SERVICE BULLETIN

NOTICE: The Type of Change and Recommended Compliance specified reflects Solar’s best judgment regarding the
Service Bulletin. All questions should be directed to your Solar 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.

NUMBER: 3.0/101A
ISSUED: October 1999
REVISED: September 2001
PRODUCT: Mars
MODEL(S): All
Specifics:

SUBJECT: MARS ENGINES - IGNITION ISSUES

Type of Change: Product Improvement

Recommended
Compliance: Earliest Convenience

Purpose:
To provide information to improve Mars engine ignition.

Revision A

• Introduces a torch “pre-light” procedure.

The torch is lit a few seconds before the main gas supply is turned on to guarantee an
established pilot flame when the main gas supply is opened.
• Increases the turbine light-off speed and abandons the interrupted crank cycle to increase
the turbine air flow and make the light-off less sensitive to fuel pressure variations.
• Extends the validity of this Service Bulletin from SoLoNOx turbines to all Mars turbines.
• Gives examples of ladder-logic changes to allow the installation of above improvements
into the start sequence of Allen Bradley PLC’s.

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NUMBER: 3.0/101A
GENERAL INFORMATION:
Several incidents of Mars engines have experienced inconsistent or rough engine ignition. In a few
cases exhaust duct damage occurred due to late engine light-off. Potential causes of hard light-offs
are: unreliable operation, extended ignition timer and a fuel schedule that supplies too much fuel
into the combustion system at light-off. This Service Bulletin provides information for improved
engine light-off with existing systems and lists the software modifications required to retrofit newer
Allen Bradley control systems.

To address the root cause of the light-off problems, Solar Turbines has altered the start sequence
on new Mars production packages in two important ways:

• Torch pre-light
The torch is lit a few seconds before the main gas supply is turned on. This modification
insures a fully established torch flame at the time the main gas supply is turned on. Main
combustor light-off will occur smoothly as the ideal air-gas mixture is reached.
• Increased light-off speed (light-and-go)
Marginal engine airflow during turbine light-off has been recognized as one of the main
reasons for the critical torch pressure adjustments and the sensitive fuel scheduling. To
correct this problem, the turbine light-off speed was increased, and the interrupted crank
cycle was abandoned. Engine light-off is now initiated directly at the end of the turbine
purge cycle without interrupting the starter motor. This increases the turbine airflow during
ignition and makes the fuel gas scheduling (torch and main gas supply pressures) less
critical.
As an added benefit, the engine start time is shortened, and the start sequence for Mars
turbines is similar to the sequence used in all other Solar product lines.

PROCEDURE:
During investigation of any reported ignition issues, the following areas should be addressed. Users
should contact the local Solar District Office for assistance with any of the following issues.

1. TORCH PRESSURE:
For a normal light-off, with the existing start sequence, the nominal gas supply pressure
to a Mars torch should be around 5 psi (35 kPa). Measure torch pressure near the torch
fuel inlet, downstream of the torch valve. The torch pressure regulator sets the torch fuel
pressure. The torch pressure for optimum light-off may vary from application to applica-
tion. If the engine is experiencing hard light-offs, the torch gas pressure settings should
be optimized. It is strongly recommended that users contact Solar Field Services for
assistance in this optimization.
Accurate torch gas pressure control is necessary to avoid ignition problems. Mars pack-
ages, produced since June, 1999, use two pressure regulators to better control the torch
pressure. Previous Mars units relied on one regulator to reduce the gas pressure from

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NUMBER: 3.0/101A
 skid supply pressure to 5 psi (35 kPa) torch pressure. With the new dual regulator sys-
tem, the first regulator reduces the gas pressure to 35 psi (241 kPa), and the second: from
35 psi to 5 psi (241 kPa to 35 kPa). The torch regulator upgrade is available as a retrofit
kit Solar P/N 1038766-100 from Solar Service Parts. The kit contains all the necessary
hardware and installation instructions necessary for successful installation. If assistance
is required in installing the kit, contact your Solar District Service Office.
After installation of the “light-and-go” logic into any Mars turbine package, the light-off
speed and engine air-flow increase, require increased torch gas flow. For light-off at
nominal purge crank speeds (21 to 25% Ngp), the torch gas pressure should be reset to
about 8 psi (55 kPa). Due to the higher air and gas flows, the torch gas pressure is much
less sensitive, and the recommended value should be correct for most applications.
2. IGNITION TIMER SETTING:

UNDER NO CIRCUMSTANCES SHOULD THE IGNITION TIMER BE IN-

CREASED TO MORE THAN 10 SECONDS.

