MTU Detroit Diesel MDEC BR 2000 Technical Publication
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MTU Detroit Diesel MDEC BR 2000 Technical Publication

Engine control system
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Technical Publication
MDEC
Engine Control System
BR 2000 / BR 4000
Stationary generator engines
S Structure and function
S Operation
S Maintenance and repair
S Operating personnel
S Plant personnel
Documentation Parts 1, 2, 3
E 531 711 / 01 E
Da imle rCh rysle r O ff -Hig h wa y

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Summary of Contents for MTU Detroit Diesel MDEC BR 2000

  • Page 1 Technical Publication MDEC Engine Control System BR 2000 / BR 4000 Stationary generator engines S Structure and function S Operation S Maintenance and repair S Operating personnel S Plant personnel Documentation Parts 1, 2, 3 E 531 711 / 01 E Da imle rCh rysle r O ff -Hig h wa y...
  • Page 2 E 2002 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
  • Page 3 Guide Page FRIEDRICHSHAFEN General information about documentation Documentation structure Documentation Title/contents Target group(s) Part Structure and function Operating personnel etc. Operation Operating personnel Maintenance and repair Plant personnel Service manual Electronic service personnel Illustrated parts catalog Operating personnel, electronic service personnel, logistics personnel Plant-specific configuration Electronic service personnel, installation...
  • Page 4 Rectification of a fault marked with this symbol either requires the customer’s service personnel or service personnel provided by MTU. The affected assembly may have to be sent to MTU for repairs. Such a fault cannot be repaired by operating personnel.
  • Page 5 Part Structure and function Page Table of contents FRIEDRICHSHAFEN Part 1 Structure and function E 531 711 / 01 E -- 12.2001 -- MDEC for stationary generator engines...
  • Page 6 Part Structure and function Page Table of contents FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 7 Part Structure and function Page Table of contents FRIEDRICHSHAFEN Table of contents Structure and function ............
  • Page 8 Part Structure and function Page Table of contents FRIEDRICHSHAFEN Table of contents (cont.) 1.4.2.3.5 Measuring point list structure ........... 1.4.2.3.6 Contrast page structure .
  • Page 9 Part Structure and function Page Table of contents FRIEDRICHSHAFEN Table of contents (cont.) 1.4.7 Safety features ............. . . 1.4.7.1 Safety shutdowns .
  • Page 10 Part Structure and function Page Table of contents FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 11 Structure and function Page FRIEDRICHSHAFEN Structure and function Engine Control System MDEC for stationary generator engines is used for engine series MTU/DDC BR 4000 and DDC/MTU BR 2000. Engine management system MDEC primarily fulfills the following tasks: ¯ Controlling the diesel engine ¯...
  • Page 12 Part Structure and function Page Features FRIEDRICHSHAFEN Features Engine Control System MDEC for stationary generator engines has the following essential features: ¯ Can be used for engine series 2000 and 4000 ¯ Electronic engine regulation and control ¯ Engine monitoring for inadmissible operating states ¯...
  • Page 13 Part Structure and function Structure Page FRIEDRICHSHAFEN Structure The structure of an overall MDEC system for stationary generator engines comprising the two sub-systems ECS-5 and MCS-5 depends on customer requirements and the superordinate genset control unit. The various sub-systems and their component parts are represented schematically in the figure below (fig. 2). MCS-5 ECS-5 Fig.
  • Page 14 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.1 Structure of Engine Control System ECS-5 Engine Control System ECS-5 consists of the following devices: ¯ Engine Control Unit ECU ¯ Engine sensors ¯ Engine actuators ¯ Engine injectors ¯ Engine cable harnesses Note: The function of the Engine Control System ECS-5 remains the same with regard to Monitoring and Control System MCS-5 and its scope.
  • Page 15 Part Structure and function Structure Page FRIEDRICHSHAFEN 1.3.2 Structure of Monitoring and Control System MCS-5 1.3.2.1 Basic scope of the MCS-5 of the MDEC for stationary generator engines MCS-5 Fig. Basic scope of the MCS-5 of the MDEC for stationary generator engines Pos.
  • Page 16 The devices of Engine Control System ECS-5 1.3.2.2.1 Engine Control Unit ECU The ECU assembly is a speed and injection governor for DDC/MTU series 2000 and 4000 engines. It is located directly on the engine. Engine Control Unit ECU features: ¯...
  • Page 17 Part Structure and function Structure Page FRIEDRICHSHAFEN Pos. Name Meaning Connector X1 Can bus connection Connector X3 BR 2000: Not used* BR 4000: High-pressure controller Connector X2 Engine cable harness connection Connector X5 Operating voltage connection Connector X4 Engine cable harness connection Connector X6 Connection for dialog unit (optional), Notebook Cover...
  • Page 18 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.2.3 MCS-5 options of the MDEC for stationary generator engines A range of options are available to allow engine management system MDEC to be adapted to suit customer- specific requirements. These options can be divided into three categories: ¯...
  • Page 19 Part Structure and function Structure Page FRIEDRICHSHAFEN Pos. Name Meaning MCS-5 Power supply Signal connection to ECS-5 devices System demarcation MCS-5 sub-system line Interface For superordinate genset control: Relay outputs for shutdown and combined alarms PIM A 512 Peripheral Interface Module PIM 2 with relay outputs Interface For superordinate genset control: Transistor outputs for warnings and alarms as well as shutdowns...
  • Page 20 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.2.3.2 Display DIS MCS-5 Fig. Display, option Pos. Name Meaning MCS-5 Power supply Signal connection to ECS-5 devices System demarcation MCS-5 sub-system line Display -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 21 Part Structure and function Structure Page FRIEDRICHSHAFEN 1.3.2.3.3 Analog display instruments MCS-5 Fig. Analog display instruments, option Pos. Name Meaning MCS-5 Signal connection to ECS-5 devices (ECU analog outputs) System demarcation MCS-5 sub-system line Display instrument Engine speed Display instruments Engine operating data Note: The display instruments can be combined as desired.
  • Page 22 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.2.4 The devices of Monitoring and Control System MCS-5 1.3.2.4.1 Peripheral Interface Module PIM A 511 Peripheral Interface Module PIM A 511 is used to display ECU internal fault codes. Indication is reali- zed by a four-figure 7-segment display.
  • Page 23 Part Structure and function Structure Page FRIEDRICHSHAFEN Ambient temperature --30 °C ¼ +70 °C Storage temperature --35 °C ¼ +70 °C Relative humidity 0 % ¼ 97 %, non-condensing Colour Blue (RAL 5015) Material Fibre-glass reinforced polycarbonate (PC) PIM 1 Dimensions (H x W x D) 75 mm x 70 mm x 90 mm Number of terminals...
