape
all engine intake, exhaust, aeration and venting ports.
7. Drain the residual 30/M protective oil from the sump; it
may be re-used for 2 more engine preparation operations.
8. Apply tags with the inscription “ENGINE WITHOUT
OIL” on the engine and onboard panel.
9. Drain the coolant, if it has not been mixed with antifreeze and corrosion inhibiting agents, affixing tags to
indicate that the operation has been carried out.
If external parts of the engine are to be protected, spray
protective liquid OVER 19 AR onto unpainted metal parts,
such as flywheel, pulleys and others; avoid spraying belts, connector cables and electrical equipment.
C78 ENS M20
C78 ENT M30-M50-M55
47
C78 ENS M20
C78 ENT M30-M50-M55
48
INSTALLATION DIRECTIVE
MAY 2006
24.ELECTRIC DIAGRAMS
Wiring diagram key
General condition for the preparation and interpretation of wiring diagrams
o Key switch open
o Engine not running
o Liquids at efficient levels and pressures
Figure 53
Connection
JC: connector
8: terminal
Component
terminal
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code
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Minimum cable cross
section in mm2
Component code or
connector code
Terminal
connection
Schema_Connettore_B
INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
49
Electrical equipment component code
A
fuel temperature sensor for EDC
SI
gear box oil temperature sensor
AC
battery
SW1
AQ
engine shut-off push-button on main panel
AS
engine shut-off push-button on secondary panel
bridge or engine room engine control selector
(on relay box panel)
start and stop push button (on relay box panel)
B
drive shaft sensor for EDC
C
camshaft sensor
CA
key switch
CS
engine start push-button on secondary panel
DL1
EDC fault indicator and blink code LED
T
manual accelerator throttle control in engine
room (on relay box panel)
PTO ON / PTO OFF selector
(on relay box panel)
blink code emission request push-button
(on relay box panel)
coolant temperature sensor (for gauge)
EC
switching solenoid valve for oil charge/discharge
U
clogged oil filter sensor (for alarm)
F
engine coolant temperature sensor for EDC
V
oil pressure sensor (for gauge)
GG
alternator
VI
high gear box oil pressure sensor (25 bar)
GH
grid heater power relay
W
low oil pressure sensor (for alarm)
H
WI
low gear box oil pressure sensor (7 bar)
I
combustion air pressure/temperature sensor for
EDC
high coolant temperature sensor (for alarm)
X
clogged blow-by filter sensor (for alarm)
IN
injectors solenoid valve
Z
clogged fuel filter sensor (for alarm)
J
low coolant level sensor (for alarm)
85150
ECU of the EDC system
K
air filter clogging sensor (for alarm)
L
instrument panel light switch
M
MC
sensor for detecting the presence of water in the
fuel pre-filter (for alarm)
CAN - BUS converter module for digital panel
MM
electric starter motor
MP
pre-lubrication and oil transfer module
MS
IVECO MOTORS indications and alarms module
O
exhaust gas temperature sensor (for gauge)
P1
sound alarm inhibition push-button
PA
throttle position sensor
PE
PH
emergency shut-down push-button
(optional, installer’s responsibility)
grid heater
PO
pre-lubrication electrical pump
QP
main analog instrument panel
QS
secondary analog instrument panel
R1
3.3 kΩ resistor to inhibit speed input
R2
DL1 resistor
R3
alternator pre-excitation resistor
S
oil temperature sensor (for gauge)
SA
buzzer
SW2
SW3
SW4
SW5
(continues on next page)
50
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
Connectors
MAY 2006
Indicator lights
A
35 pole EDC - boat components connection
EDC
EDC malfunction
B
35 pole EDC - engine components connection
SAC
presence of water in fuel pre-filter
E
EUI injectors solenoid valve
SATA
coolant high temperature
J1
on the relay box panel for external diagnostic
tool
connection between engine wiring and interface
wire harness
SBLA
low coolant level
SBPO
low oil pressure
SCP
pre-post heating
SIFA
clogged air filter
SIFB
clogged oil vapor filter
SIFC
clogged fuel filter
SIFO
clogged oil filter
SIM
expired programmed maintenance interval
SP
pre-lubrication
SS
alternator fault
SSV
engine overspeed
JA
JA
ON SECONDARY DIGITAL INSTRUMENT PANEL
set for connection to the main digital instrument
panel
JB
ON ENGINE WIRE HARNESS
set for connection to the main analog
instrument panel or to the interface wire
harness for converter module
JC
ON MAIN ANALOG INSTRUMENT PANEL
set for connection to the engine wire harness
IVECO MOTORS indications and alarms module
JD
JD
ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE
external throttle control
JE
ON MAIN ANALOG INSTRUMENT PANEL
set for connection to the secondar y
analog instr ument panel
JE
ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE
set for connection to the main digital instrument
panel
JE
ON MAIN DIGITAL INSTRUMENT PANEL
set for connection to the secondary digital
instrument panel
JE
ON MAIN INTERFACE WIRE HARNESSE
set for connection to the alarms control unit
(for Certification Bodies)
JE1
ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE
JF
set for connection to the 2° main digital
instrument panel
relay box
JF1
relay box
JG
pre-lubrication control unit
JH
ON SECONDARY ANALOG INSTRUMENT PANEL
set for connection to the main analog
instrument panel
JH
ON MAIN DIGITAL INSTRUMENT PANEL
set for connection to the interface wire harness
for converter module
JO
converter for digital panels
Gauges
CG
revolution-counter
MI
gear box oil pressure
MO
engine oil pressure
TA
engine temperature
TI
gear box oil temperature
TS
exhaust gas temperature
V
voltmeter
Relays contained in the relay box
K1
EDC main (power supply
K2
key switch electric discharge
K3
emergency engine shut-down provision
K4
enabling start engine from engine room
K5
power supply to terminal 50 of the electric
starter motor
cranking exclusion when engine is running
K6
Fuses contained in the relay box
F1- F2
self restoring (not replaceables)
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INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
51
EDC connector B
Schema_Connettore_B
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C78 ENS M20
C78 ENT M30-M50-M55
52
INSTALLATION DIRECTIVE
MAY 2006
EDC connector A
Schema_Connettore_A2°
C78_Quadro Di Bordo C78
"!44
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INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
53
Main analog instrument panel
"!44
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3!
3!
