SERVICE BULLETIN

NOTICE: Service Bulletins are proprietary to Turbomach SA, Via Campagna 15, CH-6595 Riazzino,
Switzerland. The Type of Change and Recommended Compliance specified reflects Turbomach’s best
judgment regarding the Service Bulletin. All questions should be directed to your Turbomach Field Service
Representative. Solar, Saturn, Centaur, Taurus, Mercury, Mars, Titan, SoLoNOx, and Turbotronic are
trademarks of Solar Turbines Incorporated. Cat and Caterpillar are trademarks of Caterpillar Inc.
Specifications subject to change without notice.

TBM#: SB 14-043
ISSUED: 20.10.2014
PRODUCT: CENTAUR 40, CENTAUR 50, MARS 100, MARS 90,
MERCURY 50, TAURUS 60, TAURUS 65, TAURUS 70,
TITAN 130
MODEL(S): Generator Set
Specifics: -
DISTRIBUTION: TBM Worldwide

SUBJECT: TORCH IGNITION TROUBLESHOOTING GUIDELINES

Type of Change: Product Reliability
Recommended
Compliance: Information
Type of
Modification: Information

Purpose:

To provide general torch troubleshooting guidelines.

GENERAL INFORMATION:
Difficult or inconsistent engine ignition has been reported, particularly for Mars® SoLoNOx™
engines. This document is intended to aid in diagnosing the cause of torch ignition issues and to
provide corrective measures.

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 ACTION REQUIRED:

If you encounter difficulties with torch ignition, review the following sections for common hardware
configuration issues, proper conditions for torch ignition, methods to verify torch and injector
ignition, and potential component issues. For assistance, please contact your local Turbomach
district office for support.

Hardware Verification

Follow all locally- and employer-required risk mitigation

practices.

Perform a normal system shutdown, allow equipment to coast

down to a complete stop, and allow the post-lubrication cycle to
automatically stop.

Follow appropriate hazardous energy sources lock-out and tag-

out procedures for the entire turbomachinery package,
ancillaries, and associated equipment.

Isolate the package from all sources of fuel and start gas
including any start gas exhaust system and vent system.

Allow surfaces in the proximity of the work area to cool

adequately to eliminate any burn hazard to personnel.

Combustible gases or vapors may be present. Isolate all sources

of ignition. Ensure gases or vapors are reduced to a safe level
before resuming work.

Locate the part number marked on your torch and compare it to the “core” part numbers (the six
digit number to the left of the dash) in Table 1. If the torch part number matches any of the
numbers in Table 1, the torch is a universal body torch.

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 Table 1 - “Core” Part Numbers for the Universal Body Torch
Product New Production Torch Reworked Torch

Centaur® 40 Low Btu 131148 304525

Titan™ 130 204529 304522
Mercury™ 50 245497 304523
Centaur 40 / Centaur 50
Taurus® 60 / Taurus 70
300589 304521
Mars 90 / Mars 100
Titan 130
Taurus 65 209529 304524

NOTE
If a universal body I torch was reworked to include the Burner
Acoustic Monitor (BAM)-kit-required side-port fitting (Figure 2), it will
have an “overhaul” core part number.

Figure 1 - Diagram of a Universal Body Torch

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 Figure 2 - Universal Body Torch Orifice and Torch Injector Matrix

Universal body torches (sometimes known as “Super Torches”) began to be introduced in 2000 for
certain products.

A universal body torch uses a common body with ports for gas fuel, liquid fuel, and air, plus
interchangeable torch tubes for various applications. The universal body torch can be divided into
two general categories for the sake of discussion in this document:

• Universal Body Torch I - The early generation, 2000-to-2006 universal body torches
(sometimes called “Super Torch I’s”) have three unlabeled tapered pipe thread ports on the
side and an internal orifice for gas fuel.
• Universal Body Torch II - Later design universal body torches (sometimes called “Super
Torch II’s”), introduced in 2006 on all model lines except Saturn® and Centaur 40
conventional combustion, have three straight-threaded SAE o-ring boss ports on the side
and an internal orifice for gas fuel. One distinguishing characteristic of a universal body
torch II is that the three side ports (Figure 3) are labeled as:
– “P.T.” – Intended for BAM dynamic and static pressure measurement. This port
includes a unique fitting with a tube that penetrates the torch tube wall. The fitting
requires a corresponding hole in the torch tube that does not exist on earlier
version torches.
– “S.P.” - Spare port.
– “A.R. OR T.C.” – Intended for installation of a thermocouple.