  • Page 24 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.2.4.2 Peripheral Interface Module PIM A 512 Peripheral Interface Module PIM A 512 is used to output the following information via relay contacts: -- Overspeeding -- Lube oil pressure shutdown -- Coolant temperature shutdown -- Coolant level shutdown -- Charge air shutdown -- Combined red alarm...
  • Page 25 Part Structure and function Structure Page FRIEDRICHSHAFEN 1.3.2.4.3 Peripheral Interface Module PIM A 513 The 14 transistor outputs (+24 VDC positive swit- ching) of Peripheral Interface Module PIM A 513 are used to output the following information: 1. Warning, coolant temperature too high 2.
  • Page 26 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.2.4.4 Peripheral Interface Module PIM A 515 Peripheral Interface Module PIM A 515 is a serial interface coupler. The CAN bus signals are con- verted here to the signal level of an RS422 inter- face and an RS232 interface.
  • Page 27 Part Structure and function Structure Page FRIEDRICHSHAFEN 1.3.2.4.5 Peripheral Interface Module PIM A 516 The 14 transistor outputs (+24 VDC negative switching) of Peripheral Interface Module PIM A 516 are used to output the following information: 1. Warning, coolant temperature too high 2.
  • Page 28 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.2.4.6 Peripheral Interface Module PIM A 517 Peripheral Interface Module PIM A 517 is used to output the following information via relay contacts: Slot 2: 1. ECU is faulty 2. High fuel pressure combined alarm 3.
  • Page 29 Part Structure and function Structure Page FRIEDRICHSHAFEN 1.3.2.4.7 Peripheral Interface Module PIM A 519 Peripheral Interface Module PIM A 518 is used to output and acquire the following information: Slot 2: 1. Pressure instrument control 2. Temperature instrument control 3. Four binary inputs Slot 3: 4.
  • Page 30 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.2.4.8 Display DIS The display is a decentralized information and monitoring device. It is used to indicate engine operating states, alarms and system information. Displayed data (measured values, alarms etc.) are transmitted to the display from the Monitoring and Con- trol System (MCS-5) via the field bus.
  • Page 31 Part Structure and function Structure Page FRIEDRICHSHAFEN Technical data Type DIS 7-01 Dimensions (W x H x D) 220 mm x 224 mm x 98 mm Weight 1.9 kg Operating voltage U 24 VDC Tolerance --50 %, --30 % Residual ripple In accordance with STANAG 1008, IEC 68, MIL-STD 704 Power consumption 15 W at 24 V...
  • Page 32 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.2.4.9 Display instruments Three different types of instrument are used to dis- play the following engine operating data: ¯ Engine speed (17/1) ¯ Engine oil pressure (17/2) ¯ Engine coolant temperature (17/3) ¯ Coolant temperature (17/4) Fig.
  • Page 33 Part Structure and function Structure Page FRIEDRICHSHAFEN 1.3.3 Data connections The devices of the overall MDEC system for stationary generator engines are equipped with a CAN bus to transmit data between the various sub-systems. This bus is redundant (i.e. two are provided). The CAN bus is a standard automation technology field bus allowing various systems and devices to com- municate providing they are equipped with a CAN bus interface.
  • Page 34 Part Structure and function Page Structure FRIEDRICHSHAFEN 1.3.4 Power supply The +U power supply for all the devices in the overall MDEC system for stationary generator engines is supplied directly to the appropriate device terminals and the ECU connector. 1.3.5 Earthing Both the engine and the alternator are connected to earth (PE) via an equipotential bonding strip on the skid.
  • Page 35 Part Structure and function Structure Page FRIEDRICHSHAFEN 1.3.6 Technical data Operating voltage 24 VDC, --25 %/+30 % Residual ripple less than 5 % Power consumption Depending on system design (number and type of options used), refer to the descriptions of the various devices, the total power consumption is the sum of the power consumed by the individual devices EMI/EMC...
  • Page 36 Part Structure and function Page Functions FRIEDRICHSHAFEN Functions 1.4.1 Operating functions on display DIS (option) Engine management system MDEC for stationary generator engines is operated via the display in Monitoring and Control System MCS-5. Note: Display DIS only shows information about the operating state of the engine and the overall MDEC engine management system.
  • Page 37 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.2 Display functions 1.4.2.1 Display functions of fault code display FCB in PIM A 511 Display Fig. 21 : Display on printed circuit board FCB in Peripheral Interface Module PIM A 511 The fault codes generated by the ECU are shown on the display in PIM A 511 (see fig. 21). The four digits indicating faults related to the ECU concerned have the following meaning: ¯...
  • Page 38 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.2.2 Display functions of display DIS (option) Fig. 22 : Display DIS Detailed information about the drive is shown on the display (22/1) of Monitoring and Control System MCS-5. The display is menu-guided and can be controlled using the pushbuttons underneath the screen. Menu structure is illustrated in chap.
  • Page 39 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.2.3 Display functions on the man-machine interface of the display (option) The following menu structure is used on the DIS: Overview page Meas. Contrast System Service Alarm Over- value list page page page page view Help...
  • Page 40 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.2.3.1 General screen page structure The screen pages are divided into the following areas: ¯ Status bar ¯ Central display area ¯ Key assignment display Fig. 24 : General screen page structure (example) Pos.
  • Page 41 Part Structure and function Functions Page FRIEDRICHSHAFEN Status bar Fig. 25 : Status bar structure (example) Pos. Name Meaning 25/1 Page designation Name of the selected screen page 25/2 No. of alarms display field Number of alarms waiting to be processed 25/3 Safety system override A message is displayed when safety system override is active...
  • Page 42 Part Structure and function Page Functions FRIEDRICHSHAFEN Central display area The central display area is used to display the following pages: ¯ Overview page ¯ Graphic pages Measured values in graphic representation ¯ Measured value list Measured values in alphanumeric representation ¯...
  • Page 43 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.2.3.2 Overview page structure The pages which are available for selection in a menu are shown in the central display area at the Overview page. System Page 2000 ECU Engine Control Unit 4000 ECU Engine Control Unit Auxilliary Measuring List Measuring Point List Contrast Page...
  • Page 44 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.2.3.3 System page stucture The central display area of the System page is used to display system status and software version. The System page opens automatically when a system error occurs. Fig. 27 : System page structure (example) System variable Display/input...