13
INSTALLATION DIRECTIVE
* See main indicator and
control panel wiring diagram
"!44
!#
C78_Elettrico_Quadro_fly
C78 ENS M20
C78 ENT M30-M50-M55
54
MAY 2006
Secondary analog instrument panel
1.0
1.0
JE
1.0
1
1.0
2
3
4
1.0
5
6
12
7
13
8
14
1.0
1.0
1.0
1.0
0.5
0.5
15
1.0
11
1.0
9
16
17
1.0
1.0
10 11
12
18
19
20
21 22
23
1
24
1.0
2
25
3
4
26 27
5
28
6
29
7
30
8
31
9
32
33
1.0
10 11
34
35
12
1.0
47
46
45
44
43
42
41
40
39
38
2.5
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
0.5
0.5
1.0
1.0
1.0
1.0
2.5
10
36
JE1
1.0
1.0
1.0
1.0
4
3
2
1
JD
JE
JO
JB
JD
JE1
instrument panel (engine side)
external throttle control
2° main digital instrument panel
(see “Installation directive” document.)
main digital instrument panel (engine side)
converter for digital panel
Connector key:
INSTALLATION DIRECTIVE
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
9
1.0
8
1.0
0.5
7
1.0
0.5
6
1.0
1.0
5
1.0
1.0
4
1.0
1.0
3
1.0
1.0
2
1.0
1
1.0
1.0
JB
JO
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
55
CAN - BUS converter module interface wiring
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
0.5
0.5
1.0
Sk_Cablag_Convert_C78
3
4
JB
7
2
6
1
5
13
33
34
G
120
2
Connections
32
0
0
29
2
G
7
8
12
VOLT
Identifying numbering
on each wire
8
6
8
10
58 87
116
psi
145
bar
4
14
16
19
23
20
24
19
15
16
28
11
12
18
22
18
14
10
6
2
31
21
29
17
13
9
5
1
35 30 17 38 12
JD connector integrated in the rear part
of the indications and alarms module
24 20
7
3
8
4
3
INSTALLATION DIRECTIVE
10 meter long
wire harness
5
100
175 210
105
250
°F
°C
C78 ENS M20
C78 ENT M30-M50-M55
8
min
X100
40
80
56
MAY 2006
Wiring of a specific personalised instrument board
Sk Strumenti Quadri VDO C78
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
57
Wiring of the double personalised instrument board (main and secondary board)
°C
80
40
min
X100
100
175 210
105
250
°F
2
120
0
0
29
bar
4
MAIN PANEL
G
8
7
6
5
4
3
2
1
24
6
8
10
58 87
116
psi
145
28
16
32
VOLT
G
4
3
2
1
8
7
6
5
12
11
10
9
16
15
14
13
20
19
18
17
24
23
22
21
OFF ON
START
JB
JB
13
5
33
34
32
2
7
37 24 28
20
19
18
31 29
35 30 17 38 12
8
bar
°C
80
40
SECONDARY PANEL
min
X100
100
175 210
105
250
°F
G
8
7
6
5
4
3
2
1
4
6
8
10
58 87
29
116
psi
0
145
24
2
120
0
16
28
32
VOLT
G
4
3
2
1
8
7
6
5
12
11
10
9
16
15
14
13
20
19
18
17
24
23
22
21
Sk Strumenti Quadri VDO 1°+2° C78
3
*
–
+
AC2
Two-engines
installation
4
–
BAT
4
–
AC1
70
IE1
M
30
70
10
+
Single engine
installation
10
10
10
50
JB
18
MM
10
1
GG2
B+
B+
GG
1
50
MM
18 JB
30
87
85
30
M
RL
86
70
+ BAT
BAT +
BAT –
70
–
AC2
+
–
+
*
AC1
-
-
-
-
-
+ BAT
– BAT
M
50
30
MM
GG1
1
B+
AC1: Main Battery
AC2: Battery for auxiliary services
IE1: Engine 1 electrical system
IE2: Engine 2 electrical system
RL: Relay 50A max.
*: Electrical power supply for services
Key:
4
4
10
4
4
70
Sk Accum_Servizi S2
70
18
JB
IE2
C78 ENS M20
C78 ENT M30-M50-M55
10
58
INSTALLATION DIRECTIVE
MAY 2006
Supplementary services battery recharge
MAY 2006
INSTALLATION DIRECTIVE
25.C78 ENS M20 ENGINE
Due to the light supercharge pressure required, the C78
ENS M20 engine does not require the presence of the air/air
heat exchanger. The electric system is common also to other
engines of the same family, but the C78 ENS M20 engine is
differentiated by the use of specific sensors for temperature
and combusting air pressure. To connect these sensors to
the engine wiring system it is necessary to use an extension
cable connected to the H connector.
The following pages show the global wiring scheme and the
electric scheme of the connections between the EDC and
the A connector, where it is possible to identify the H1 and
H2 sensors and the relating H extension cable necessary for
the connection.
C78 ENS M20
C78 ENT M30-M50-M55
59
06_002_C
Engine wire harness
U
S
W
M
S
WI
WI
B
SI
VI
T
SI
VI
X
X
T
K
K
O
Z
A
H
C
MM
H2
J
GG
+B
GH
Figure 54
Interface wire harness
B EDC
A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor E. EUI solenoid valves - F. Engine coolant temperature sensor for EDC - H2. Combustion air pressure
PA
sensor for EDC - I. High coolant temperature sensor (for alarm) - J. Low coolant level sensor (for alarm)
PO
- K. Air filter clogging sensor (for alarm) - M. Sensor for detecting the presence of water in the fuel pre-filter
EC
(for alarm) - O. Exhaust gas temperature sensor (for gauge) - H1. Intake air temperature sensor for EDC
A EDC
- S. Oil temperature sensor (for gauge) - T. Coolant temperature sensor (for gauge) - U. Clogged oil filter
sensor (for alarm) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - X. Clogged
blow-by filter sensor (for alarm) - Z. Clogged fuel filter sensor (for alarm) - EC. Switching solenoid valve for
oil charge/discharge - GG. Alternator - GH. Pre-heating power relay - JB. Instrument panel connection wire harness - JE. Alarms control unit (for Certification Bodies) - JF, JF1. Relay
box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle position sensor - PO. Pre-lubrication electrical pump - SI. Gearbox oil temperature sensor VI. High gearbox oil pressure sensor (25 bar) - WI. Low gearbox oil pressure sensor (7 bar) - * Sensor H1/H2 wiring harness.
V
W
V
E
I
H1
C78 ENS M20
C78 ENT M30-M50-M55
JB
JA
JG
F
*
– BATT
+ BATT
JE
JF1
JF
60
INSTALLATION DIRECTIVE
MAY 2006
WIRE HARNESS C78 ENS M20 ENGINE
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INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
61
C78 ENS M20 ENGINE Wiring diagram EDC connector A
Schema_Connettore_A2° ENS
62
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
MAY 2006
INSTALLATION DIRECTIVE
C78 ENS M20
C78 ENT M30-M50-M55
63
26.APPENDIX
Page
���������������������������������
LUBRICATING OIL TRANSFER MODULE
64
PRE-LUBRICATION AND OIL TRANSFER MODULE
64
STARTING AID
ELECTRONIC CONTROL GOVERNING LEVERS 66
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
68
ELECTRICAL DIAGRAMS FROM THE SAFETY SYSTEM 82
METHOD OF USE OF THE SAFETY SYSTEM INTERFACE
85
65
64
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
LUBRICATING OIL TRANSFER MODULE
MAY 2006
PRE-LUBRICATION AND OIL
TRANSFER MODULE
Figure 1
Figure 2
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1
04_036_C
1
2
04_037_C
1. Oil intake/exhaust control. 2. Switching solenoid valve control.
1. Oil intake/exhaust control.
Lubricating oil transfer operations are simplified by the
presence of an electrical control system connected to the JG
connector of the interface wiring harness. Manual control for
transfer operations is positioned on the front panel unit. For
safety reasons, control is enabled only with the key switch in
the “OFF” position
%6
/.