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 Figure 3 - Universal Body Torch II Side Port Labeling

NOTE
Do not replace the “P.T.” port fitting with a plug or other fitting. This
fitting is unique and necessary if BAM is installed. Leave the fitting intact
and capped off with Solar PN 960825C1 [Swagelok™ PN SS-400-P] when
not is use.

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 Gas Fuel Orifice

Follow all locally- and employer-required risk mitigation

practices.

Perform a normal system shutdown, allow equipment to coast

down to a complete stop, and allow the post-lubrication cycle to
automatically stop.

Follow appropriate hazardous energy sources lock-out and tag-

out procedures for the entire turbomachinery package,
ancillaries, and associated equipment.

Isolate the package from all sources of fuel and start gas
including any start gas exhaust system and vent system.

Allow surfaces in the proximity of the work area to cool

adequately to eliminate any burn hazard to personnel.

Combustible gases or vapors may be present. Isolate all sources

of ignition. Ensure gases or vapors are reduced to a safe level
before resuming work.

The gas torch orifice might be internal or external:

• The universal body torch introduced the use of an internal gas fuel orifice (Figure 4) for the
Mars engine, in contrast to the previous requirement for an external orifice. Other engine
models already used an internal gas orifice. If an internal orifice becomes damaged and too
difficult to replace, it is acceptable to remove it and install an external orifice instead.
Otherwise, continue to use an internal orifice on all universal body torches.

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 Figure 4 - Internal and External Orifices

• Mars non-universal body torches, whether in original condition or reworked for BAM, have
an external orifice installed in the gas port.

If you have a universal body torch, confirm that there is only one orifice in the gas path (Figure 4
above and Figure 5 below).

Figure 5 - Example of a Schematic for a Gas-Only Torch Igniter

NOTE
There must be only one orifice, whether internal or external, feeding
gas fuel to the torch for all packages. More than one orifice will result
in insufficient gas fuel flow.

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 If there is no orifice in the line and normal supply pressure is applied to the torch, the torch will
likely not ignite due to an overly rich fuel-air mixture. If two orifices are present in the line (which
might happen if a universal body torch were installed in place of an earlier model of torch without
removing the inline orifice), there will be excessive restriction of the gas fuel flow, and the torch
will most likely not ignite due to a very lean fuel-air mixture.

Gas Fuel Torch Pressure

For a normal light-off with the existing start sequence, the nominal gas supply pressure to a torch
should be near the values in Table 2.

Table 2 - Recommended Torch Supply Pressure

Product Gas Pressure Gas Pressure
(psig) (bar)
Saturn 20 3 0.2
Centaur 40/ Centaur 50/ Taurus 60/ Taurus 65/ 10 0.7
Taurus 70/ Titan 130
Mercury 50 18 1.25
Mars 90/ Mars 100 10 0.7

If necessary measure torch pressure near the torch fuel inlet, downstream of the torch valve and
pressure regulators, as indicated below in Figure 6.

Figure 6 - Location for a Pressure Gauge Connection

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 The torch pressure for optimum light-off may vary from application to application. It is strongly
recommended that you contact your local Turbomach District Service Office for assistance with
torch pressure optimization. The torch pressure regulator controls the torch fuel pressure. Minor
adjustments can be made to the regulator during ignition attempts; however, multiple start
attempts should be avoided.

The following instructions can be used to set torch pressure prior to a start attempt:

Follow all locally- and employer-required risk mitigation

practices.

Perform a normal system shutdown, allow equipment to coast

down to a complete stop, and allow the post-lubrication cycle to
automatically stop.

Follow appropriate hazardous energy sources lock-out and tag-

out procedures for the entire turbomachinery package,
ancillaries, and associated equipment.

Isolate the package from all sources of fuel and start gas
including any start gas exhaust system or vent system.

Allow surfaces in the proximity of the work area to cool

adequately to eliminate any burn hazard to personnel.

Combustible gases or vapors may be present. Isolate all sources

of ignition. Ensure gases or vapors are reduced to a safe level
before resuming work.