  • Page 45 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.2.3.4 Graphic page structure The current operating values of a plant such as engine speed, injection quantity, lube oil pressure and cool- ant temperature are shown on the ECU overview in the Graphic page display field. Fig.
  • Page 46 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.2.3.5 Measuring point list structure Project-related measured values are represented alphanumerically in the display field of the measuring point list, these are not shown on the graphic pages. Invalid measured values are identified as follows: ¯...
  • Page 47 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.2.3.6 Contrast page structure Bargraphs for brightness and contrast are shown in the central display area of the Contrast page together with the information that simultaneously pressing function keys F1 and F5 (within 3 seconds) resets the LC display to the default factory settings.
  • Page 48 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.2.3.7 Service page structure The central display area of the Service page is used to display (display mode) and modify system settings (edit mode). Edit mode: Fig. 31 : Service page structure (example) System variables Display/settings Date:...
  • Page 49 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.2.3.8 Alarm page structure The alarms are displayed in the order of their occurrance in the central display area of the Alarm page. Alarm names appear in the first column, alarm status in the second column (UNACK for unacknowledged, ACK for acknowledged) and the type of alarm in the third column (yellow, red).
  • Page 50 Part Structure and function Page Functions FRIEDRICHSHAFEN Column num- Entry Meaning ber on Alarm page AL ¼ “Alarm”, warning or alarm caused by a binary signal LO ¼ “Low”, warning or alarm due to low limit value violation HI ¼ “High”, warning or alarm due to high limit value violation TD ¼...
  • Page 51 Part Structure and function Functions Page FRIEDRICHSHAFEN Column num- Entry Meaning ber on Alarm page UNACK “Unacknowledged Alarm”, warning, alarm or message from an external system is active and unacknowledged UNACK_ALM “Unacknowledged Alarm”, (printout only) warning, alarm or message from an external system is active and unacknowledged UNACK_RTN “Unacknowledged Return”,...
  • Page 52 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.2.3.9 Help page structure Alarm message structure is explained in the central display area of the Help pages. System error numbers and the associated system error designations are listed on Help page 1. The abbreviations and associated descriptions of the various types of message are listed on Help page 2 to 4.
  • Page 53 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.2.4 Display functions of the display instruments (option) Fig. 34 : Monitoring and Control System MCS-5 display instruments (example) Pos. Function name Meaning 34/1 Coolant temperature Coolant temperature display 34/2 Lube oil pressure Engine lube oil pressure display 34/3 Engine speed...
  • Page 54 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.3 Acquisition functions 1.4.3.1 Plant signals 1.4.3.1.1 Signals to Engine Control Unit ECU The following plant signals are acquired by the ECU of the MDEC engine management system for stationary generator engines: Signal ECU channel Engine stop BE 1...
  • Page 55 Part Structure and function Functions Page FRIEDRICHSHAFEN Signal PIM channel Output 2, temperature display instrument, free assignment INST 4 slot 2 Input 1, plant pressure sensor, free assignment 4 ... 20 mA chan. 1 slot 3 Input 2, plant pressure sensor, free assignment 4 ...
  • Page 56 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.3.2 Engine signals 1.4.3.2.1 Sensors The following engine signals are acquired by the ECU of the MDEC engine management system for statio- nary generator engines: Sensor Signal BR 2000 BR 4000 Camshaft speed Lube oil pressure Coolant temperature Lube oil temperature...
  • Page 57 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.3.2.2 Sensors on the engine BR2000 BR4000 Measu- Tem- Tem- Tem- Tem- Tem- Pres- Pres- Pres- Pres- red va- pera- pera- pera- pera- Level pera- Level Speed Speed sure sure sure sure riable ture ture ture...
  • Page 58 Part Structure and function Page Functions FRIEDRICHSHAFEN Speed sensors Type Sensor range Electr. signal Number Camshaft speed Type 1 80 -- 2800 rpm 0 -- 80 V Crankshaft speed Type 1 80 -- 2800 rpm 0 -- 80 V Fig. 35 : Structure of type 1 Temperature sensors Type...
  • Page 59 Part Structure and function Functions Page FRIEDRICHSHAFEN Pressure sensors Type Sensor range Electr. signal Number Lube oil pressure Type 1 0 -- 10 bar relative 0.5 – 4.5 VDC Charge air pressure Type 2 0.5 -- 4.5 bar absolute 0.5 – 4.5 VDC Fuel pressure after filter Type 4 0 -- 15 bar relative...
  • Page 60 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.4 Control functions The MDEC engine management system for stationary generator engines is responsible for the following engine control functions: ¯ Start sequence control ¯ Stop control ¯ Emergency start control ¯ Controlling processes when the “Override” function is active ¯...
  • Page 61 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.4.1 Engine start 1.4.4.1.1 Normal engine start The start sequence is controlled by the software integrated in Engine Control Unit ECU. START key t>t Start termination Start interlock time Start termination Fault message <T Coolant “Preheat temperature low”...
  • Page 62 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.4.1.2 Engine restart The term “Restart” is used for a repeated engine start request which is received when the engine is running down following a stop command. The response of the engine in this case depends on the speed at which it is running when the new start request is received: ¯...
  • Page 63 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.4.2 Engine stop Engine stopping is initiated by activating the appropriate binary input on the Engine Control Unit ECU or by the engine safety system. The injection valves are no longer active and no more fuel is injected. Any attempt to initiate starting is interrupted.
  • Page 64 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.5 Monitoring functions Engine management system MDEC for stationary generator engines fulfills the following monitoring tasks: ¯ Controlling analog displays (option) for Engine speed Engine lube oil pressure Engine lube oil temperature Engine coolant temperature ¯...
  • Page 65 Part Structure and function Functions Page FRIEDRICHSHAFEN Possible activities of the engine safety system are: ¯ Outputting a fault message number via a Peripheral Interface Module PIM (option) ¯ Output of combined alarms (RED or YELLOW) and individual alarms ¯ Dynamic feeding limitation ¯...
  • Page 66 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.6 Regulating functions Engine management system MDEC for stationary generator engines realizes the following engine regulating functions: ¯ Speed governor/feeding governor (depending on operating state) ¯ Injection regulation for solenoid valve-controlled injection with mapped injection start control ¯...
