ECU-7/E2/G

M1 / E ADEC / G

Advanced Diesel Engine Controller

Detroit, August 2017, Dean Converse

 Agenda

01 Training Center
02 Rolls-Royce / MTU
03 Design and Function of the ECU-7
04 ECU-7 Wiring Diagram
05 Design and Function of the SAM / MAU
06 SAM Wiring Diagram
07 Installation and Functions of DiaSys Software
08 Parameter Functions and Structure
09 Troubleshooting
10 Exchange of Components
11 Test (Verification of Success)

Page 2 | ADEC/G | MTU Detroit Diesel, VOPT I 2011

 02

Rolls-Royce / MTU

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 Rolls-Royce Power Systems 02

Under the MTU brand, Rolls-Royce Power Systems markets large high-speed
engines and propulsion systems for ships, heavy land, rail, defense vehicles, and
for the oil and gas industry. The product portfolio for distributed energy systems,
which are marketed under the MTU Onsite Energy brand, includes diesel gensets
for emergency, base load and peak load applications, in addition to cogeneration
plants for the generation of combined heat and power based on gas engines
and/or gas turbines. The Norwegian subsidiary Bergen Engines manufactures
medium-speed diesel and gas engines for marine and power generation
applications. Fuel injection systems manufactured by L'Orange are also included
in the product portfolio.

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MTU 02

MTU is one of the leading providers of high-speed,

high-performance diesel engines and complete
propulsion systems for marine, rail and heavy land
vehicles as well as for industrial applications and
decentralized power generation plants.
(Off-highway applications)

Its product portfolio includes diesel engines, electronic

systems, gas engines and gas turbines, injection
systems as well as decentralized energy
generation plants powered by diesel, gas and fuel
cells.

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MTU 02
Milestones of Corporate Development

Page 10 | ECU-7/E2/G | Converse

 03

Design and Function of the ECU-7

Engine Control Unit

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Series 2000/4000 03
PowerGen – Plant Overview

Optional

MTU Display 10 Powerview Display

ECU 7

MAU

MTU CAN Bus

SAM

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Series 2000/4000 03
PowerGen- MTU-Abbreviations
• ADEC Advanced Diesel Engine Control
• ECU 7 Engine Control Unit Version 7
• SAM Service Automation Module
• CF Compact Flash
• CCB Can Connecting Board
• DILA Diagnostic Lamp
• MAU Medium Attachment Unit
• DIS 10 MTU Display 10
• CAN Controller Area Network
• MPS Motor Parameter Set
• APS Application Parameter Set

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Series 2000/4000 03
PowerGen – Design and Function

To control and regulate a diesel engine, a large number of measurement

variables and control signals have to be recorded, evaluated and processed.

This information can either be generated on the engine side (e.g. operating
data such as pressures and temperatures) or on the system side, i.e. by
devices from a higher-order system, which decides on how the diesel engine
has to operate.

The ECU 7 (ADEC) engine governor was designed and developed to cover a
large number of engine types and applications (marine, rail, C&I and gensets).

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Series 2000/4000 03
PowerGen – Purpose

• Control engine operation

• Monitor operating status

• Control the injection quantity

and engine speed

ADEC (ECU-7)
• Indication of faulty operation (Display,SAM)

• Communication with other electronic components via CAN bus

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Series 2000/4000 03
PowerGen – ADEC Release Timetable

December 2005 Series 2000 G 12V/16V/18V (60Hz)

January 2006 Series 4000 16V (G and C&I Application)

April 2006 Series 2000 G 12V/16V/18V (50Hz)

April 2006 Series 4000 12V (G and C&I Application)

July 2006 Series 2000 G 12V/16V/18V (50/60 Hz Switchable)

July 2006 Series 4000 20V (G and C&I Application)