1. Ensure fuel gas to the skid is OFF (off-skid fuel valves if used, or hand valves) and the lines
in the package are vented safely.
2. Install a pressure gauge at the location shown in Figure 6, above.
3. Apply compressed air to the system as follows:
a. Disconnect the tubing to the inlet of the filter F2044 in Figure 5.
b. Install the fittings necessary and apply compressed air at 10 bar to the inlet of the
filter F2044.
4. Set the nominal gas pressure to the torch as follows:
a. Using the control signal or a temporary jumper, open the torch shutoff valve
(V2041).
b. Adjust the Fine Pressure Regulator (HC2040 in Figure 5) to the pressure previously
established or to the value in Table 2.

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 5. Once adjusted, return the shutoff valve to its normal operation, remove the air line, replace
the standard tubing, and proceed with a normal start attempt.

Air does not have the same properties as natural gas, and the supplied fuel gas will be at a higher
pressure than the majority of compressed air sources available. After setting the regulator using
air, the torch pressure may be slightly different when gas flows through the regulators during start
attempts. Minor adjustments can be made to the torch regulator during the ignition attempt.

If the torch does not light at the suggested gas pressure, increase the pressure by 0.3 bar (~5
psi). Once the torch lights, increase pressure another 0.1 bar. Should the torch still fail to light,
inspect the components of the torch according to the following instructions.

Injector Ignition (Light-Around) Verification

The following criteria indicate that the torch is lit but is not leading to a light-around of the
injectors:
1. Only the individual T5 readings in the vicinity of the torch have a slight increase (~5 to
15°C).
2. BAM readings should have a small spike.

If the torch lights, but there is no light-around, it is possible that the flame is remaining within the
torch. Increase the gas torch pressure by 0.3 bar (~4 psi) and repeat the ignition attempt.
Increasing the pressure can extend the flame further into the combustion chamber. Do not
exceed 2.4 bar (35 psig).

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 Troubleshooting Issues Specific to the Universal Body Torch II

Follow all locally- and employer-required risk mitigation practices.

Perform a normal system shutdown, allow equipment to coast down

to a complete stop, and allow the post-lubrication cycle to
automatically stop.

Follow appropriate hazardous energy sources lock-out and tag-out

procedures for the entire turbomachinery package, ancillaries, and
associated equipment.

Provide notification and obtain appropriate permission to perform

testing of the igniter system prior to proceeding.

Isolate the package from all sources of fuel and start gas including
any start gas exhaust system or vent system.

Allow surfaces in the proximity of the work area to cool adequately

to eliminate any burn hazard to personnel.

Ensure no combustible mixtures exist in the surrounding

environment prior to proceeding.

1. Remove the spark plug from the torch and verify the gap is approximately 2.4 mm (Figure
7). Adjust if necessary. Clamp the plug to a good ground and force the exciter output 5
seconds ON, 5 seconds OFF, and again 5 seconds ON. During both ON periods you should
observe a good, clean, consistent spark.
a. If there is no spark, or the spark rate is inconsistent, check the high-tension lead
and the exciter, and replace the spark plug if necessary. If the spark plug is
functioning properly, proceed to the following step.

Figure 7 - Spark Plug - Appropriate Gap Measurement

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 2. Remove an injector near the torch and borescope to make sure the torch tube is properly
engaged in the grommet (Figure 8).

Figure 8 - Proper Torch Engagement – Mars SoLoNOx Engine

a. If the torch is not properly engaged, light-around is not likely to occur. This could be
the source of the problem. In any case, proceed to the next step, but do not re-install
the injector until the torch has been re-installed and verified for proper engagement.
3. Remove the universal body torch and check to see whether:
a. The torch tube is loose. If so, replace it with a new torch (go to step 5).
b. There are foreign bodies in the torch tube. Contact your local Solar district service
office for assistance.
4. The internal orifice (P/N 136579-1 for most product lines) for the gas port in the universal
body torch is 0.40 inches in diameter, has a 5/16-18 UNC thread size, and can be installed
and removed with a 5/32 inch (0.156 inch) male hex wrench (“Allen key”). The 136579-1
orifice measures from 0.039 to 0.041 inches in diameter when new. Saturn’s and Low-BTU
Centaur 40’s use a 0.047-inch diameter orifice instead.
a. Verify the orifice is not plugged and measure it using a pin gage. For dual fuel
torches, make sure there is no liquid build-up or contamination in the housing of the
torch.
b. Remove any contaminants and proceed to the next step.
5. Re-install the torch to the engine. Ensure the flange on the housing of the torch is mated
to the combustor without forcing it. Forcing the installation can lead to a damaged tube,
especially with the Mars torch due to the angled torch tube.
6. Attempt to start the engine.
a. If the torch still fails to light across the range of recommended pressures, please
contact your local Solar district service office for assistance.
b. If the torch lights but there is no light-around, increase the gas fuel pressure in
increments of 0.3 bar (~ 4 psi) up to a maximum of 2.4 bar (35 psig). Again, if
there is still no light-around, please contact your local district office for assistance.

