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ADEC Advanced Diesel Engine Controller for Br.4000/2000 Generator Application
Series 2000/4000 Generator Application
Optional
MTU Display
Power View Display
ECU 7
CAN Bus
SAM or SAM+ 2
Series 2000/4000 Generator Application
Abbreviation
¾ ADEC
Advanced Diesel Engine Control
¾ ECU 7
Engine Control Unit
¾ SAM
Service Automations Module
¾ DILA
Diagnostic Lamp
3
ADEC/MDEC Difference
ADEC (ECU7)
MDEC (ECU4)
Injection Injector
triple 24 - 48 V
single 24 V
Computing velocity I/O max. Housing Temperature Box-Self test
800 % 90 105 °C yes
100 % 75 75 °C no
Features
CAN-Bus for future extension Adjustable Engine Monitoring Adjustable Safety System Torque Based Engine Management
4
Engine Control Unit ECU-7 Main difference MDEC/ADEC Main difference MDEC to ADEC (service view): - No internal 30A Fuse - No pluggable Memory Modules „EDM“ and „IDM“ - No internal “Fault Code Display” - The Parameter set is divided in Engine Parameter (MPS) and Application-Parameter (APS) Æ update via EPROM Database possible - New Parameter Structure (ZZ.KKKK.PPP) - Extended Error Code List - No Serial Interface for Dialog Unit. The Connection is only via CAN possible. Attention! New service tools are required. For the Dialog with ADEC the Diasys Version must be 2.32 or higher. The hardware key needs to have the ADEC Authorisation
5
New Tools for Generator Application USB to CAN Converter
PCMCIA to CAN Converter
CAN Dialog Cable 2m, 9pol. Sub D / 12pol. round Connector
Connection for Dialog Cable
6
ECU-7 Anschlüsse und Diagnose Plug X1
Plug X2
Plug X3
Plug X4
System Cable
Sensor Harness
Power Supply
Injector Harness
DILA (Diagnostic Lamp)
7
ECU-7 Diagnostic Lamp (DILA) The Diagnostic LED (DILA) shows the following Codes: Zeit
0 Sec
1 Sec
2 Sec
3 Sec
4 Sec
Normal Operation Applications Loader active Offline-ITS Error External RAM defect External FLASH defect No Firmware available Application crashed
TOP TOP11 Yellow YellowAlarm Alarm TOP TOP22 Red RedAlarm Alarm TOP 3 Lube Oil Pressure Stop TOP 3 Lube Oil Pressure Stop TOP 4 Starter On TOP 4 Starter On
AO AO11 T T- -Coolant Coolant AO AO22 PP––Lube LubeOil Oil
0-10V 0-10V 0-10V 0-10V
Analog Input
PCS 5
9
Sensorik Br.4000/2000 mit ECU 7 Sensors Serie 4000 Level LevelCoolant CoolantWater Water Level LevelIntercooler IntercoolerWater Water T T- -Coolant Coolant T T––Charge Charge T T––Rail RailFuel Fuel T T––Coolant CoolantIntercooler Intercooler T T––Lube LubeOil Oil PP––Fuel Fuelafter afterFilter Filter PP––Fuel Fuel(Common (CommonRail) Rail) PP––Lube LubeOil Oil PP- -Charge ChargeAir Air NN- -Crankshaft Crankshaft NN- -Camshaft Camshaft
Sensors Serie 2000 FF33 33
Level LevelCoolant CoolantWater Water
F33 F33
BB66 BB99
T T- -Coolant Coolant T T––Charge ChargeAir Air
BB66 BB99
BB33 33 BB26 26
T T- -Fuel Fuel
BB33 33
BB77 BB34 34
T T––Lube LubeOil Oil
BB77
PP––Lube LubeOil Oil PP––Charge ChargeAir Air
BB55 BB10 10
NN- -Crankshaft Crankshaft NN- -Camshaft Camshaft
BB13 13 B1 B1
FF57 57
BB48 48 BB55 BB10 10 BB13 13 B1 B1
10
ADEC für Generator Anwendung
Robust und einfaches Design
9 Erhöhter Temperaturbereich von – 40°C bis +105C° innerhalb der vorgeschriebenen Spezifizierung 9 Schock und vibrationsgeprüft bis 3,6 GRMS 9 Schutzklasse: IP69K Wichtig ! ADEC wurde für härtere Rahmenbedingungen als MDEC/DDEC Entwickelt.