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Series 2000/4000 03
PowerGen – ADEC Specifications
The mechanical structure and thermal load capabilities of the engine governor
are such that it can be installed directly on the engine:
• Housing temperature range during operation: – 40°F to +176°F
• Ambient temperature during operation up to 221°F
• Relative humidity up to 95%
• Shock resistance 3.6 g/rms
• Protection class IP69K, i.e. dust-proof and waterproof when subject to direct
water spray at up to 100 bar
• Resistant against salt fog
• Resistant against chemicals (included biodiesel)
• Power Supply : 16,8 VDC .. 24VDC .. 32 VDC

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Series 2000/4000 03
PowerGen – Technical Information

• Injection system
Common Rail or PLD

• Programmable injector control

One Box for 4 different injector types

• Multiple injection
42V Injector control voltage, speeds up the injector response time and
improves engine emissions and fuel consumption

• 20 injector drive outputs with one box

No multible ECM‘s needed

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Series 2000/4000 03
PowerGen – Technical Information

• Torque based engine management

Easy handling of power calibration

• Flexible monitoring
Customer needs can be adjusted in the field

• Parameter set is separated into

Engine Parameters (MPS)
Application Parameters (APS)

• Extended Failure Code List

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Series 2000/4000 03
PowerGen – ECU-7 Connections
LED (red)
- OFF (No Power Supply)
- ON (Normal Operation)
- Flashing slow (Incorrect Data Set /MPS, APS)
- Flashing fast (Internal Error, e.g. defective RAM)

Plug X4
Injector Harness

Plug X1
System Cable / Connection to Plant Side Plug X2 Plug X3
Connection to External Controller Engine Sensor Harness Power Supply
(e.g Pressures,Temps,Speed
(CAN, ANA-IN/OUT, BIN-IN/OUT) Sensors, Injection Pump)

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Series 2000/4000 03
PowerGen – Self-Test Function

• The ECU-7 governor carries out self-tests during

activation and normal operation.
• The result is indicated in a LED on the ADEC
governor (DILA).

• LED OFF Æ No power supply

• LED ON Æ ADEC is OK
• LED Flashing Æ ADEC is defect.

• Internal failures can be detected by supplying

power without the X1, X2 and X4 cables
connected

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 Series 2000/4000 03
PowerGen – ECU Diagnostic LED (DILA)
The Diagnostic LED (DILA) shows the following codes:

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

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Series 2000/4000 03
PowerGen – Integrated Test System (ITS)

After the supply voltage has been switched on, the ITS carries out extensive internal
system checks. It monitors all important engine governor functions as well as the
connected electrical components:
• Electronics within the actual engine governor
• Sensors
• Actuators
• Bus communication
• Power supply
The ITS detects faults, localizes them and reports them via combined alarms. In addition
a fault message is transmitted via CAN to a higher-level monitoring system (if installed)
where it can then be visualized for the operator.

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Series 2000/4000 03
PowerGen – ECU-7 Cover

Warning:
Opening or tampering with the
securing screws on the rear
cover will void warranty.
Note:
No serviceable components
inside!

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Series 2000/4000 03
PowerGen - Main Difference MDEC to ADEC

- No internal 30A Fuse

- No plugable Memory Modules

- No internal Fault Code Display

- The Parameter set is divided into two sets (MPS) and (APS)
- (Motor Parameter Set) (Application Parameter Set)

- New Parameter Structure (ZZ.KKKK.PPP)

- Extended Error Code List

- No Serial Interface for Dialog Unit. The Connection is only via CAN.

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Series 2000/4000 03
PowerGen - Main Difference MDEC to ADEC

No internal 30 A Fuse

No plugable Memory
Modules EDM and IDM

No internal Fault Code Display

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Series 2000/4000 03
PowerGen - Main Difference MDEC to ADEC

ADEC (ECU-7) MDEC (ECU-4)

Injection Type Triple Single

Injector Voltage 24 - 42 V 24 V

Computing Velocity 800 % 100 %

Inputs / Outputs 90 75
Max.Housing Temperature 221 °F 167 °F
ECU-Self Test Yes No

Features: CAN-Bus for future extension

Adjustable Engine Monitoring
Adjustable Safety System
Torque Based Engine Management