The as-shipped ignition timer setting in the Allen Bradley software is 10 seconds. How-
ever, for a normal ignition, the torch should light within 3 to 4 seconds after the ignition
is initiated. The ignition timer setting can be reduced to 5 seconds, provided ignition can
consistently be achieved within that time.
3. TORCH:
Mars SoLoNOx torches are difficult to engage into the combustor floating grommet due
to their offset non-radial design. If light-off problems persist after the torch gas pressure
has been checked, proper torch engagement should be verified. Remove a fuel injector
at the 5 o’clock to 7 o’clock position and insert a flexible Borescope tip between the
outer combustor shell and the outside housing. Guide the Borescope tip until you see
the side of the torch and the outside wall of the combustor. The torch should line up
and fully engage into the floating combustor grommet. A new extended length torch,
P/N 195005-102, that replaced the earlier -101 design has been incorporated in new and
overhauled engines since 1996 and is designed to eliminate the possibility of the torch
disengaging.
In addition, several cases have been reported where engine light-off problems were ex-
perienced due to an incorrect fuel-metering orifice installed during the torch assem-
bly. Mars SoLoNOx engine torches have a .040 inch (1.0 mm) diameter orifice P/N
951879C1. During engine light-off troubleshooting, the orifice in the torch should be
checked for proper size and for fouling and obstructions.

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 4. PRE-LIGHT:
Improvements in light-off reliability can be achieved by “pre-lighting” the torch. New
production engines light the torch four seconds before the main gas supply is switched
on. This delay insures that the pilot flame is fully established by the time the main fuel
gas is metered into the combustion chamber. Due to the fully established pilot flame, the
main fuel starts to burn as soon as a combustible mixture is present, insuring a reliable
and smooth light-off.
Attachment 1 lists the light-off sequence with “pre-light” for Mars dual fuel turbines and
newer Allen Bradley control systems. Single fuel control logic and other types of control
systems can be individually adapted based on the above example. Please contact Solar
Field Services for assistance.
5. LIGHT-AND-GO START SEQUENCE:
This start sequence omits the engine “roll-down” after the engine purge sequence and
initiates ignition directly after the purge cycle, keeping the starter engaged during the
entire start cycle. Due to the increased light-off speed, the turbine airflow is higher and
metering of the torch and main fuel gas is less critical.
New fuel pressure and pressure switch settings:
• If the fuel gas schedule is correct, the main gas fuel flow will adjust itself to the new
conditions.
• The torch gas pressure must be increased from the current value to 8 psi (55 kPa).
• Liquid fuel schedules for torch and main fuel flow will adjust themselves to the
higher combustion chamber pressure and should not require adjustment.
• The fuel pressure increase due to the elevated light-off speed is small. The shut
downs, “High gas fuel start pressure” (TP341-1 or S341-1; nominal 8 psig (55 kPa))
and/or “High liquid fuel start pressure” (TP341-2 or S341-2; nominal 12 psig (83
kPa)), do not require resetting. Check fuel schedules and timer settings if problems
with these switches arise after the increase in light-off speed.
Crank speed:
• The correct crank speed is obviously critical to make the new "light-and-go"
system work. Nominal crank speed is between 21 and 25% Ngp. This speed is
ideal for the new ignition sequence.
• All direct drive AC start motors crank within this speed range, and no changes
are required.
• On electro-hydraulic (hydrostatic) start systems, the pressure control valve for
partial stroke (PCV901, attached to the hydraulic motor) must be set to achieve
a crank speed within 21 and 25% Ngp.