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 Fail-to-Light Troubleshooting for Liquid Fuel Systems

Follow all locally- and employer-required risk mitigation

practices.

Perform a normal system shutdown, allow equipment to coast

down to a complete stop, and allow the post-lubrication cycle to
automatically stop.

Follow appropriate hazardous energy sources lock-out and tag-

out procedures for the entire turbomachinery package,
ancillaries, and associated equipment.

Provide notification and obtain appropriate permission to

perform testing of the igniter system prior to proceeding.

Isolate the package from all sources of fuel and start gas
including any start gas exhaust system or vent system.

Allow surfaces in the proximity of the work area to cool

adequately to eliminate any burn hazard to personnel.

Ensure no combustiblemixtures exist in the surrounding

environment prior to proceeding.

Monitor each individual T5 thermocouple during a start attempt. If after two failed attempts,
there is no increase in T5 and the torch is cold:
1. Check the torch.
a. Is the spark plug working?
i. With the spark plug removed, check the gap and adjust if required.
ii. Clamp the plug to a good ground and force the exciter output 5 seconds ON, 5
seconds OFF, and again 5 seconds ON.
iii. During both ON periods you should observe a good, clean, consistent spark. If
not, check the high-tension lead and exciter.
b. Remove the torch and check for any foreign bodies.
2. Check the fuel line going to the torch.
a. Ensure the hardware is in satisfactory condition and free of leakage.
b. Check the pressure, connecting the gauge by way of a tee fitting. DO NOT ADJUST
THE PRESSURE.

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 3. Check the air assist filter.
a. If you have an air assist filter with 1/2" NPT ports and suspect you have insufficient
air flow, consider upgrading to the 1” NPT-ported air assist filter, P/N 1089034-10X.
The filter is now used in new-production equipment, replacing the previous 1/2"
NPT-ported filter to minimize pressure loss during startup. This is more likely to be
an issue with larger engines which require a higher air assist flow.
4. Adjust the main air assist regulator
a. Equipment delivered from the factory is preset to a conservative value. However,
higher viscosity fuels are more difficult to atomize. Consider readjusting the
differential pressure.
b. If light-off does not improve, return the pressure to the original setting.
5. Check the air assist to the torch.
a. Ensure the hardware is in satisfactory condition and free of leakage.
b. Check the pressure by tapping into the line with a tee fitting and connecting a
pressure gage nearly the torch air assist port.
i. On Taurus 70, Mars 90 and 100, adjust the needle air assist valve to 2.5 bar
(36 PSID) above PCD.
ii. On Titan 130’s and 250’s adjust the needle air assist valve to 2.8 bar (40
PSID) above PCD. Also, it has been noted that Mars torches sometimes light
off better at lower pressure, around 1.7 bar (25 PSID). Experiment as needed,
in 0.3 bar (5 PSID) increments, but do not exceed 3.45 bar (50 PSID) above
PCD.
iii. Engines smaller than those listed above do not have a separate torch air assist
regulator. Only adjustment of the main air assist regulator is possible in this
case.
6. For Turbotronic™ 4 units, only, adjust the liquid fuel flow limit:
a. For Turbotronic 4 packages, there is a kVal that may require adjustment.
KT_Liq_Ltoff_Fuel_Limit.Val limits liquid fuel flow to the injectors and the torch
during light-off. The factory setting is typically conservative. Gradually increase the
kVal as needed until a consistent light-off is achieved.

NOTE
It is recommended that you contact your local Turbomach District Service
Office for assistance with the kVal adjustment, above.

If further troubleshooting is required, please contact your local Turbomach District Service office.

NOTE
Part numbers discussed herein are subject to change without notice. The
most current, applicable part number is identified when ordering.

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