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Series 2000/4000 03
PowerGen – Input/Output ECU-7

DI 1 Engine Stop
DI 2 Switch 50/60 Hz
TOP 1 Yellow alarm
DI 3 Idle Mode
TOP 2 Red alarm
DI 4 Alarm Reset Trans. Outputs
TOP 3 Lube oil stop
DI 5 Speed Up +24V switch
TOP 4 Starter on
DI 6 Speed Down
Digital Input
DI 7 Engine Start
+24V switch
DI 8 Override
AO 1 Coolant temp. 0-10V
Analog Output
AO 2 Lube oil pressure 0-10V

AI1 Speed Demand U 0-10V

Analog Input
Speed Demand I 4-20mA
AI 2 Engine Torque Demand (LSG)
CAN1 (Default)
0-10V PCS 5
CAN2 (Redundant)

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Series 2000/4000 03
PowerGen – ECU-7 Connector X1
System Cable
• X1 8 Binary Inputs (DI)

• X1 1 Speed Demand Frequency (FIP)

• X1 2 Speed Demand Analogue (AI)
• X1 1 Emergency Stop Input (ESI)
• X1 2 CAN (CAN_P, PCS-BUS)
X1
• X1 4 Transistor Outputs for Plant Signals (TOP)
• X1 1 Frequency Output (FO)
• X1 2 Analogue Outputs (AO)

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Series 2000/4000 03
PowerGen – ECU-7 Connector X2

Sensor Harness
• X2 1 CAN (CAN_E, Engine Bus)
• X2 4 Transistor Output for Engine Signals (TOE)
• X2 12 Temperature Inputs (TI)
• X2 14 Pressure Inputs (PI)
• X2 3 Level Switch Inputs (LSI)
• X2 2 Analogue Speed Inputs (ASI)
• X2 4 Frequency Inputs (FI)
X2

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Series 2000/4000 03
PowerGen – ECU-7 Connector X3 and X4

Power Supply Harness

• X3 4 x 24 Volt Power Supply
• X3 4 x Battery Ground
• X3 24 Volt Ignition Output
• X3 24 Volt Ignition Input
Injector Harness
X3 X4
• X4 20 Outputs for Injectors (IO)
• X4 4 PWM Outputs

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Series 2000/4000 03
PowerGen – Engine Sensors
Series 4000-03 Series 2000 PLD
Coolant water level F33 Coolant water level F33
Coolant water level intercooler F57 Coolant water temp. B06
Coolant water temp. B06 Charge air temp. B09
Charge air temp. B09 Fuel temp. B33
Rail fuel temp. B33 Lube oil temp. B07
Coolant temp. intercooler B26 Lube oil pressure B05
Lube oil temp. B07 Charge air pressure B10
Fuel pressure after filter B34 Crankshaft speed B13
Fuel high pressure B48 Camshaft speed B01
Lube oil pressure B05
Charge air pressure B10
Crankshaft speed B13
Camshaft speed B01

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Series 4000 03
PowerGen – Engine Sensors Locations

1) B50 (P-crankcase)
2) B5.3 (P-lube oil before filter)
3) B05 (P-lube oil after filter)
4) B33 (T-fuel rail)
5) B07 (T-lube oil)
6) B01 (Camshaft speed)
7) B48 (P-fuel rail)
8) B43 (P-charge-air coolant
9) B26 (T-charge-air coolant
10) B06 (T-coolant)

Page 33 | ECU-7/E2/G | Converse

Series 4000 03
PowerGen – Engine Sensors Locations

1) B4.1-B4.8
(T-Exhaust A-side)
2) B34
(P-fuel after filter)
3) M8
(HP fuel pump actuator)

Page 34 | ECU-7/E2/G | Converse

Series 4000 03
PowerGen – Engine Sensors Locations

1) B4.11-B4.18
(T-Exhaust B-side)
2) B16
(P-coolant)
3) B10
(P-charge-air)
4) B09
(T-charge air)