  • Page 67 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.6.2 Idle speed governor - - maximum speed governor - - feeding governor Depending on the current operating state, the governor in the Engine Control Unit operates as: ¯ All-speed governor (only after engine starting) ¯...
  • Page 68 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.6.3 Common Rail injection system (series 4000 only) Firing Speed governor Unlimited Quantity limitation Characteristic maps Inj.start/inj. end gov. quantity seq. set quantity speed PI(DT Injection start Closing/ Setting Maximum quantity opening Injection quantity M = f (speed) pulses timing SV...
  • Page 69 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.6.4 PLN injection system (series 2000 only) Firing Speed governor Unlimited Quantity limitation Characteristic maps Inj. start/inj. end gov. seq. speed set quanity quantity Injection start Closing/ Setting Maximum quantity opening Injection quantity pulses M = f (speed) timing SV...
  • Page 70 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.6.5 Angle measuring/determining engine timing The timing is defined in the electronics on the basis of information from angle measuring sensors on two measuring gears. One measuring gear is mechanically coupled to the crankshaft and one to the camshaft. The crankshaft sensor detects the precise angle of the crankshaft under normal operating conditions in order to determine the injection timing and thus derive the engine speed.
  • Page 71 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.6.6 Speed droop 1.4.6.6.1 Speed droop calculation Speed droop influences the effective set speed depending on engine output. The maximum, speed-depen- dent engine output is limited by the DBR curve. Speed droop does not influence the set speed at the 100% output point.
  • Page 72 Part Structure and function Page Functions FRIEDRICHSHAFEN Load DBR curve Resultant speed at load L1 Zero load Idling speed Set speed value Speed droop Engine Nominal speed speed Maximum speed at zero load Zero Fig. 48 : Graphic representation of the speed adjusting range and speed droop Speed droop is defined as the relative change in speed when the engine is unloaded.
  • Page 73 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.6.7 Power limitation (quantity limitation) 1.4.6.7.1 Dynamic quantity limitation Dynamic quantity limitation, i.e. variable limitation of the fuel injected, is used to protect the engine against overloading and to optimize exhaust emission values. Engine Control Unit ECU determines the maximum injection quantity on the basis of preset and stored characteristic engine maps.
  • Page 74 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.6.8 Speed setpoint handling The speed setting (= speed setpoint) is the control variable for the engine speed control loop. An internally programmed speed setpoint is approached when the engine is started (at a network frequency of 50 Hz: 1500 rpm;...
  • Page 75 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.7 Safety features 1.4.7.1 Safety shutdowns Safety shutdowns are activated by the engine safety system in case of ¯ Limit value violation ¯ Sensor defect (depending on configuration) This applies to the following measuring points: ¯...
  • Page 76 Part Structure and function Page Functions FRIEDRICHSHAFEN Engine Control Unit ECU response to high coolant temperature The “Coolant temperature alarm” output is activated if the coolant temperature exceeds T and a Limit1 “Combined red alarm” is signalled. Note: The switchgear controller must open the generator switch when the “Combined red alarm” is signalled (to be configured by the client).
  • Page 77 Part Structure and function Functions Page FRIEDRICHSHAFEN 1.4.7.1.1 Integral Test System (ITS) The Integral Test System ITS monitors all vital functional areas of Engine Control Unit ECU and the connec- ted electrical and electronic components: ¯ Electronics of the actual engine governor inside Engine Control Unit ECU ¯...
  • Page 78 Part Structure and function Page Functions FRIEDRICHSHAFEN 1.4.7.1.3 Sensor/actuator monitoring The various sensor and actuator channels of the engine management system are designed to tolerate faults (e.g. short-circuit) as far as possible. Faults such as wire break, short-circuit etc. are detected by a plausibility check and signalled to a superordi- nate Monitoring and Control System (if applicable) by means of a combined alarm.
  • Page 79 Part Operation Page Table of contents FRIEDRICHSHAFEN Part 2 Operation E 531 711 / 01 E -- 12.2001 -- MDEC for stationary generator engines...
  • Page 80 Part Operation Page Table of contents FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 81 Part Operation Page Table of contents FRIEDRICHSHAFEN Table of contents Operation ..............Safety requirements .
  • Page 82 Part Operation Page Table of contents FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 83 Furthermore, the following shall be observed: ¯ The safety requirements (if provided) in other relevant MTU manuals ¯ Warning and safety information and operating and limit values attached to the products as required ¯...
  • Page 84 FRIEDRICHSHAFEN Safety requirements for commissioning Before first using the electronic product, it must be installed in accordance with the instructions and approved to MTU specifications. Whenever the device or system is taken into operation ¯ All maintenance and repair work must have been completed ¯...
  • Page 85 Part Operation Operating procedures Page FRIEDRICHSHAFEN Operating a display Information about operating states of the propulsion line and the overall electronic system (i.e. Engine Control System ECS-5 and Monitoring and Control System MCS-5) can be called up on a number of screen pages on the display.
  • Page 86 Part Operation Page Operating procedures FRIEDRICHSHAFEN Meaning of the symbols The various symbols have the following meanings: Symbol Description Acknowledges alarms (shown on the display) Opens the Alarm page Scrolls Up to select a menu option on the Overview page Scrolls Up page-by-page on graphic pages, Measured value list, Help page and Alarm page A dotted arrow indicates that the function key is inactive...
  • Page 87 Part Operation Operating procedures Page FRIEDRICHSHAFEN Symbol Description Increases the input value Decreases the input value Lamp test, all luminous pushbuttons and indicators on Local Operating Station LOS light up brightly Language switching (e.g. German/English) The texts are stored in 2 languages Horn off Silences the horn connected to the relay output if it is sounding Other operating procedures...
  • Page 88 Part Operation Page Operating procedures FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 89 Part Maintenance and repair Page Table of contents FRIEDRICHSHAFEN Part 3 Maintenance and repair E 531 711 / 01 E -- 12.2001 -- MDEC for stationary generator engines...
  • Page 90 Part Maintenance and repair Page Table of contents FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...