The module is connected to the JG connector of the
interface wiring harness.
The task of pre-lubricating the engine’s internal components
is managed and controlled by the electronic circuit of the
module when the key switch is placed in “ON” position. The
operation can also be conducted by acting manually, with the
key switch in the “OFF” position, only on the oil intake/exhaust
push-button positioned on the unit. If the push-button is
placed for a few seconds in the “DISCHARGE” position, the
filters and the internal engine ducts will be filled.
Lubricating oil transfer sequence:
1. Place the “EV-OFF/ EV-ON” (2) switch in the “EV-ON”
position, thus energizing the switching solenoid valve
to place the emptying/filling junction in communication
with the electrical pump and with the oil sump.
2. Use the “CHARGE/DISCHARGE” (1) push-button to
complete the desired operation.
3. Place the “EV-OFF/ EV-ON” switch back to the “EV-OFF”.
Figure 3
2
1
3
80836
1. One way valve - 2. Switching solenoid valve (EC) 3. Electrical pump (PO).
MAY 2006
INSTALLATION DIRECTIVE
STARTING AID
Figure 4
1
3
2
05_061_C
1. Specific junction pipe - 2. Electrical grid heater 3. Power relay.
When the engine is to be used at temperatures lower than 15 °C, an electrical grid heater is installed, (PH). Its operation
is controlled by the electronic unit of the injection system.
The element will be placed between the turbocharger and
the air-water heater exchanger (after-cooler), replacing the
terminal part of the intake duct. Connection to the electrical
wiring provided is achieved interposing a specific relay (GH)
and connection to the power supply grid, (see Chapter 24)
For use at temperatures lower than -25 °C, adoption of an
auxiliary preheating system is recommended.
C78 ENS M20
C78 ENT M30-M50-M55
65
C78 ENS M20
C78 ENT M30-M50-M55
66
INSTALLATION DIRECTIVE
MAY 2006
ELECTRONIC CONTROL GOVERNING LEVERS
For version with analogue instruments
Figure 5
JC
JC
MAIN
INSTRUMENT
PANEL
JE
JH
JE
SECONDARY
INSTRUMENT
PANEL
JH
MAIN
CUSTOMIZED
INSTRUMENT
PANEL
JB
4
SECONDARY
CUSTOMIZED
INSTRUMENT
PANEL
JB
JB1
ENGINE
EQUIPMENT
3
JD
JO
CONVERTER
MODULE
A
EDC
2
JB
JB
B
JA
JF
05_041_C
1
JF1
RELAY
BOX
BATTERY
1. Engine wiring connector for connection of the control panels - 2. Interface wiring for the installation of electronic control levers 3. Connector for the connection of the exterior governor - 4. Conversion module for codifying the signals of the exterior governor.
This option offers the chance, in alternative to that prepared
for the engine, electronic management of the engine rev.
speed.
Installation must take place inserting the interface wiring (2)
between the engine and the wiring of the control panels
to which the exterior governor will be connected and the
electronic module for converting the electric signals from the
lever into electronic information recognisable by the EDC
central unit.
If this solution is used the accelerator position sensor
installed on the engine will remain electrically connected but
unused and the EDC central unit will manage the engine
speed according to the power signal applied to the JD connector terminals (3).
If the electronic acceleration system fails, it will be possible
to manage the engine rev speed in an emergency, by disconnecting the JD connector and mechanically activating the
lever of the sensor installed on the engine.
INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
67
Interface wiring
Figure 6
3
1
4
2
05_043_C
1. Connector JB1 - 2. Connector JD - 3. Connector JO - 4. Connector JB.
The JB connector will be coupled to the JB connector of the
engine wiring, while the JB1 connector will be coupled to the
JB connector of the wiring connecting the control panel.
The converter module will be connected to the JO
connector while the JD connector will be available to make
the connections to the electronic governance system unit.
Connector JD
Figure 7
PIN 1
05_042_C
PIN 3
The connection requires a METRI-PACK 150 three-way connector with male terminals.
PIN
Wire code
(U) Voltage
Interpreted function
Imax
1
7731
+B with key in ON position
Electronic throttle enabling
0,5 A
2
0000
0 V - (Ground)
Common reference terminal
-
0 to 0,2 V
Poor value. EDC recognises a fault
-
0,2 to 0,5 V
Accelerator at minimum level
0,5 to 4,5 V
Accelerator min. to max., U function
-
4,5 to 4,8 V
Accelerator at maximum level
-
4,8 to 5 V
Excessive value. EDC recognises a fault
3
5584
NOTE: The voltage values for the rotation of the motor must be between 0.2 and 4.8 V. Values below 0.2 V or above 4.8 V
generate the recognition of a fault and consequent deactivation of the function.
68
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Unit installed
Figure 8
electronic
RPMx100
HOURS
V
oC
oF
1
2
bar
3
4
5
6
electronic
RPMx100
HOURS
V
oC
bar
oF
7
8
9
10
11
12
05_045_C
1. Fuel filters which can be replaced when the engine is rotating - 2. EDC electronic unit - 3. EDC auxiliary unit - 4. Acoustic alarm 5. Warning light - 6. Control panel - 7. Electronic monitoring and alarm management unit - 8. Connector JC - 9. Connector JS 10. Emergency engine cutout button - 11. Oil filters which can be replaced when the engine is rotating 12 . JB, JC wiring, specific for homologated systems.
The electric and electronic equipment of engines requiring
a conformity declaration issued by the Certifying bodies
comprises, in addition to that provided for the standard
configuration, a series of components for the measurement,
processing and recording of engine operating parameters.
The aim of the system is to emit acoustic and optic alarms
indicating that set limits have been exceeded.These limits will
be programmed in accordance with different homologation
requirements and may, when necessary, cut-out the engine
in an emergency.
The system is made up of an electronic unit for the acquisition, display and recording of events occurring while the
engine is running, using a series of sensors for this specific
purpose; the alarm signals produced by the Unit will be emit-
ted by acoustic and optic alarms installed by the Yard or by
the Fitter. For boats equipped with only one engine, to offer
a higher level of safety during navigation, it is necessary to
install a second auxiliary EDC unit alongside the EDC engine
controlling electronic unit to enable rapid replacement in the
event of a failure.
MAY 2006
INSTALLATION DIRECTIVE
Electronic monitoring unit
C78 ENS M20
C78 ENT M30-M50-M55
69
Sensors
Figure 9
05_046_C
This unit monitors the operation of the specific safety system.
With its computerised logic it acquires the electric signals
issued by the sensors linked up to it, converting them into
physical parameters of temperature, pressures and revs. This
data is displayed on the liquid crystal display and processed
according to the set parameters to draw attention to any
approach towards the critical limits programmed and alarms
should these limits be exceeded. Equipped with a built-in
clock/calendar function, it is able to record and memorise the
last 1000 alarms issued and the values of about 1000 samples of signals from sensors. It also issues electric signals to
activate the acoustic and luminous alarm signals as requested
by the homologation standards.