Page 35 | ECU-7/E2/G | Converse

Series 4000 03
PowerGen – Engine Sensors Locations

1) B13 (Crankshaft speed)

Page 36 | ECU-7/E2/G | Converse

Series 2000 03
PowerGen – Engine Sensors Locations
1) B07 T-lube oil
2) B05 P-lube oil
3) B09 T-charge air
4) B10 P-charge air
5) B01 Camshaft speed
6) B13 Crankshaft speed
7) B06 T-coolant
8) B33 T-fuel

Page 37 | ECU-7/E2/G | Converse

Design and Function of the ECU-7 03
Pin assignment X1 Connector (System Cable)

Image

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Design and Function of the ECU-7 03
Pin assignment X2 Connector (Sensor Harness)

Image

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Design and Function of the ECU-7 03
Pin assignment X3 Connector (Power Supply)

Image

Page 40 | ECU-7/E2/G | Converse

Design and Function of the ECU-7 03
Pin assignment X4 Connector (Injectors)

Image

Page 41 | ECU-7/E2/G | Converse

 04

ECU-7 Wiring Diagram

Drawing # XZ00E50000005

Sensors S-2000 Drawing # X00025471

Sensors S-4000 Drawing # XZ00E50000216

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 05

Design and Function of the (MAU) and (SAM)

(MAU) Medium Attachment Unit
(SAM) Service Automation Module

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Series 2000/4000 05
PowerGen – MAU Design and Function

The (MAU) is a gateway for diaolg between the ECU and DiaSys.

DaiSys Dialog

CAN 2

CAN 1

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Series 2000/4000 05
PowerGen – MAU Design and Function
(Onsite,SDMO/Kohler) Node # 6

External
Switchgear Cabinet
Dialog Unit and Diasys 2.xx
ECU-7
CAN 1

CAN 1
CAN 2 CAN

Node # 1
Node # 2
MAU

Page 45 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Design and Function

Robust and simple Design

• Operating Voltage (24V) Min/Max 12-32V

• High operating temperature (-40F – 167F)

• High vibration and shock resistance

- rail mounted up to 1 g/rms
- spring mounted up to 4 g/rms

• Fulfills protection class IP40

Page 46 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Design and Function

• Evaluation of additional analog and binary signals

(additional sensors, control signals etc.)
• Analog and binary outputs for indicators and lamps in customer
switch cabinet
• Processing of additional customer or application related functions
• Indication of ECU-7 and SAM fault codes
• Integrated output for connection of the MTU CAN-Bus to existing
customer bus systems (e.g. J1939 / CANOPEN)
• Backup of ECU-7 life data
• Interface for connection of service PC (DiaSys)

256 MB Max Size

Page 47 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Design and Function

Memory Card Display for

for Application Software Fault Codes and Mini-Dialog
Slots for Additional
I/O or Interface
Cards

Push Buttons for

Mini-Dialog

Image
Plugs with Spring
Loaded Terminal strips for
Easy Connection of I/O Diagnostic Lamp
Signals

Ethernet Interface Interface to Dialog

for Remote Diagnostics Unit
and Web Based Monitoring

Page 48 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Software Evolution

40011 A12 & 13 40011 A14 40011 A37

SAM SAM 2000/4000

basic basic w. FDH SAM
advanced
SAM
2000 / 4000 advanced
Smart
SAM SAM
Connect
plus plus w. FDH 1600

till end 2008 till 04/2009 from 05/2009 approx. from 2010

Page 49 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Software Differences