  • Page 91: Table Of Contents

    Part Maintenance and repair Page Table of contents FRIEDRICHSHAFEN Table of contents Maintenance and repair ............Safety requirements .
  • Page 92 Part Maintenance and repair Page Table of contents FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...

  • Page 93: Maintenance And Repair

    Furthermore, the following shall be observed: ¯ The safety requirements (if provided) in other relevant MTU manuals ¯ Warning and safety information and operating and limit values attached to the products as required ¯...
  • Page 94 Inform the MTU service department or its representative in case of damage which cannot be rectified by plant personnel. On completion of maintenance and repair work, ensure that no superfluous parts (tools etc.) remain inside the device or system.

  • Page 95: General Information About This Manual

    Part Maintenance and repair General information about this manual Page FRIEDRICHSHAFEN General information about this manual Refer to order-specific documents (e.g. drawings) if necessary in case of deviations from the information provided in this manual. 3.2.1 Task duration and personnel qualification Information about task duration is only intended to serve as a guide and is based on the work being carried out under normal working conditions.

  • Page 96: Structure

    Part Maintenance and repair Page General information about this manual FRIEDRICHSHAFEN 3.2.3 Structure The chapters in this manual describing specific work are structured as shown in fig. 51. Task Task Activity overview descriptions descriptions Listing Illustrated text Table Listing Illustrated text (Maintenance schedule/fault code table/troubleshooting...

  • Page 97: Tools, Expedients And Consumables

    3.3.2 For repair The following tools, expedients and consumables are required to perform the repair work described: ¯ Tool kit SME 4-01 (see MTU manual “Tool kit SME 4-01, Part 5”) ¯ Cable ties in various lengths ¯ Self-adhesive insulating tape E 531 711 / 01 E -- 12.2001 --...

  • Page 98: Troubleshooting Devices

    Dialog unit (see fig. 53) Fig. 52 : MDEC simulator for connector X2 The use of the MDEC simulator is described in MTU document “ECS-5 Testing and simulation device ECU-4 (X2)”, document no. E 532 085. Fig. 53 : Dialog unit Use of the dialog unit is described in MTU documentation “DiaSys 2.xx”, document no.
  • Page 99 However, the cable from connector X6 must also be looped through the simulator to provide the power supply. Detailed information about this simulator is provided in MTU documentation “Service and work- shop equipment catalog”, document no. E 531 759. E 531 711 / 01 E -- 12.2001 --...

  • Page 100: Malfunctions

    Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Malfunctions 3.4.1 Safety instructions Injury hazard! Before commencing repair work, always: Stop the engine and lock out to preclude starting! DANGER System failure possible! Short-circuits caused by carrying out repair work on devices with the operating voltage switched on may result in total system failure during operation.