Some sensors produce electric signals with a value proportionate to their physical entity
(temperature, pressure or rev. speed), allowing the electronic
unit to monitor the engine operation to measure tendencies
to approach the critical values; others indicate, with commutation by an electric switch, that a set pressure or temperature limit has been exceeded, generating an immediate
“alarm” signal.
Given the high level of safety required, many of the monitoring system sensors are connected exclusively to this
system; this means that the engine equipment comprises
several components to measure the same physical entity but
dedicated to different systems. In order to obtain an effective control of the integrity of the wiring, there are several
resistors, connected in series with or parallel to the connection lines of the main sensors, which are used to recognise
the conditions of cut-out or short-circuit of the connectors.
After installation it is best to check that these components
are correctly connected to the wiring (Figure 10).
Figure 10
05_047_C
- Line balancing element -
In observance of the provisions of the certifying bodies, the
system equipment includes the presence of solutions which
make it possible to check the efficiency of the monitoring
functions and measure the relative parameters. By way of
example, there is a valve which cuts off the oil in the connection of the “Low oil pressure” (WA) sensor, in order to test
the efficiency of the related function and an unused extension cable (BA1 – BA1U).
C78 ENS M20
C78 ENT M30-M50-M55
70
INSTALLATION DIRECTIVE
Wiring
MAY 2006
Electrical starting motor
The presence of the Safety system in question in the electrics
of the boat requires the use of specific
wiring unlike standard wiring.
The connection of the monitoring unit and the components
connected to it are made on the JB-JC wiring used for the
connection of the main control panel to the engine wiring.
The electric connection of the system devices is made using
connectors. Every multipolar connector is polarised to prevent inversion and is dedicated to a particular function.
The electric diagrams, referred to the identification of the
inputs/outputs of the connectors of the
monitoring unit may vary following the programming of particular features of the application.
Figure 12
2
1
3
caution
To obtain the engine cut-out function by the JS monitoring
unit it is necessary to unite the two JE connectors on the
JB-JC wiring and the engine wiring.
1
2
Insulated pole power network (optional)
Figure 11
Equipment power supply
3
"
3
,
)'
05_109_C
1. Excitation coil command (50) - 2. Positive power
pole (+B) - 3. Negative supply pole (-BATT).
n"
05_113_C
The power network may be carried out in order to avoid
using both the structure of engine and the structure of the
hull (if this is metallic). For this purpose the electrical starting
motor and the alternator required for this equipment are
characterized by the presence of the terminals for electrical
connections both with the positive and with the negative
pole of the battery.
Technical characteristics:
-
Supply nominal voltage 24 V
-
Absorbed power 5 kW
-
Terminal connection “50” M5 x 0,8 tightening couple 2-2,5 Nm
-
Terminal connection “+B” M10 x 1,5 tightening couple 14,7-17, 7 Nm
-
Terminal connection “-BATT” M8 x 1,25 tightening couple 9,8-11,8 Nm
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
Alternator
71
Auxiliary EDC electronic unit
This is fastened to the side of the unit in use to enable rapid
replacement in the event of a failure.
Should it be necessary to replace it, proceed as follows:
Figure 13
o stop the engine;
o wait 10 seconds, then disconnect the terminal clamps
from the battery;
o roceed as follows to extract and reinsert the connectors.
Figure 14
+B
80802A
REMOVING ECU CONNECTORS
-B
S
05_112_C
IG
L
Technical characteristics:
-
Nominal voltage 24 V
-
Nominal voltage 90 A
-
Terminal connection “+B” M8 x 1,25
tightening couple 12,5 Nm ± 20%
-
Terminal connection “-B” M6 x 1
tightening couple 6,0 Nm ± 20%
+B. (24 V)
-B. (0 V)
S. (Sense)
Power supply output terminal
Power supply output terminal
Reference voltage of battery charge status
(connected to +B terminal or to be connected to the positive pole of the battery in
case of remote installation of the battery);
IG. (Ignition) Regulator enabling signal (connected to voltage +, driven by key switch);
L. (Lamp)
Power supply voltage of recharge/alarm indicator light located on the panel.
80802B
INSERTING ECU CONNECTORS
At the end of the operation:
o reconnect the battery terminal clamps;
o start up the engine to run an efficiency test.
C78 ENS M20
C78 ENT M30-M50-M55
72
INSTALLATION DIRECTIVE
MAY 2006
Synoptic
Figure 15
BA
JSA
JSB
MONITORING
UNIT JS
JSC
JSD
JSE
JSF
BA1
BA1U
IA
IR
WA
IR1
WVA
BAR
VA
BAD
VCA
WR
JEM
WR1
FA
JC
MAIN
INSTRUMENT
JE
PANEL
JC
JE
SECONDARY
INSTRUMENT
JH
PANEL
JH
ENGINE
EQUIPMENT
A
EDC
ELECTRONIC
UNIT
B
EDC
ELECTRONIC
AUXILIARY
UNIT
JB JB
1
JA JA
2
JE
JE
3 JF
JG
JF1
RELAY
box
4
batterY
05_032_C
1. Specific wiring unit for installation of instrument panel and monitoring unit - 2. Engine wiring 3. Interface wiring - 4. Power network.
DESTINATION OF CONNECTORS OF THE SAFETY SYSTEM (excluding standard supply connectors)
BA. Drive shaft sensor - BAD. Diode for BA - BAR. Resistor for BA - BA1, BA1U. Connectors of the extension cable for engine rev.
speed - FA. Acoustic and luminous alarms - IA. Coolant temperature sensor - IR. Parallel resistor for IA - IR1. Series resistor for IA JE. Connector for cutting out agitated engine - JEM. Connector for cutout switches in the case of an emergency and motor cutout
from the engine room - JS. Electronic monitoring unit - JSA, JSB, JSC, JSD, JSE, JSF. Connectors for monitoring unit - VA: Engine oil
pressure sensor - VCA. Fuel pressure sensor - WA. Engine oil low pressure sensor - WR. Parallel resistor for WA WR1. Series resistor for WA - WVA. Coolant pressure and low pressure sensor.