11
ADEC für Generator Anwendung
Einfache Diagnostik Der ADEC Regler führt einen Selbsttest während des Einschaltens und im normalen Betrieb durch. Das Ergebnis wird an einer LED am ADEC Regler angezeigt (DILA). LED An LED Blinkt LED Aus
Æ ADEC ist OK Æ ADEC ist defekt. Æ Keine Spannungsversorgung
Interne Fehler können durch anliegen der Spannungsversorgung und abgezogener Reglerverkabelung erkannt werden.
Box Tausch Diagnostik Lampe
12
Br.2000/4000 Generator Anwendung Optionen MTU Display
Power View
MTU oder
Configuration 1. SAM or SAM + Node Nr.4
CAN 1. CAN 2.
Node Nr.5
Diasys 2.xx
13
Br.2000/4000 Generator Anwendung
Node Nr.6 External Switchgear Cabinet
SDMO/Kohler Configuration 2.
CAN 1.
Diasys 2.xx
CAN 1. CAN 2.
MAU
14
Br.2000/4000 Generator Anwendung
Customers with external Controller (not SDMO/Kohler)
Node Nr.6 CAN Open/J1939
Configuration 3.
External Controller Customer Switchgear Cabinet
CAN 1. CAN 2.
Diasys 2.xx
CCB2 wird für Kunden Schnittstelle benötigt 15
ADEC & SAM Übersicht der Einbindung des Kunden Schaltschranks
Easy ADEC/SAM Hardware change Application/Engine Software + Data are stored in both the SAM Memory as well as in the ADEC Memory. The download of the complete software is automatically initiated after connecting a new ADEC of SAM hardware to the remaining module.
Data Storage Concept ¾ Life data storage Engine life data is stored continuously every hour, after every engine stop or emergency stop in the SAM-Memory as a backup.
Cylinder Cut Out Only half of the injectors are activated by the Engine Control Unit when cylinder cut-out are active. Switching over to the other half of the injectors takes place when a switching time has expired. This ensures that the engine runs without producing smoke. The input B_IN1switch off the Cylinder Cut OUT Function.
SAM Function 29
Test Overspeed Switch
Activating the input B_IN3 lowers the overspeed switching threshold such that the engine shut down at any speed. This makes possible to check that the overspeed shutdown function operates correctly.
SAM Function 30
Test Switch Outputs
Enable ( over a parameter for every output) CAN OPEN TEST t CAN J1939 TEST
&
SAM
>=1
>=1
SAM B_IN2 LAMP TEST
BR_OUT 1-4 BT_OUT 1-20
SAM signal
ECU DIx LAMP TEST CAN LAMP TEST ECU
>=1
TOP1-4
&
Default setting Enable ( über Parameter)
I/O Config
>=1
ÉCU TOP via software
SAM Function 31
Default Test Switch Outputs Eingnag
Funktion
Ausgang
Funktion
Defaultwert
B_IN 2
Test Switch Out
BR_OUT1
Pre lube on
0
BR_OUT2
Fuel pump on
0
BR_OUT3
Fan 1
0
BR_OUT4
Damper
0
BT_OUT1
Overspeed alarm lamp
1
BT_OUT2
Coolant temp.
warning lamp
1
BT_OUT3
Coolant temp.