  • Page 101: Fault Displays

    Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN 3.4.2 Fault displays Faults in the overall MDEC system are indicated at the devices of the MCS-5 sub-system as follows: ¯ Fault code numbers (generated inside Engine Control Unit ECU) on a 4-figure 7-segment display in PIM A 511 ¯...
  • Page 102 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 (Not used) (Not used) (Not used) (Not used) (Not used) Charge air temperature ' Engine documentation L1 T-CHARGE AIR too high (first limit value overshot) Charge air temperature ' Engine documentation L2 T-CHARGE AIR too high (second limit...
  • Page 103 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Coolant level too low, Check coolant level in L1 COOLANT LEVEL message appears simulta- expansion tank neously with no. 24 ' Engine documentation Coolant level too low, Check coolant level in L2 COOLANT LEVEL message appears simulta-...
  • Page 104 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 (Not used) (Not used) (Not used) (Not used) (Not used) Lube oil temperature too ' Engine documentation L1 T-LUBE OIL high (first limit value over- shot) Lube oil temperature too ' Engine documentation L2 T-LUBE OIL high (second limit value...
  • Page 105 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Alarm ‘First limit value The measured value is read L1 T-EXTERN 1 violated’ for ext. tempera- in via the CAN. The alarm is ture channel 1 handled in MDEC. Alarm ‘Second limit value The measured value is read L2 T-EXTERN 1...
  • Page 106 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Low pressure gradient on High pressure system RAIL LEAKAGE starting or high pressure leaking, air in the system gradient on stopping ' Engine documentation Rail pressure above set Interface transformer mal- RAIL PRESSURE value ®...
  • Page 107 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Start error message, star- Check for further messages START SPEED LOW ter speed (MP 169.02) not reached within the time defined in MP 169.03 (counting starts when the starter is activated) ®...
  • Page 108 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Fault memory checksum ' Electronics service ERR REC1 NOT error in EDM (redundant VALID data record 1) Fault memory checksum ' Electronics service ERR REC2 NOT error in EDM (redundant VALID data record 2) (Not used)
  • Page 109 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 If the supply voltage is Check battery/generator L2 SUPPLY VOLT. above the set upper limit HIGH value 2 (MP 102.03) the engine is stopped, if confi- gured (in MP 102.14 = T) ECU temperature too high Check electronics environ- L1 T-ELECTRONIC...
  • Page 110 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 This fault can have various Fault analysis for internal L1 5V BUFFER TEST causes: electronic fault: 1. Pressure sensor fault Disconnect connectors X2 2. Sensor wiring and X3, ECU is faulty if fault 3.
  • Page 111 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Internal electronics failure Replace Engine Control Unit BANK1 ECU DEFECT ® engine does not start, electronics faulty, test with See ID: T-E-G24-0001 engine at standstill only Page 40 (Not used) Internal electronics failure Replace Engine Control Unit...
  • Page 112 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) Module in maintenance Check whether the MI is MI MODULE FAIL indicator faulty or missing properly installed ' Electronics service...
  • Page 113 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 A CAN mode is selected in Test the devices connected CAN NO PU-DATA which communication is to the CAN initialized with the help of Download again via BDM the PU data module.
  • Page 114 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 (Not used) (Not used) (Not used) (Not used) Sensor defect (coolant Short-circuit or wire SD T-COOLANT temperature) breakage, check sensor and wiring to B6 ' Electronics service Sensor defect (fuel tempe- Short-circuit or wire SD T-FUEL...
  • Page 115 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Sensor defect (Rail pres- Short-circuit or wire SD P-RAIL FUEL sure) ® high pressure breakage, check sensor and governor emergency wiring to B48 operation ' Electronics service Sensor defect (lube oil Short-circuit or wire SD T-LUBE OIL...
  • Page 116 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 (Not used) (Not used) (Not used) (Not used) Sensor defect crankcase Compare alarms 230 and SD ENG.SPEED SEN- speed a n d sensor SORS defect camshaft speed Sensor defect (crankshaft Short-circuit or wire SD CRANKSHAFT...
  • Page 117 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Internal ECU failure Electronics faulty SD POWER SUPPLY Replace Engine Control Unit See ID: T-E-G24-0001 Page 40 Internal ECU failure Electronics faulty SD T-ELECTRONIC Replace Engine Control Unit See ID: T-E-G24-0001 Page 40...
  • Page 118 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 (Not used) Sensor defect (analog Short-circuit or wire SD SPEED DEMAND speed setting) ® speed is breakage, check set speed set to a fault value or transmitter and wiring remains set to the actual ' Electronics service speed (adjustable, MP...
  • Page 119 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used) (Not used)
  • Page 120 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Cylinder A5: Replace solenoid valve if TIMING CYLINDER --FPGA fault status = 2 this occurs frequently --Time-of-flight t < 600 μs ' Engine documentation --Time-of-flight t > 1400 μs Cylinder A6: Replace solenoid valve if TIMING CYLINDER...
  • Page 121 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Cylinder B6: Replace solenoid valve if TIMING CYLINDER --FPGA fault status = 2 this occurs frequently --Time-of-flight t < 600 μs ' Engine documentation --Time-of-flight t > 1400 μs Cylinder B7: Replace solenoid valve if TIMING CYLINDER...
  • Page 122 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Cabling fault cylinder A4 SV short-circuit or +SV line WIRING CYLINDER ® misfiring shorted to electronic ground (Requirement: Engine block grounded) Replace solenoid valve or cable harness ' Engine documentation Cabling fault cylinder A5 SV short-circuit or +SV line...
  • Page 123 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Cabling fault cylinder A9 SV short-circuit or +SV line WIRING CYLINDER ® misfiring shorted to electronic ground (Requirement: Engine block grounded) Replace solenoid valve or cable harness ' Engine documentation VCabling fault cylinder A10 SV short-circuit or +SV line...
  • Page 124 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Cabling fault cylinder B4 SV short-circuit or +SV line WIRING CYLINDER ® misfiring shorted to electronic ground (Requirement: Engine block grounded) Replace solenoid valve or cable harness ' Engine documentation Cabling fault cylinder B5 SV short-circuit or +SV line...
  • Page 125 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Cabling fault cylinder B9 SV short-circuit or +SV line WIRING CYLINDER ® misfiring shorted to electronic ground (Requirement: Engine block grounded) Replace solenoid valve or cable harness ' Engine documentation Cabling fault cylinder B10 SV short-circuit or +SV line...
  • Page 126 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Fault (interruption) in Check cabling and solenoid OPEN_LOAD CYL. A6 cabling of cylinder A6 ® valve for interruption misfiring Replace solenoid valve or cable harness ' Engine documentation Fault (interruption) in Check cabling and solenoid OPEN_LOAD CYL.
  • Page 127 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Fault (interruption) in Check cabling and solenoid OPEN_LOAD CYL. B3 cabling of cylinder B3 ® valve for interruption misfiring Replace solenoid valve or cable harness ' Engine documentation Fault (interruption) in Check cabling and solenoid OPEN_LOAD CYL.
  • Page 128 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Fault (interruption) in Check cabling and solenoid OPEN_LOAD CYL. cabling of cylinder B10 ® valve for interruption misfiring Replace solenoid valve or cable harness ' Engine documentation Internal electronics failure PA circuit faulty or free- POWER STAGE...
  • Page 129 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 Solenoid valve wiring fault SV line shorted to electronic STOP MV-WIRING ® engine stop ground (engine block applied to electronic ground) Replace cable harness ' Engine documentation (Not used) (Not used) (Not used)
  • Page 130 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 TAA2 faulty 1. Wire breakage or short- TRAN.OUT2 PLANT circuit Replace cable harness ' Engine documentation 2. Electronics faulty Replace Engine Control Unit See ID: T-E-G24-0001 Page 40 TAA3 faulty 1.
  • Page 131 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Fault display Meaning/cause Counteraction 2000 4000 TAA6 faulty 1. Wire breakage or short- TRAN.OUT6 PLANT circuit Replace cable harness ' Engine documentation 2. Electronics faulty Replace Engine Control Unit See ID: T-E-G24-0001 Page 40 (Not used) (Not used) (Not used)

  • Page 132: Replacing Engine Control Unit Ecu

    Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN 3.4.2.1 Replacing Engine Control Unit ECU ID no.: T-E-G24-0001 Duration: 15 min Qualification: System components/devices Engine Control Unit ECU on the engine ¯ New Engine Control Unit ECU ¯ Suitably programmed memory modules as necessary (see below) ¯...
  • Page 133 Page FRIEDRICHSHAFEN Additional information Inform MTU customer service if a fault message appears indicating an invalid data ¯ record after replacing the ECU. A valid data record must be programmed in this case (specialist personnel!) or suitably programmed modules ordered and inser- ted.

  • Page 134: Removing The Housing Of Engine Control Unit Ecu From The Engine

    Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN 3.4.2.1.1 Removing the housing of Engine Control Unit ECU from the engine ID no.: A-E-G24-0001 Engine Control Unit ECU 4 (55/4) is located directly on the engine. It is screwed on by means of various adapter brackets (55/6) which are con- nected to the engine via cable shock absorbers (55/5).

  • Page 135: Opening The Cover On Engine Control Unit Ecu

    Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN 3.4.2.1.2 Opening the cover on Engine Control Unit ECU ID no.: A-E-ECU-0002 1. Place Engine Control Unit ECU such that the sockets are facing towards you. 2. The cover is secured to the housing of Engine Control Unit ECU by ten Phillips screws, undo these screws one after the other using a Phil- lips screwdriver.