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
73
Wiring
Figure 16
F
JF1
J
GH
E
JF
I
P
W
T
JG
T
H
W
VI
+ BATT
S
V
VI
S
V
A
SI
SI
U
– BATT
JA

JA
K
WI
GG
C
Z
K
WI
M
PA
X
O
PO
+B
X
B
EC
MM
EJ
JE
JE
A B

JB
JSB
JSC
JB
IR
IR1
JEM
JC
IA
VA
JC

A EDC
VA
WA
WVAG
WVA
WR
WR1
JSE
QP
BAR
BAD
JSF
WVAA
WVAS
electronic
RPMx100
FA1
FA2
HOURS
VCA
05_033_C
JSD
MONITORING UNIT
B EDC
JSA
BA1U
VCA
V
BA1
oC
oF
BA
bar
FA3
FA4
DESTINATION OF CONNECTORS OF THE STANDARD ENGINE (excluding safety system connectors)
A. Fuel temperature sensor for EDC - B. Drive shaft sensor for EDC - C. Camshaft sensor - E. EUI solenoid valves F. Engine coolant temperature sensor for EDC - H. Combustion air pressure sensor for EDC - I. High coolant temperature J. Low coolant level sensor - K. Air filter clogging sensor - M. Sensor for detecting the presence of water in the fuel pre-filter O. Exhaust gas temperature sensor - P. Intake air temperature sensor for EDC - S. Oil temperature sensor - T. Coolant
temperature sensor - U. Clogged oil filter sensor - V. Oil pressure sensor - W. Low oil pressure sensor - X. Clogged blow-by
filter sensor - Z. Clogged fuel filter sensor - EC. Switching solenoid valve for oil charge/discharge - GG. Alternator GH. Pre-heating power relay - JA. Interface wiring - JB. Instrument panel connection wire harness - JE. Alarms control
unit (for Certification Bodies) - JF,JF1. Relay box - JG. Pre-lubrication control unit - MM. Electric starter motor - PA. Throttle
position sensor - PO. Pre-lubrication electrical pump - SI. Gear box oil temperature sensor - VI. High gear box oil pressure
sensor (25 bar) - WI. Low gear box oil pressure sensor (7 bar).
C78 ENS M20
C78 ENT M30-M50-M55
74
INSTALLATION DIRECTIVE
MAY 2006
Monitoring unit
Figure 17
200
150
134
131
(The picture shown is purely indicative)
JSA
JSB
1
11
JSD
11
JSE
1
Dimensions in mm
1
11
134
JSC
1
Drilling template 183 mm x 135 mm
JSF
1
1
11
11
11
182
The total integration of the system with the engine equipment means that the installation procedures already listed
for the standard version are joined by the placement of the
electronic monitoring unit inside a console or dashboard,
05_031_C
which can be fitted outside, as well as the preparation of the
alarm management components pursuant to the homologation standard: acoustic and luminous signals, cut-out buttons.
GENERAL FEATURES AND REFERENCE STANDARDS
Power supply
12/24 V d.c.
Current absorption
500 mA (approx.)
Performances in compliance with
*
R.I.N.A. “Regulation for automation systems” - Section E
Functional, climatic, vibration and EMC tests in accordance with * IEC 945 “Maritime navigation and radio-communication
equipment and system - General requirements - Methods of
testing and required test results”
*
The test reports are supplied by request
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
75
Function of JS connection terminals
pin
1
2
3
4
5
6
7
8
9
10
11
JSA
Thermocouples
JSB
Supply
Exhaust fumes temperature
Exhaust fumes temperature
-
JSC
CAN network
Supply 12/24 V (+)
Supply 12/24 V (+)
Mass (-)
Mass (-)
N.C. relay 1 - Acoustic signaling(2)
Mass (-)
N.O. relay 1 - Acoustic signaling
N.C. relay 2 - light signal(2)
Mass (-)
N.O. relay 2 - light signal
CAN (H)
CAN (L)
GPS - NMEA 0183(2) protocol
Echo sounder - NMEA 0183(2) protocol
GPS/Eco sounder(2) Mass (-)
-
NOTE: one of the terminals of the following components is connected to the electric mass: VCA, WVA(G), VA, WA, BAD, IA, JE.
pin
JSD
Sensors
JSE
Signals
JSF
Signals and alarms
1
2
3
4
5
6
7
Gear box oil pressure(2)
Coolant pressure (WVAS)(1)
Engine oil pressure (VA)(1)
Sea water circuit pressure(2)
Engine oil temperature (S)(1)
Low engine oil pressure (WA)(1)
Water in the pre-filter (M)(1)
Engine revs (EDC)(1)
Engine revs (BA)(1)
Low coolant level (J)(1)
Low gear box oil pressure(2)
Air filter blockage (K)(1)
Low coolant pressure (WVAA)(1)
Fuel filter blockage (Z)(1)
8
Fuel pressure (VCA)(1)
Engine revs (BAR - BA)(1)
9
10
11
EDC (failure signal)(1)
High coolant temperature (IA)(1)
Mass (-)
Oil filter blockage (U)(1)
Engine cut-out (pin 4 JSF)
1) Code of the component or sensor to which the terminal is connected
2) The terminal is prepared but not connected with the wiring.
3
2
1
6
5
4
9
8
7
11
10
05_051_C
CONNECTORS JS SEEN FROM WIRING SIDE
N.C. Cut-out relay 3(2)
12/24 V (+) common relay 3 stoppage
N.O. Cut-out relay 3 (JE)(1)
Alternator recharge (L)(1)
Pre-lubrication (opt.)
Imp. Voltage signal 12/24 V (+)
Engine stopping circuit damaged
(JEM - JE)(1)
-
C78 ENS M20
C78 ENT M30-M50-M55
76
INSTALLATION DIRECTIVE
MAY 2006
Position of the safety system sensors
Figure 18
1
8
7
2
3
4
2
5
05_048_C
6
1. Engine rotation speed and EDC system damaged signal - 2. Oil temperature analogical sensor - 3. Low oil pressure sensor (WA) 4. Oil filters congestion sensor - 5. WA efficiency test tap - 6. Oil pressure analogical sensor (VA) - 7. Cooling liquid pressure and low
pressure analogical sensor (WVA) - 8. Cooling liquid high temperature sensor (IA).
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
77
Figure 19
9
2
1
8
3
7
4
6
5
05_049_C
1. Fuel pressure analogical sensor (VCA) - 2. Engine cooling liquid level sensor - 3. Battery recharge signal - 4. Fuel filter congestion
sensor - 5. Presence of water in the fuel sensor - 6. Engine rotation speed sensor (BA) - 7. EDC engine rotation speed sensor 8. Air filter congested signal - 9. Exhaust gas or thermocouple temperature analogical sensor (O).
C78 ENS M20
C78 ENT M30-M50-M55
78
INSTALLATION DIRECTIVE
MAY 2006
Coolant high temperature sensor (IA)
Drive shaft rev. speed sensor (BA)
Figure 22
Figure 20
05_052_C
This is of the inductive type and when the engine is running
it produces a sinusoidal alternate signal the value of which
increases in proportion to the engine rev. speed. The sensor
BA enables the measurement of the engine rev- speed using
the passage of the holes positioned in a radial arrangement
on the outer circumference of the flywheel. The presence of
the resistor BAR and the diode BAD can alter the value of
the sensor resistance if measured on the JSE connector of
the monitoring unit.
Resistance value at 20°C
220 ± 20 Ω
Poles
Isolated
Exhaust gas temperature sensor (O)
05_053_C
Figure 21
Thermometric switch which supplies the information for the
engine high temperature alarm.
04_260_N
NiCr-Ni thermocouple sensor with insulated poles, providing the signal for the analog indication of exhaust gas
temperature.