SAM SAM SAM SAM

basic plus basic w. FDH advanced

•Redundant Data Storage •Fuel Level Monitoring

•Redundant Data Storage •Redundant Data Storage
•Life Data Storage •Day Tank / Storage Tank Control
•Life Data Storage •Life Data Storage
•CAN BUS Communication •Fuel Pump Control
•CAN BUS Communication •CAN BUS Communication
•Operating Signals •Fan Control
•Operating Signals •Operating Signals
•Warnings / Alarms •Shutter Control
•Warnings / Alarms •Warnings / Alarms
•Fault Codes •Fuel Prefilter Monitoring
•Fault Codes •Fault Codes
•Webserver Access •Generator Excitation Control
•Webserver Access •Webserver Access
•Remote Control •Generator Winding Temp. Monitoring
•Remote Control •Remote Control
•Load Step Control
•Fuel Level Monitoring
•Preheating Control
•Day Tank / Storage Tank Control
•Circulation Pump Control
•Fuel Pump Control
•Fan Control
•Shutter Control
•Fuel Prefilter Monitoring
•Generator Excitation Control
•Generator Winding Temp. Monitoring
•Load Step Control
•Preheating Control
•Circulation Pump Control

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Series 2000/4000 05
PowerGen – SAM Design and Function

Input / Output Capability

• 20 Binary Output Channels
• 2 PWM Output Channels
• 8 Instrument Output Channels
• 28 Binary Input Channels
• 8 Analog Input Channels
• 2 Frequency Inputs (Speed)
• 2 CAN Interfaces to Customer
• 1 Ethernet Interface
• 1 Serial Interface
• 1 Interface Plug for Dialog Unit
• Possibilities of Input/Output and Interface Expansion with Plug in Cards (3 max)

Page 51 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Design and Function
B_Out 1 Over speed Alarm B_Out 15 Generator Temp. Limit 1
B_Out 2 Coolant Temp. Level 1 B_Out 16 Subsidiary Excitation ON
B_Out 3 Coolant Temp. Level 2 B_Out 17 Generator Voltage
B_Out 4 Charge Air Temp. Limit 1 B_Out 18 Circulation Pump ON
B_Out 5 Charge Air Temp. Limit 2 B_Out 19 Downtime Heating ON
B_Out 6 Intercooler Level Stop B_Out 20 Day Tank Min. Alarm

Binary Transistor B_Out 7 Coolant Level Stop

Output B_Out 8 Fan 2 On
+ 24 Volt Switched B_Out 9 Preheat Temp. Not Reached
B_Out 10 Lube Oil Pressure Limit 1
B_Out 11 Engine Running
B_Out 12 Fuel Pressure Limit 1
B_Out 13 Load Assumption Ready
B_Out 14 Priming Press. Not Reached

Page 52 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Design and Function

PWM Power Output

PWM_OUT 1 Fan Control 3
PWM : 0 ……100% PWM_OUT 2
F_out : 5……500HZ

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Series 2000/4000 05
PowerGen – SAM Design and Function

V_OUT 1 Engine Speed

V_OUT 2 Coolant Water Temperature
V_OUT 3 Lube Oil Temperature
Instrument Output V_OUT 4 Fuel Pressure After Filter
U_Out: 0 – 10 V V_OUT 5 Charge Air Pressure
V_OUT 6 Charge Air Temperature
V_OUT 7 Fuel Temperature
V_OUT 8 Fan Control 3

Page 54 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Design and Function
B_IN 1 Cylinder Cut Out B_IN 15 Spare
B_IN 2 Test Switch Out B_IN 16 Spare
B_IN 3 Test Over speed B_IN 17 Spare
B_IN 4 Priming Pump On B_IN 18 Spare
B_IN 5 Spare B_IN 19 Rating Switch 1
B_IN 6 Mode Switch (Mode1/2) B_IN 20 Rating Switch 2
B_IN 7 Water in Fuel Pre filter 1 B_IN 21
Binary Input
B_IN 8 Water in Fuel Pre filter 2 B_IN 22
+24V switch
B_IN 9 Spare B_IN 23
B_IN 10 FAN Control Manual On B_IN 24
B_IN 11 ECU – Parameter Switch B_IN 25
B_IN 12 Spare B_IN 26
B_IN 13 Spare B_IN 27
B_IN 14 Spare B_IN 28

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Series 2000/4000 05
PowerGen – SAM Design and Function