  • Page 136: Transferring Memory Modules In Engine Control Unit Ecu

    Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN 3.4.2.1.3 Transferring memory modules in Engine Control Unit ECU ID no.: A-E-ECU-0011 Danger of engine damage! The data stored in these memory modules always applies to a specific engine (not a type of engine, but one specific engine having its own unique engine no.).
  • Page 137 Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN Check polarity! There is a line (60/4) marking pin 1 on the Interface Data Module IDM and its socket; these two lines must match up. CAUTION 6. Press the data module (60/3) at the back into the socket on printed circuit board ECB 4-01 (60/2) until the snap-in clips (60/1) engage.

  • Page 138: Fitting The Cover On Engine Control Unit Ecu

    Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN 3.4.2.1.4 Fitting the cover on Engine Control Unit ECU ID no.: A-E-ECU-0006 1. Check that the round seal is not damaged, otherwise replace it. 2. Ensure that the seal is properly seated in the groove in the housing all the way round.

  • Page 139: Mounting The Housing Of Engine Control Unit Ecu On The Engine

    Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN 3.4.2.1.5 Mounting the housing of Engine Control Unit ECU on the engine ID no.: A-E-G24-0002 1. If the four hex-head bolts (64/3) have been undone, screw them through the appropriate adapter brackets (64/2) by hand into the thread on the cable shock absorbers (64/4).
  • Page 140 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN 6. Fit the first connector (65/1) of a cable harness on the corresponding connector socket (65/2) on Engine Control Unit ECU 4. 7. Turn the bayonet union nut (65/4) clockwise using connector pliers (65/3) until it locks into place.

  • Page 141: Using The Mdec Simulator

    Part Maintenance and repair Malfunctions Page FRIEDRICHSHAFEN 3.4.2.2 Using the MDEC simulator ID no.: T-E-G24-0002 Duration: 60 min Qualification: System components/devices Engine Control Unit ECU on the engine ¯ MDEC simulator ¯ Additional safety notes The engine must never be started when the simulator is connected. ¯...
  • Page 142 Part Maintenance and repair Page Malfunctions FRIEDRICHSHAFEN Sensor Signal ECU channel BR 2000 BR 4000 Intercooler coolant level NSE1 Fuel temperature high-pressure side Fuel pressure high-pressure side Engine coolant level NSE3 Fig. 66 : MDEC simulator 1 Connector X2 2 Potentiometer for setting analog values 3 Jumper plugs to simulate line interruption and for tapping signals (e.g.

  • Page 143: Maintenance

    Part Maintenance and repair Maintenance Page FRIEDRICHSHAFEN Maintenance 3.5.1 Maintenance overview Periodic maintenance work on the Engine Control System Column 2 in table 1 lists the intervals for routine maintenance work. The maintenance intervals are adapted to the engine maintenance system. Maintenance of electronic components by operating personnel (operators and plant personnel) is restricted to maintenance echelons W1 to W3.

  • Page 144: Visual Inspection, Mechanical Testing And Cleaning

    Part Maintenance and repair Page Maintenance FRIEDRICHSHAFEN 3.5.2 Visual inspection, mechanical testing and cleaning ID no.: T-M-G24-0003 Duration: 20 min Qualification: System components/devices Engine Control Unit ECU ¯ Peripheral Interface Module PIM A 511 ¯ Display DIS (option) ¯ Further Peripheral Interface Modules PIM A 51x (option) ¯...

  • Page 145: Cleaning Device(S) Externally

    Part Maintenance and repair Maintenance Page FRIEDRICHSHAFEN 3.5.2.1 Cleaning device(s) externally ID no.: A-N-NNN-0016 1. Clean all listed devices with the recommended expedients. 2. Renew illegible identification and inscriptions on all listed devices. 3.5.2.2 Checking device(s) externally ID no.: A-N-NNN-0017 1.

  • Page 146: Structure Of Engine Control Unit Ecu 4

    Part Maintenance and repair Page Structure and function (supplement) FRIEDRICHSHAFEN Structure of Engine Control Unit ECU 4 3.6.1 External structure Engine Control Unit ECU 4 is enclosed in a diecast housing with a screw-fitted cover. approx. 48 all dimensions in mm Fig.
  • Page 147 Part Maintenance and repair Structure and function (supplement) Page FRIEDRICHSHAFEN The connections for the plant, power supply, dialog unit and the cable harnesses are written on the housing cover. Pre-cut system cables and cable harnesses are connected to these connectors (X1 ... X6, see table below).