Operating power
Condition at ambient
temperature
Commutation temperature:
Poles
Temperature
Voltage
°C
mV
100
4,10
200
8,13
300
12,21
400
16,40
500
20,65
600
24,91
700
29,14
800
33,30
900
37,36
from 6 V to 24V
normally open
°C
Isolated
Electric diagram:
05_054_C
INSTALLATION DIRECTIVE
MAY 2006
Engine oil low pressure sensor (WA)
C78 ENS M20
C78 ENT M30-M50-M55
79
Engine oil pressure sensor (VA)
Figure 23
Figure 24
04_237_N
05_055_C
Switch activated by the fluid pressure, which supplies the
information for the engine lubricant low pressure alarm.
Operating power
from 6 V to 24V
Component which supplies a rheostatic signal for the analogical indication of the fluid pressure.
Operating power
from 6 V to 24 V
Setting field from
0 bar to 10 bar
normally closed
Resistance value at 0 bar
10 Ω +3/-5 Ω
Commutation pressure:
0,4 / 0,8 / 1,2 bar
Resistance value at 2 bar
52 ± 4 Ω
Poles
Isolated
Resistance value at 4 bar
88 ± 4 Ω
Resistance value at 6 bar
124 ± 5 Ω
Maximum value of resistance
184 Ω
Operating temperature
from - 25°C to +100°C
Poles
Isolated
Condition at ambient pressure
Electric diagram:
05_054_C
Coolant oil temperature sensor (S)
Figure 25
05_114_C
Resistor with negative temperature coefficient, providing the
signal for analog temperature indication.
Operating voltage
6 V to 24 V
Calibration range
0°C to 120 °C
Resistance value at 90°C
51,2 ± 4,3 Ω
Poles
isolated
80
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
Refrigerating liquid pressure and low
pressure sensor (WVA)
MAY 2006
Fuel pressure sensor (VCA)
Figure 27
Figure 26
04_237_N
05_056_C
This integrates a component which supplies the rheostatic
signal for the analogical indication of the pressure and a
switch activated by the pressure which supplies the information for the engine coolant low pressure alarm.
Operating power
12 / 24 V
Rheostat
Field of intervention
from 0 to 5 bar
Stamping of the terminals
M-G
Wiring terminals
WVAG - WVAS
Switch
Condition at ambient pressure
normally open
Closing pressure
≥ 0,25 bar
Stamping of the terminals
M - WK
Wiring terminals
WVAG - WVAA
Component which supplies the rheostatic signal for the analogical indication of the fluid pressure.
Operating power
12 / 24 V
Field of intervention
from 0 bar to 10 bar
Poles
Isolated
INSTALLATION DIRECTIVE
MAY 2006
Line balancing components
C78 ENS M20
C78 ENT M30-M50-M55
Engine cut-out control buttons (JEM)
Figure 28
Electric diagram:
Figure 29
EMERGENCY
05_047_C
2
Electric diagram:
05_058_C
05_060_C
Code
IR
1,5 kΩ 1W
IR1
470 kΩ 1W
WR
1,5 kΩ 1W
WR1
470 kΩ 1W
BAR
4,7 kΩ 1W
The balancing resistor R has a value of 10 kΩ.
Electric diagram:
05_059_C
Code
BAD
STOPPAGE DURING EXCITATION
Resistor features
Diode code
1N 4007
81
82
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
ELECTRICAL DIAGRAMS FROM THE SAFETY SYSTEM
Code of components of the standard version
Code of components of the safety system
A
Fuel temperature sensor for EDC
BA Drive shaft sensor
B
Drive shaft sensor for EDC
BAD Diode for BA
C
Camshaft sensor
BAR Resistor for BA
E
EUI solenoid valves
F
Engine coolant temperature sensor for EDC
BA1, BA1U Connectors of the extension cable for engine rev. speed
H
Combustion air pressure sensor for EDC
I
High coolant temperature
J
Low coolant level sensor
K
Air filter clogging sensor
M
Sensor for detecting the presence of water in the fuel pre-filter
O Exhaust gas temperature sensor
P
Intake air temperature sensor for EDC
S
Oil temperature sensor
T
Coolant temperature sensor
U
Clogged oil filter sensor
V
Oil pressure sensor
W Low oil pressure sensor
X
Clogged blow-by filter sensor
Z
Clogged fuel filter sensor
EC Switching solenoid valve for oil charge/discharge
GG Alternator
GH Pre-heating power relay
JB
Instrument panel connection wire harness
JE Alarms control unit (for Certification Bodies)
JF, JF1Relay box
JG
Pre-lubrication control unit
MM Electric starter motor
PA
Throttle position sensor
PO Pre-lubrication electrical pump
SI
Gear box oil temperature sensor
VI High gear box oil pressure sensor (25 bar)
WI Low gear box oil pressure sensor (7 bar)
FA Acoustic and luminous alarms
IA
Coolant temperature sensor
IR
Parallel resistor for IA
IR1 Series resistor for IA
JE Connector for cutting out agitated engine
JEM Connector for cutout switches in the case of an emergency and motor cutout from the engine room
JS
Electronic monitoring unit
JSA, JSB, JSC, JSD, JSE, JSF
Connectors for monitoring unit
VA Engine oil pressure sensor
VCA Fuel pressure sensor
WA Engine oil low pressure sensor
WR Parallel resistor for WA
WR1Series resistor for WA
WVACoolant pressure and low pressure sensor
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
83
Wiring unit JB - JC
MS
CG
QP
20
CA
30
30
TA
MO
C
C
V
JH
4
10
JE
L+
3
2
1
JD
2
8
4
9
6
7
9
1
7
SSV
SIFO
SP
SIFB
SIFC
SS
SIFA
10 19 15 13
8
2
3
17 18
16 12 11 14
6
20
JD
SA
P1
AQ
JC 1
5
L
L-
JH
4
50
0 0 0 1
AS
10
SBLA
0
JE
4
40
SCP
50
SAC
10
15
EDC
SATA
SBPO
X100
40 36 39 14 15 16 13
5
10 11
JC 33
44 27 41 26 25 21 42 22 43 23 45 46 47
32
34
3 17 20 24 28 29 37
19 18 30 38 12 35 31
JC
JEM 1
JEM 2
JEM 3
JEM 4
JS
BA1 A
1
BA1 B
5
BA1U B
BA1U A
1
JSA
2
VCA
3
VCA
4
7
FA 2
JSB
8
FA 1
P
FA 3
10
FA 4
11
WVAA
1
WVAG
2
JSC
WVAS
VA
2
VA
3
5
470 Ω
WR1 1
6
WR1 2
7
JSD
8
1,5 kΩ
WR 2
9
WR 1
10
11
WA 1
WA 2
P
WA 3
1
WA 4
2
3
BA A
5
BA B
6
JSE
7
BAD A
BAD K
8
10
11
BAR 1
4,7 kΩ
BAR 2
3
IR1 1
IR1 2
470 Ω
4
5
6
1,5 kΩ
IR 2
7
IR 1
8
JSF
IA 1
IA 2
T
IA 3
JE 1
IA 4
JE 2
JE 4
1
JB
2
4
8
28 22
9
6
7
40 36 39 14 15 16 13
5
10 11
JB 33
JA
1
44 27 41 26 25 21 42 22 43 23 45 46 47
A
32
34
JA
O
NORMAL
ENGINE
ROOM
F2
30 11
B
WI
VI
19 18 30 38 12 35 31
JF
JB
13
JA
6
JG
SI
JA
B
26
D1
SW1
3 17 20 24 28 29 37
JF
28
K2
JF1
SW1
"A"
K3
14
13
D9
7
2
D10
D2
K5
SW2
"STOP"
6
1
+
BATT
JF1
JF2
15
9
10
21
B+
16
+
3
D12
JA
M A B
AC
1
-
6
-
2
3
4
15 32 33 34
5
12 11
3
6 18
T
BATT
JA
V
S
1
C
3
2
1
1
A
2
M
GG S IG L
GG
B+
K
I
W
B
3
J
1
X
2
U
A
Z
2
B
85150
1
C78 unità monitor omolog
-
+
4
4
C78 Conn_B omolog
9
8
6
5
*%
BAT
-
AC
+
50
7
D12
K5
JF
JA 22
26
JB 8
7
JA
1
M
30
$
F2
16
15
JF1
50
$
+
MM
JF 11
15
JC
25
JC 8
2
JB
JA
JF
JF1 JF1
BAT
CA
30
28
JF1
2
30
14
13
7
2
1
70
D9
JF 16
!