stop lamp
1
BT_OUT4
Charge air
warning lamp
1
BT_OUT5
Charge air alarm lamp
1
BT_OUT6
Level intercooler stop Lamp
1
BT_OUT7
Level coolant stop lamp
1
BT_OUT8
Fan 2 on
0
BT_OUT9
Preheat not reached lamp
1
BT_OUT10
Lube oil press. warning lamp
1
BT_OUT11
Engine running
0
BT_OUT12
Alarm fuel pressure
1
BT_OUT13
Load assumption ready
0
BT_OUT14
Pre lube pres. reached
1
BT_OUT15
Governor temp. lamp
1
BT_OUT16
Subsedary excitation on
0
BT_OUT17
Generator Voltage
0
BT_OUT18
Circulation pump on
0
BT_OUT19
Downtime heating on
BT_OUT20
Day tank min alarm
0 SAM Function 1
32
Pre Lube On Switch
Input B_IN4 activate for one times the pre lube output BR_OUT1
SAM Function 33
Manual Damper and Fan On Switch
The input B_IN10 activate manual the damper output BR_OUT4, Fan1 BR_OUT3 and B_OUT8.
SAM Function 34
Turn Switch
The input P_IN7 activate the manual turn function.
SAM Function 35
Analogue Gauges Outputs SAM Basic SAM Basic
Description
0 - 10V to
V_OUT1
Engine Speed
0 - 2000rpm
V_OUT2
Coolant temp.
0 -120°C
V_OUT3
Lube oil temp.
0 -120°C
V_OUT4
Fuel press. after filter
0 - 10 bar
V_OUT5
Charge air press.
0 - 5bar
V_OUT6
Charge air temp.
0 -120°C
V_OUT7
Fuel temp.
0 -120°C
V_OUT8
Fan control
0 - 10V
SAM Function 36
Analogue Gauges Outputs SAM Plus
SAM Function
SAM Plus V_OUT1
Nominal Speed
0 - 2000rpm
V_OUT1
Feedback Speed Demand
0 - 2000rpm
V_OUT1
Feedback Speed Demand Eff.
0 - 2000rpm
V_OUT1
Engine Speed Crankshaft
0 - 2000rpm
V_OUT4
Pressure 1
0-10bar
V_OUT4
Pressure 2
0-10 bar
V_OUT6
T-Coolant Intercooler
0-120°C
V_OUT8
Speed Demand
0-10V
V_OUT8
Engine Power Reserve
%
V_OUT8
Injection Quantity Act.DBR %
%
V_OUT8
Injection Quantity 0-120%
%
V_OUT8
Nominal Power
kW
V_OUT8
Tank Level Daily Tank
0-100000 Litre
V_OUT8
Tank Level Main Tank
0-100000 Litre
V_OUT8
Exhaust temp. A
0-800°C
V_OUT8
Exhaust temp. B
0-800°C
V_OUT8
Gen. Winding Temperature. 1
0-200°C
V_OUT8
Gen. Winding Temperature. 2
0-200°C
V_OUT8
Gen. Winding Temperature. 3
0-200°C
37
SAM Function
Binary Outputs SAM Basic
Input
Function
Output
Function
B_IN 2
Test Switch Out
BR_OUT1
Pre lube on
SAM Basic
BT_OUT1
Overspeed alarm lamp
SAM Basic
BT_OUT2
Coolant temp.
warning lamp
SAM Basic
BT_OUT3
Coolant temp.