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 • Pneumatic start systems with 2-step pressure regulation must be adjusted to
crank between 21 and 25% Ngp (old expansion turbine or new Hilliard positive
displacement starter).
• Old pneumatic start systems with a single step pressure regulator (mainly
packages built in the 1980’s) crank much faster than desirable. Crank speeds well
above 30% Ngp can be experienced. Service Bulletin 3.0/105D recommends a
maximum crank speed of 25% Ngp for all Mars engines. Solar is developing
a retrofit kit to install the newer 2-step start system for customers wishing to
convert to the "light-and-go" ignition system.
• Hydrodynamic (Pelton wheel) starters cannot be economically adapted to a
reduced crank speed. A conversion to a modern AC direct drive system is
recommended in these cases.

Retrofit:
With the exception of older pneumatic and hydrodynamic start systems, software
changes-only are required, together with a few adjustments of pressure settings.
Attachment 2 lists the “light-and-go” logic for newer control systems and AC direct drive
start systems.
Attachment 3 lists the "light-and-go" logic for newer control systems and electro-hy-
draulic start systems.
6. LIQUIDS IN TORCH LINE:
The six-o’clock position of the torch and the torch fuel line provides the combustor with a
low collection point for water and other liquids. The torch line will condense water from
PCD air. During the engine light-off investigation, the torch and the torch line should
be drained of any liquids, which have accumulated in them. If liquid contamination is
observed in the gas fuel line, corrective action should be initiated to properly condition
the fuel gas per Solar Specification ES 9-98.
7. CHECK VALVE:
One other possible contributor to poor ignition is trapped PCD air in the fuel system. To
eliminate trapped PCD air, the check valve VCS933-2 could be moved downstream of
the torch solenoid L340-1. Verify proper operation of the check valve VCS933-2 at this
position. To improve torch light-off, this change has been incorporated on Mars packages
shipped from the factory after June, 1999.

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 8. FUEL SCHEDULE:
Most Mars packages are equipped with an electro-pneumatic servo controlled L344-6
fuel system. The fuel system can supply excessive fuel into the engine during light-off, if
the fuel schedule is set too high or the airflow is too low. With the fuel schedule K-values
set to factory setting, the fuel supply pressure of the throttle valve ranges from 6 to 8 psig
(41 to 55 kPa). The impact of a late light-off from the torch may be reduced if the fuel
schedule is lowered or the airflow is improved. Field experience has indicated that, if
a hard light off occurs, a lower fuel schedule may be required to get a more reliable
light-off. In some cases, a gas fuel supply pressure of 3 psig (21 kPa) to the throttle
valve is optimum for an ignition time of 3-4 seconds. It is strongly recommended that
users contact Solar Field Services for assistance in this optimization.

ACTION REQUIRED:
• Investigate your basic light-off parameters and compare with above recommendations.
Make sure, that critical values like torch gas pressure, main fuel pressure and maximum
ignition timer setting do not exceed the given limits.
• No changes in the basic light-off logic (e.g., adding torch ”pre-light” or “light-and-go”) are
required unless unreliable or hard engine light-offs are experienced.

Only qualified and experienced personnel should investigate the hard light-off problem. It is
strongly recommended that users contact Solar Field Services for assistance.

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 ATTACHMENT 1
MARS LIGHT-OFF LOGIC WITH TORCH "PRE-LIGHT" FOR NEWER DUAL FUEL PACKAGES

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 ATTACHMENT 2
"LIGHT-AND-GO" START LOGIC FOR MARS PACKAGES WITH NEWER CONTROL
LOGIC AND DIRECT DRIVE AC START SYSTEMS

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 ATTACHMENT 3
"LIGHT-AND-GO" START LOGIC FOR MARS PACKAGES WITH NEWER CONTROL
LOGIC AND ELECTRO-HYDRAULIC (HYDROSTATIC) START SYSTEMS

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