JA
JB
*
-
R
1
JA
JF
15 25 29 34
JA 5 12
JF 18 31
9 10 21
D10
16
32
14
33
9
$
35
10
25
11
-
15
B
F
E V
D8
J1
JD 2
5
JB 13
11 12 24 13
9
5 27
18
6
JB 12
JC 12
JD 3
$
*&
7
29
3
JA
JF
PA
*"
STOP
DL1
2
$
$
*!
*&
*3&
*3%
*3&
E C A B D
*%
*#
2 10
START
!1
*%-¬
SW5
SW2
*#
*%-
85150
4 10 17 35 23 16 1
JA 3
JF 3 4 15 16
$
$
$
$
SCP EDC
4
JB 38
JC 38
JA
26
3
JF
K1
28
17
A
JA 23 24 29 27 18 6 20
D
17
C
F1
JF 23 36 32 22 20 12 27
JB 11
JB 10
T U
JB
JA
JF
SW4
13
K3
+
A
ENGINE
ROOM
K2
B
37
SW3
$
NORMAL
$
&
*&
*"
*!
1
2
GH
*#
*%-
JG
*"
1 12
PH
4
7
4
3 2
9 10
GG
S IG L
K6
8
JA 2
M
PO
30
2
1
GG
17
JA
R3
D3
3 11 5
JA
JB 18
JC 18
D18
6
13
37
37
33
EC
B
A
JA 14
JF
MP
10
C78 ENS M20
C78 ENT M30-M50-M55
50
10
10
84
INSTALLATION DIRECTIVE
MAY 2006
EDC system – connector B
INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
85
METHOD OF USE OF THE SAFETY SYSTEM INTERFACE
The following information relates to the method of use of
the system in the configuration which is considered to be the
IVECO MOTORS standard. Information concerning functions which require connection to external systems such as
echo sounders and GPS, which are outside the safety system,
are voluntarily explained briefly. The programming method
which must be carried out by the Supplier or by the Assistance Service technician is not explained. For all the information which are not contained in this document, please refer
to the manuals issued by the Supplier.
caution
The system is supplied programmed to suit the homologation instructions arranged; every need linked to different
programming of the operating characteristics will be met
by the information presented by the Constructor with
specific documentation. Please remember that the settings, allowed to adapt the system to different installations,
will only be possible after the system password has been
entered.
Monitoring
The monitoring interface enables a constant verification of
the mechanic parameters required by the homologation
norms so that it is possible to quickly identify the arousal of
an anomalous condition. The information contained in the
unit memory also enables the analysis of the events relating to the period preceding the survey. If there is an alarm
status, an acoustic signal is emitted and the box containing
the anomalous parameter data is visually highlighted through
a flashing border.
The function of the keys changes depending on the different
displays.
Basic operations
o Press the keys “<<” and “>>” to display the sequence of
the pages containing the information relating to all the
monitored parameters, including maintenance rates and
optional information (see the relating figures).
The IVECO MOTORS standard configuration requires the
detection of the following data:
o Pressure of engine cooling liquid (FRESHWATER PRESS)
o Low lever of engine cooling liquid (LOW WATER LEVEL)
o Low pressure of engine cooling liquid (FRESHWATER LOW P)
o Excessive temperature of engine cooling liquid (HIGH WATER TEMP)
o Pressure of engine lubricating oil (OIL PRESS)
o Absence of engine lubricating oil pressure (LOW OIL PRESS)
o Temperature of engine lubricating oil (OIL TEMP)
o Oil filter blocked (OIL FILTER CLOG)
o Presence of water in fuel (WATER IN FUEL)
o Fuel pressure (FUEL PRESS)
o Fuel filter blocked (FUEL FILTER CLOG)
o Injection system failure (INJECT WARNING)
o The battery is not recharging (BATTERY WARNING)
o On going pre-lubrication (PRELUBRICATING)*
o Power System Tension (VOLTMETER)
Figure 30
o Exhaust gas temperature (EX GAS TEMP)
o Engine rotation speed from EDC system (ENGINE E)
o Engine rotation speed from sensor (ENGINE S)
o Engine rotation speed sensor damaged (PICK-UP L FAULT)
1
o Engine stopping circuit damaged (MAN STOP L FAULT)
2
6
3
o Automatic engine stopping circuit damaged (AUTOSTOP L FAULT)
o Air filter blocked (AIR FILTER CLOG)
o Gear oil pressure (GEAR OIL PRESS)*
o Absence of pressure in the gear oil (LOW GEAR OIL P)*
5
4
05_035_C
1. Analogue indicators in the form of bars or circles with
reference to the parameter, value and unit of measurement 2. Recognition of the pre-set alarm limits - 3. Page number 4. Membrane keys - 5. luminous indicators - 6. Key functions.
o Sea water pressure (SEA WATER PRESS) *
*) Information given only in the presence of the relating
parts.
The setting of the alarm threshold must be carried out by
the Technical Assistance Service personnel and requires the
inputting of a password.
86
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
Video mode setting
MAY 2006
Figure 32
The interface performances enable the modification of the
brightness, the contrast and the image presentation mode,
which is characterized by the inversion of the day/night.
1
2
o Press the “MENÚ” key to display the fast choice window.
o Press the keys “<<” and “>>” to highlight the display
mode to be regulated: “BRIGHTNESS”, “CONTRAST”,
DAY/NIGHT”.
o Press the “OK” key to confirm your choice.
o Modify the parameter setting using the “<<” and “>>”
keys
4
o Press the “OK” key again to confirm.
o Press the “CLR” key to exit the “MENU”.
