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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

ADEC

Advanced Diesel Engine Control

ECU 7

Engine Control Unit

SAM

Service Automations Module

DILA

Diagnostic Lamp

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

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) 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

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

ECU-7 Anschlsse und Diagnose


Plug X1

Plug X2

Plug X3

Plug X4

System Cable

Sensor Harness

Power Supply

Injector Harness

DILA (Diagnostic
Lamp)

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

Ein/Ausgnge 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 PPLube
LubeOil
Oil

0-10V
0-10V
0-10V
0-10V

Analog Input

PCS 5

Sensorik Br.4000/2000 mit ECU 7


Sensors Serie 4000
Level
LevelCoolant
CoolantWater
Water
Level
LevelIntercooler
IntercoolerWater
Water
T T- -Coolant
Coolant
T TCharge
Charge
T TRail
RailFuel
Fuel
T TCoolant
CoolantIntercooler
Intercooler
T TLube
LubeOil
Oil
PPFuel
Fuelafter
afterFilter
Filter
PPFuel
Fuel(Common
(CommonRail)
Rail)
PPLube
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 TCharge
ChargeAir
Air

BB66
BB99

BB33
33
BB26
26

T T- -Fuel
Fuel

BB33
33

BB77
BB34
34

T TLube
LubeOil
Oil

BB77

PPLube
LubeOil
Oil
PPCharge
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 fr Generator Anwendung

Robust und einfaches Design

9 Erhhter Temperaturbereich von 40C bis +105C


innerhalb der vorgeschriebenen Spezifizierung
9 Schock und vibrationsgeprft bis 3,6 GRMS
9 Schutzklasse: IP69K
Wichtig !
ADEC wurde fr hrtere Rahmenbedingungen als
MDEC/DDEC Entwickelt.

11

ADEC fr Generator Anwendung

Einfache Diagnostik
Der ADEC Regler fhrt einen Selbsttest whrend
des Einschaltens und im normalen Betrieb durch.
Das Ergebnis wird an einer LED am ADEC Regler
angezeigt (DILA).
LED An
LED Blinkt
LED Aus

ADEC ist OK
ADEC ist defekt.
Keine Spannungsversorgung

Interne Fehler knnen 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 fr Kunden


Schnittstelle bentigt
15

ADEC & SAM


bersicht 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


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. > 85C

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

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
80C

Level Off 45C


Level On 40C

BT_OUT19 Preheating system on


Output will be controlled by the engine
coolant temperature.
>45 Grad Off <= 40 Grad On.

0C
Preheating system BT_OUT19
24V
0V

SAM Function

t
25

Prefilter Monitoring

Bedia sensor detection water in fuel


B_IN7 and B_IN8
Yellow alarm and failure message

SAM Function
26

Rating 1 and 2 Switch


SAM send 2 PVs via CAN Bus to ADEC
Is on SAM nothing connected than we send Rating 0 = no Limit.

Build active rating


Rating 0=no LIMIT

ENGINE SPEED

Rating 1= Limit 1
Rating 2 = Limit 2
Rating 3 = Limit 3

Max_torque_rating

Prepared for
future use

MAX_TORQUE_CAN

RATING_SWITCH2
B_IN 20
REQUESTED_TORQUE

RATING_SWITCH1
B_IN 19

Min

Requested Torque to
Combustion Management

SAM Function
27

PID Control 1 and 2 table

0
B_IN11

ECU Parameter 1

ECU Parameter 2

SAM Function
28

Cylinder Cut Out Switch

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 ( ber Parameter)

I/O Config

>=1

CU 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

BR_OUT2

Fuel pump on

BR_OUT3

Fan 1

BR_OUT4

Damper

BT_OUT1

Overspeed alarm lamp

BT_OUT2

Coolant temp.

warning lamp

BT_OUT3

Coolant temp.

stop lamp

BT_OUT4

Charge air

warning lamp

BT_OUT5

Charge air alarm lamp

BT_OUT6

Level intercooler stop Lamp

BT_OUT7

Level coolant stop lamp

BT_OUT8

Fan 2 on

BT_OUT9

Preheat not reached lamp

BT_OUT10

Lube oil press. warning lamp

BT_OUT11

Engine running

BT_OUT12

Alarm fuel pressure

BT_OUT13

Load assumption ready

BT_OUT14

Pre lube pres. reached

BT_OUT15

Governor temp. lamp

BT_OUT16

Subsedary excitation on

BT_OUT17

Generator Voltage

BT_OUT18

Circulation pump on

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 -120C

V_OUT3

Lube oil temp.

0 -120C

V_OUT4

Fuel press. after filter

0 - 10 bar

V_OUT5

Charge air press.

0 - 5bar

V_OUT6

Charge air temp.

0 -120C

V_OUT7

Fuel temp.

0 -120C

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

0-120C

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

0-800C

V_OUT8

Exhaust temp. B

0-800C

V_OUT8

Gen. Winding Temperature. 1

0-200C

V_OUT8

Gen. Winding Temperature. 2

0-200C

V_OUT8

Gen. Winding Temperature. 3

0-200C

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.
>=120C

L3 Temp.

SAM Function
44

Exhaust Temperature A and B Side

A_IN1 and A_IN2


Exhausttemp.1 and 2
PT100 0-800C

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

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