  • Page 148: Internal Structure

    Part Maintenance and repair Page Structure and function (supplement) FRIEDRICHSHAFEN 3.6.2 Internal structure Fig. 68 : Internal structure of Engine Control Unit ECU (cover removed) 1 Printed circuit board ECB 4-01 2 Connecting cable 3 Round cord seal 4 Flat fuse 5 Housing Printed circuit board ECB 4-01 inside the housing incorporates all electronic components (with the exception of the smoothing capacitor).
  • Page 149 Part Maintenance and repair Structure and function (supplement) Page FRIEDRICHSHAFEN Fig. 69 : Configuration of the electronic components on printed circuit board ECB 4-01 1 LED power supply (+24 VDC, +15 VDC, --15 VDC, +5 VDC) 2 LED RESET 3 Processor 4 Engine data and program memory module EDM (MEM 6) 5 Interface data module IDM 6 Engine cable harness and plant connector...
  • Page 150 Part Maintenance and repair Page Structure and function (supplement) FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 151 Abbreviations Page FRIEDRICHSHAFEN Abbreviations Baureihe, series Controller Area Network (bus system) Display Default Lost Engine Control System Engine Control Unit Engine Monitoring Unit Electromagnetic Compatibility ETC 2 Exhaust Turbocharger no. 2 FMEA Failure Mode and Effects Analysis Ground Integral Test System Kilobaud Liquid Cristal Display mbar...
  • Page 152 Page Abbreviations FRIEDRICHSHAFEN Abbreviations (cont.) Remote Control System Redundancy Lost Revolutions per minute Sensor Defect SISY Sicherheitssystem, safety system Safety System System Volt Volt Alternating Current Volt Direct Current -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 153 Connector assignment Page FRIEDRICHSHAFEN Connector pin assignment Connector X1: Connector type: VPT 06 GSE 22--55 P Target: Cable harness, plant View to socket: Plant Fig. 70 : Pins connector X1 Channel Signal Comments IUE1 5V_ISO 5 V/20 mA electrically isolated IUE1 U_IN 0 V ...
  • Page 154 Page Connector assignment FRIEDRICHSHAFEN Channel Signal Comments U <4 V = low / U > 8 V = high --IN Electrically isolated U <4 V = low / U > 8 V = high --IN Electrically isolated U <4 V = low / U > 8 V = high --IN Electrically isolated U <4 V = low / U >...
  • Page 155 Connector assignment Page FRIEDRICHSHAFEN Channel Signal Comments TAA5 24 V/300 mA TAA5 TAA6 24 V/2 A TAA6 (Plant supply, moving-coil instruments FZ) CAN1 HIGH Electrically isolated CAN1 CAN1 CAN2 HIGH Electrically isolated CAN2 CAN2 Note: Refer to Appendix B for detailed schematic input circuitry of the ECU (“Channel” designation in column 1).
  • Page 156 Page Connector assignment FRIEDRICHSHAFEN Connector X2: Connector type: VPT 06 GSE 22--55 PW Target: Cable harness, engine View to socket: Engine Fig. 71 : Pins connector X2 Channel Signal Comments 0 V ... 5 V/internal 2k0 pullup to 5V_TE_BUF 0 V ... 5 V/internal 2k0 pullup to 5V_TE_BUF 0 V ...
  • Page 157 Connector assignment Page FRIEDRICHSHAFEN Channel Signal Comments 5V_BUF1 5 V/20 mA 0 V ... 5 V/internal 47k5 pulldown 5V_BUF2 5 V/20 mA 0 V ... 5 V/internal 47k5 pulldown 5V_BUF2 5 V/20 mA 0 V ... 5 V/internal 47k5 pulldown 5V_BUF3 5 V/20 mA 0 V ...
  • Page 158 Page viii Connector assignment FRIEDRICHSHAFEN Channel Signal Comments DME1 U <--400 mV = low / U > 400 mV = high DME1 --IN DME2 U <--400 mV = low / U > 400 mV = high DME2 --IN PDM1 24 V/3 A PDM1 TAM1 24 V/1.5 A...
  • Page 159 Connector assignment Page FRIEDRICHSHAFEN Connector X3: Connector type: VPT 06 GSE 16--26 P Target: Cable harness, engine View to socket: Engine extension Fig. 72 : Pins connector X3 Channel Signal Comments 0 V ... 5 V/internal 2k0 pullup to 5V_TE_BUF 0 V ...
  • Page 160 Page Connector assignment FRIEDRICHSHAFEN Channel Signal Comments PDM2 TAM3 24 V/1.5 A TAM3 TAM4 24 V/1.5 A TAM4 RS232 RS232 RS232 TA_EDM 24 V_OUT EDM supply/2 A TA_EDM Note: Refer to Appendix B for detailed schematic input circuitry of the ECU (“Channel” designation in column 1).
  • Page 161 Connector assignment Page FRIEDRICHSHAFEN Connector X4: Connector type: VPT 06 GSE 20--41 PW Target: Cable harness, engine (solenoid valves) View to socket: Solenoid valves Fig. 73 : Pins connector X4 Channel Signal Comments HIGH 24 V/20 A Bank 1 HIGH 24 V/20 A Bank 1 HIGH...
  • Page 162 Page Connector assignment FRIEDRICHSHAFEN Channel Signal Comments HIGH 24 V/20 A Bank 1 MV10 HIGH 24 V/20 A MV10 Bank 1 MV11 HIGH 24 V/20 A MV11 Bank 2 MV12 HIGH 24 V/20 A MV12 Bank 2 MV13 HIGH 24 V/20 A MV13 Bank 2 MV14...
  • Page 163 Connector assignment Page xiii FRIEDRICHSHAFEN Connector X5: Connector type: CIR 06 G2 -- 18--11 S Target: Cable harness, plant (power supply) View to socket: Power Fig. 74 : Pins connector X5 Channel Signal Comments POWER +24 V = 24 V/30 A vers POWER +24 V...
  • Page 164 Page Connector assignment FRIEDRICHSHAFEN Connecto X6: Connector type: VPT 06 GSE 12--10 P Target: Dialog unit View to socket: Dialog Fig. 75 : Pins connector X6 Channel Signal Comments DIALOG RS232 DIALOG RS232 DIALOG RS232 24 V_OUT Dialog unit supply (max. 3 A) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...
  • Page 165 ECU channel input circuitry Page FRIEDRICHSHAFEN ECU channel input circuitry = 24 V ECU 4 --IN Cable W003 Fig. 76 : Binary input BE schematic E.g. accelerator = 5 V pedal E.g. control lever 5V_ISO ECU 4 I_IN U_IN GND_ISO Cable W003 Fig.
  • Page 166 Page ECU channel input circuitry FRIEDRICHSHAFEN ECU 4 --IN Inductive sensor Cable Fig. 79 : Angle measuring input KW1/NW1 schematic ECU 4 --IN Inductive sensor Cable Fig. 80 : Speed measuring input DME schematic = 5 V ECU 4 NI1000 Cable Fig.
  • Page 167 ECU channel input circuitry Page xvii FRIEDRICHSHAFEN = 5 V 5V_BUF ECU 4 Pressure sensor Cable Fig. 82 : Pressure measuring input DE schematic = 5 V 5V_BUF5 ECU 4 Filter Pressure sensor Cable Fig. 83 : Pressure measuring input DEH schematic = 24 V ECU 4 Cable...
  • Page 168 Page xviii ECU channel input circuitry FRIEDRICHSHAFEN U = 15 V ECU 4 Cable W003 Fig. 85 : Transistor output TAA schematic = 24 V ECU 4 Cable W003 Fig. 86 : Transistor output TAM schematic = 24 V ECU 4 Cable Fig.
  • Page 169 ECU channel input circuitry Page FRIEDRICHSHAFEN MV 1 MV 20 ECU 4 Cable Fig. 88 : Solenoid valve output MVA (injector control) schematic Connector XC6 RS232 RS232 Dialog ECU 4 unit Dialog cable Fig. 89 : Dialog unit connection schematic Electrical isolation CAN (H) Terminal...
  • Page 170 Page ECU channel input circuitry FRIEDRICHSHAFEN (This page intentionally blank) -- 12.2001 -- E 531 711 / 01 E MDEC for stationary generator engines...

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