3
Advanced operations
05_126_C
1. Parameter displayed - 2. Outside the stairs and measurement
unit - 3. Period selection key (last 15 minutes, 1 hour, 6 hours,
24 hours) - 4. Displayed duration period.
Figure 31
o “SAVE”: this enables the recording of the values of the
parameters detected by the system in specific moments
of the system working. Recording is carried out when
the “OK” is pressed. The following pressures cause other
data acquisitions. The recorded values can be shown in
all the set modes.
05_124_C
The values of the monitored parameters can be shown in
different ways, including a diagram showing their evolution
over a period of time.
To chose the display mode, do as follows:
o Press the “MENÚ” key and display the fast choice window.
o Use the “<<” and “>>” keys to select the “DATALOGGER” option inside the window.
o Press the “OK” key to confirm and display a second
window containing the options which can be chosen.
o To select the required display mode use the “<<” and
“>>” keys.
o Press “OK” to confirm.
Modalità di visualizzazione
o “GRAPHICS”: this displays the evolution of the parameters value over time; the “ZOOM” key enables the
modification of the time period shown on the display.
o Press the “<<” and “>>” keys to display the diagrams
relating to the different parameters.
o Press the “CLR” key to exit form this mode.
o “AUTO REC.”: this choice enables the modification of
the data recording mode. It is not possible to carry out
modifications.
o “HOURCOUNTER”: this enables the management of
the effective propeller/s movement hours; the data is
displayed, as hours (ENGINE) or statistics (STATISTIC)
only after inputting the correct password. This data can
be used by the Assistance Centres Personnel to add just
the programming of the maintenance intervals. From
this mode it is possible to select the option “SERVICE
RESET”, which is explained in the paragraph: “Maintenance rates monitoring”.
o “FUELCOUNTER”: (not programmed).
o “SERVICE ONLY”: this is used only for the programming
which must be carried out by the personnel of the Technical Assistance Service and requires the inputting of a
password.
INSTALLATION DIRECTIVE
MAY 2006
C78 ENS M20
C78 ENT M30-M50-M55
87
Maintenance rates monitoring
Maintenance intervals resetting
This unit is programmed to enable the monitoring of the
hours during which the engine works before set maintenance interventions. Only the Technical Assistance Service
Personnel can modify the data relating to the hours of the
different intervals.
The unit hour counter decreases the data according to
the effective working hours and, until negative values are
reached, it enables the identification of interventions considerably before the need.
After each maintenance intervention, it is the boat user, or
the personnel in charge, that must reset the display of initial
data used for the counting.
The list of the number of working hours of the engine/s
allowed before maintenance interventions can be displayed
using the basic operations described in the sequence of
pages which can be opened using the “<<” and “>>” keys.
If one of the listed maintenance interventions has been carried out, to reset the counting data referring to the number
of hours after which interventions is required again, do as
follows:
o Press the “MENU” key to display the fast choice windows.
o Use the “<<” and “>>” keys to select the “DATALOGGER” option inside the window.
o Press the “OK” key to confirm and display a second
window containing the choice options.
o Select the “HOURCOUNTER” mode by pressing the
“<<” and “>> keys.
o Press the “OK” key to confirm.
Figure 34
Figure 33
05_125_C
1
2
05_127_C
o Use the “<<” and “>>” keys to select the option “SERVICE RESET”, inside the new window.
1. Engine working hours indicator - 2. Indicator of the remaining
hours before intervention is required.
o Press the “OK” key to confirm and display the programmed interventions list together with the number of
working hours still allowed before the next intervention
is required or, if there is a minus sign (-) the hours of
delay from the intervention request.
o Use the “<<” and “>>” keys to highlight the option
relating to the intervention which has been finished
o Press the “OK” key twice consecutively to confirm.
o Verify that the number of hours shown as a maximum
period is displayed. If this is not the case, repeat the last
operations of the procedure.
88
C78 ENS M20
C78 ENT M30-M50-M55
INSTALLATION DIRECTIVE
MAY 2006
Alarms management
Navigation monitoring
The electronic system carries out in a sequence the verification of all the parameters which must be checked, irrespective of the page shown on the display. Two lower and two
higher thresholds are set for each parameter, which respectively refers to the pre-alarm and to the alarm and which
sometimes coincide. The programmed thresholds are shown
on the bar analogical indicator which relates to the parameter (see the figure). Only the Technical Assistance Service
personnel can modify these settings.
If the interface has been connected with a GPS or self-piloting system (refer to the “JS connectors terminal working”
section) which is able to supply navigation data according
to the NMEA 0183 protocol, a pointing diagram useful to
navigate will be shown among the monitoring pages.
Abbreviations list:
RNG – Distance from the next waypoint
BRG – Direction of the next waypoint
VMG – Real speed at waypoint
ETE – Expected arrival time
TRN – Course direction for waypoint
XTE – Off course mistake
Figure 35
Figure 36
1
05_129_C
05_128_C
If a parameter value is higher than the set threshold, the
acoustic signal is activated and the box representing the
indicator is highlighted through a dark flashing border (clear
border in the “NIGHT” mode)
Press the “CLR” key to stop the acoustic signal and the
border flashing. The border is still displayed. The alarm condition is visually shown until the normal status is reset and the
“ACK” key is pressed.
CAUTION
When an alarm signaling occurs, in order to verify that a
damage really exists, it might be useful to press the “ACK”
key. If the limit has only temporarily been passed, the alarm
signaling stops immediately. If the alarm continues it is necessary to carry out the diagnosis of the cause. Once the
cause is definitively removed, in order to reset the normal
display status, press the “ACK” key.
3
2
1. Destination (Waypoint) - 2. Course and speed 3. Position of the moment.
INSTALLATION DIRECTIVE
MAY 2006
89
Safety behaviour
Depth monitoring (Echo sounder)
If the interface has been connected with an echo sounder
(refer to the “JS connectors terminal working” section) which
is able to supply water depth data according to the NMEA
0183 protocol, a diagram showing the depth evolution and
the relating numeric value, including possible temperature,
will be shown among the monitoring pages.
Figure 37
1
C78 ENS M20
C78 ENT M30-M50-M55
2
3
05_130_C
1.Water temperature - 2. Depth of the moment 3. Graphic representation of the sea floor altimetry.
In order to guarantee the integrity of the engine and avoid
major risks for the crew, The Monitoring Electronic Unit is
programmed to cause the automatic stopping of the engine
(this operation is carried out through the relay 3 and after
connecting the JE connectors).
The following conditions are at the base of the engine automatic stopping:
-
Lubrication low oil pressure (LOW OIL PRESS, WA sensor)
-
Cooling high water temperature (HIGH WATER TEMP, IA sensor)
-
Engine excessive rotation speed (ENGINE S, BA sensor).
90
C78 ENS M20
C78 ENT M30-M50-M55
Update notes
INSTALLATION DIRECTIVE
MAY 2006
IVECO S.p.A.
PowerTrain
Viale Dell’Industria, 15/17
20010 Pregnana Milanese - MI - (Italy)
Tel. +39 02 93.51.01 - Fax +39 02 93.59.00.29
www.ivecomotors.com