ADEC™ _ Advancet Diesel Engine Controller for BR 4000 and BR 2000 _ Generator Application _ MTU®.pdf

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

8

Ein/Ausgänge Br.4000/2000 mit ECU 7 DIDI11 Engine EngineStop Stop DIDI22 Droop Droop22switch switch DIDI33 DIDI44

Idle IdleMode Mode Alarm AlarmReset Reset

DIDI55 DIDI66

Speed SpeedUp Up Speed SpeedDown Down

Trans. Outputs

DIDI77 DIDI88

Engine EngineStart Start Override Override

Digital Input

AI1 AI1 Speed SpeedDemand DemandUU Speed SpeedDemand DemandI I

+24V switch

+24V switch 0-10V 0-10V 4-20mA 4-20mA

Analoger Output

AIAI22 Engine EngineTorque TorqueDemand Demand(LSG) (LSG)0-10V 0-10V Freq. Freq.InInSpeed SpeedDemand DemandFrequency Frequency10 10-500 -500Hz Hz CAN1 CAN1 CAN2 CAN2

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

Customer Switchgear Cabinet •Single Alarms •External Signals

Serial Interface RS232/485 /422

CAN Open SAE J 1939

Diasys 2.xx

Instrumente • T - Coolant • P - Lube Oil

SAM ADEC Inputs/Outputs for ADEC

16

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.

LOP Backup Engine management software + data:

SAM

Backup Engine Application Software + Data Application Software +data: memory empty

New ADEC Hardware

Engine management software + data: memory empty

SAM Function 17

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.

Backup Engine life data

Engine life data: • engine hours • error log • load profile

SAM

ADEC

SAM Function 18

SAM Service Automation Module

19

SAM Service Automation Module

Slots for additional I/O Plug-in Cards

Compact Flash Memory Card for Application SW

Display for Fault-Codes and Mini-Dialog Pushbutton for Mini-Dialog

DiagnosticLamp Plugs with spring loaded terminal strips Ethernet Interface for Remote Diagnostics and Web Based Monitoring

Interface to DialogUnit

20

SAM Service Automation Module Fan Speed & Damper Control

Binary Outputs

Preheater Control

Tank Level Monitoring and Pump Control

Prefilter Monitoring

Generator Temp. Monitoring

Raiting 1 and 2 Switch

Exhaust Temperature Side A and B

PID Control table 1 and 2 Switch

SAM and SAM+ Function

Cylinder Cutt Out Switch

WEB Page

Test Overspeed Switch Test Switch Outputs Pre Lube On Switch Manual Damper and Fan on Switch Turn switch Analogue Gauge Outputs Analogue Gauge Outputs

21

Fan Speed Control Damper Control Engine on FAN 1 and 2 on Damper open

En gi ne

st

ar t

e gin En

Time delay 0-10min or Coolant temp. > 85°C

Engine start

rt sta

Engine on FAN 1 and 2 on Damper open

Manual FAN/Damper ON B_IN10: Fan1, FAN 2 and Damper on Default value:

LIM1 = 28°C LIM2 = 32°C Hyst. LIM1 = 3°C Hyst. LIM2 = 3°C

Engine stop

Engine stop FAN1 off Damper off Roomtemp>lim1 Engine stop FAN1 off, Damper open Roomtemp>lim2 Engine stop FAN1 and 2 on, Damper open

FAN1 =

BR_OUT3

FAN2 =

BT_OUT8

Damper =

BR_OUT4

Ambient temperature. =

A_IN8

SAM Function 22

Front mounted Fan radiator driven by electrical engine

Generator Engine

Engine room

GENO

SAM Mot

Engine Fan Control controls the FAN via the

BR_OUT3

Damper

Ambient temperature A_IN8

FAN1

engine coolant temperature BR_OUT4

23

Roof mounted Fan radiator

FAN2 Table radiator TB_Version Generator Engine

Engine room

GENO

BR_OUT3

Mot

Damper

Ambient temperature A_IN8

FAN1 SAM Engine Fan Control control the FAN via the engine coolant temperature

BT_OUT8

BR_OUT4

SAM Function 24

Preheater Control BT_OUT18 Circulation pump on preheating system Output is on when the engine not run.

Power supply SAM 24V Engine runs 0V t Engine stop

Engine running - Signal

t Circulation pump BT_OUT18 24V 0V t Coolant temperature 80°C

Level Off 45°C Level On 40°C

BT_OUT19 Preheating system on Output will be controlled by the engine coolant temperature. >45 Grad Off =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/%]

Exchange

PCS5

Yellow alarm

MINIDIALOG

BR_OUT2 Alarm High +Pump off

Tankanzeige [liter]

A_IN_ISO2 Level4 95%Level > Level4

4-20 mA

BR_OUT2

Level3 90% Tank scale

Monitoring Analoges Tanklevel [0-100%] Default: Lineare Tankcurve 10 Points

LEV1 to Level4 is adjustable via Diasys

Level2 60%

Level < Level4-Hyst

Fuel Pump off

Level > Level3

Level < Level2 BR_OUT2

Level1 40%

Fuel Pump on

Level < Level1

Level > Level1+Hyst1

Min Alarm, Fuel Pump on

BR_OUT2

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.

LOP Backup Engine management software + data:

SAM

Backup Engine Application Software + Data Application Software +data: memory empty

New ADEC Hardware

Engine management software + data: memory empty

SAM Function 46

Data Storage Concept

¾ Life data storage Engine life data is stored continously every hour, after every engine stop or emergency stop in the SAM-Memory as a backup.

Backup Engine life data

Engine life data: • engine hours • error log • load profile

SAM

ADEC

SAM Function 47

WEB PAGE SAM

SAM Function 48

Dialog SAM and ADEC USB to CAN Converter

PCMCIA to CAN Converter

CAN Dialog cabel 2m, 9pol. Sub D / 12pol. round conector

Interface for Dialogunit

SAM Function 49