stop lamp
SAM Basic
BT_OUT4
Charge air
warning lamp
SAM Basic
BT_OUT5
Charge air alarm lamp
SAM Basic
BT_OUT6
Level intercooler stop Lamp
SAM Basic
BT_OUT7
Level coolant stop lamp
SAM Basic
BT_OUT9
Preheat not reached lamp
SAM Basic
BT_OUT10
Lube oil press. warning lamp
SAM Basic
BT_OUT11
Engine running
SAM Basic
BT_OUT12
Alarm fuel pressure
SAM Basic
BT_OUT14
Pre lube pres. reached
SAM Basic
BT_OUT18
Circulation pump on
SAM Basic
38
Binary Outputs SAM Plus
SAM Function
Input
Function
Output
Function
B_IN 2
Test Switch Out
BR_OUT2
Fuel pump on
SAM Plus
BR_OUT3
Fan 1
SAM Plus
BR_OUT4
Damper
SAM Plus
BT_OUT8
Fan 2 on
SAM Plus
BT_OUT13
Load assumption ready
SAM Plus
BT_OUT15
Generator temp. lamp
SAM Plus
BT_OUT16
Subsidary excitation on
SAM Plus
BT_OUT17
Generator Voltage
SAM Plus
BT_OUT19
Downtime heating on
SAM Plus
BT_OUT20
Day tank min alarm
SAM Plus
39
SAM Functions SAM Basic Redundant Data Storage Life Data Storage CAN BUS Communication Operating Signals
SAM Function
SAM Plus Fuel Level Monitoring Day Tank / Storage Tank Control Fuel Pump Control Fan Control Shutter Control
Warnings / Alarms Fuel Pre- Filter Monitoring Fault Codes Web server Access Remote Control
Generator Excitation Control Generator Winding Temp. Monitoring Preheating Control Circulation Pump Control Exhaust gas 1 and 2
Next
40
Transistor Output SAM Basic Input
Function
Output
Function
B_IN 2
Test Switch Out
BR_OUT1
Pre lube on
SAM Basic
BT_OUT1
Overspeed alarm lamp
SAM Basic
BT_OUT2
Coolant temp.
warning lamp
SAM Basic
BT_OUT3
Coolant temp.
stop lamp
SAM Basic
BT_OUT4
Charge air
warning lamp
SAM Basic
BT_OUT5
Charge air alarm lamp
SAM Basic
BT_OUT6
Level intercooler stop Lamp
SAM Basic
BT_OUT7
Level coolant stop lamp
SAM Basic
BT_OUT9
Preheat not reached lamp
SAM Basic
BT_OUT10
Lube oil press. warning lamp
SAM Basic
BT_OUT11
Engine running
SAM Basic
BT_OUT12
Alarm fuel pressure
SAM Basic
BT_OUT14
Pre lube pres. reached
SAM Basic
41
Transistor Output SAM Plus
SAM Function
Input
Function
Output
Function
B_IN 2
Test Switch Out
BR_OUT2
Fuel pump on
SAM Plus
BR_OUT3
Fan 1
SAM Plus
BR_OUT4
Damper
SAM Plus
BT_OUT8
Fan 2 on
SAM Plus
BT_OUT13
Load assumption ready
SAM Plus
BT_OUT15
Generator temp. lamp
SAM Plus
BT_OUT16
Subsidiary excitation on
SAM Plus
BT_OUT17
Generator Voltage
SAM Plus
BT_OUT18
Circulation pump on
SAM Plus
BT_OUT19
Downtime heating on
SAM Plus
BT_OUT20
Day tank min alarm
SAM Plus
42
Tanklevel Monitoring and Pump Control
ANALOGOUTPUT SAM V_OUT8
Output is switch able
Tank curve via DIASYS adjustable Standard curve linear 0-100% = 4-20mA Skalierung [l/%]
At LEV < LEV1 => Combined alarm yellow + BT_OUT20 „Alarm Daytank“ + Minidiag screen
SAM Function 43
Generator Monitoring
Limit 1 B_OUT15
L1 Temp. L2 Temp. >=120°C
L3 Temp.
SAM Function 44
Exhaust Temperature A and B Side
A_IN1 and A_IN2 Exhausttemp.1 and 2 PT100 0-800°C
SAM Function 45
Logistic Concept
Easy ADEC/SAM Hardware change Application/Engine Software + Data are stored in both the SAM Memory as well as in the ADEC Memory. The download of the complete software is automatically initiated after connecting a new ADEC of SAM hardware to the remaining module.