A_IN1 Exhaust Temperature 1

A_IN2 Exhaust Temperature 2
Analog Input
A_IN3 Pressure 1
0V – 10V
A_IN4 Pressure 2
0V – 5V
A_IN5 Generator Winding Temp.1
PT 100 / PT 1000
A_IN6 Generator Winding Temp.2
A_IN7 Generator Winding Temp.3
A_IN8 Ambient Temperature

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Series 2000/4000 05
PowerGen – SAM Design and Function

BR_OUT 1 Priming Pump

Binary Relays BR_OUT 2 Fuel Pump On
Output BR_OUT 3 FAN 1 On
+ 24 Volt Switched BR_OUT 4 Shutter Open/Closed

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Series 2000/4000 05
PowerGen – SAM Design and Function

A_IN_ISO1 Spare
A_IN_ISO2 Level Day – Tank
Isolated Analog Input
A_IN_ISO3 Spare
A_IN_ISO4 Level Holding Tank

Page 58 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Intergrated Test System (ITS)
After the power supply has been switched on,
the ITS carries out extensive internal software checks as:

• RAM Test (Read / Write)

• Flash Memory
• Interfaces
• Bus communication

Easy Diagnose Function with LED (DILA)

The SAM LED indicates the condition of the SAM, The function is the same
as the function of the ECU-7 Diagnostic lamp.

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Series 2000/4000 05
PowerGen – SAM Diagnostic LED

LED ON Î SAM is OK

LED flashing Î SAM is defective

LED OFF Î no 24V supply

or LED defect

Page 60 | ECU-7/E2/G | Converse

 Series 2000/4000 05
PowerGen – SAM Diagnostic LED
The Diagnostic LED (DILA) shows the following codes:

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

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Series 2000/4000 05
PowerGen – Malfunction Indication at Mini Display
Time Type Code

A EC 219
SD T-Intake Air

Integrated fault code display

(Minidialog) to display
ECU 7 and SAM fault codes

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Series 2000/4000 05
PowerGen – Malfunction Indication at Mini Display
Integrated fault code display for ECU 7 and SAM fault Codes
• A = Alarm currently active
• B = Alarm was active within the past hour
• C = Alarm was active within the past four hours
• D = Alarm was active within the past four to twelve hours
• E = Alarm was active more than twelve hours ago

Fault type code EC : Error Code (ECU-7)

SE : System Error
AL : Fault Message (SAM)

A EC 219 Fault type code, see „operating instruction“

SD T-Intake Air
plain text (scrolls, if more than 16 characters)

Page 63 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Design and Function

Remote Monitoring and Diagnostic Ethernet Interface

• CAN Interface for Dialog unit

• Additional Ethernet interface (TCP/IP) for:

• Remote diagnostics, from any PC
through Ethernet LAN
• Web based indication through
integrated Web server- functionality

CAN Interface
for Dialog unit

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Series 2000/4000 05
PowerGen – SAM Web Based Monitoring

SAM phys. connection

Crossover cable

Page 65 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – SAM Web Based Monitoring

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Series 2000/4000 05
PowerGen – SAM Web Based Monitoring

Page 67 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – Data Storage Concept

• Life data storage

Backup Engine life data

Engine life data is

stored continuously
every hour, after every
Engine life data:
engine stop or • engine operating hours
emergency stop in the • error log
SAM memory as a • load profile etc.
backup.

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Series 2000/4000 05
PowerGen – Data Restore Concept

Easy ADEC box change Backup Engine Management

Software + Data
Application and Engine Backup Engine - Application
management Software + Datas Software + Data
are stored in the SAM-Module
as a backup.
Application Software + Data:
Auto download of the complete memory has to be empty

software is initiated after Engine Management Software +

connecting a new empty ADEC Data: memory has to be empty
to the SAM-Module
SAM software must be at least
A37 or higher.

Page 69 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – Application (1)
(Onsite,SDMO/Kohler) Node # 6

External
Switchgear Cabinet

ECU-7 Dialog Unit and Diasys 2.xx

CAN 1

CAN 1
CAN 2 CAN

Node # 2
MAU Node # 1

Page 70 | ECU-7/E2/G | Converse

Series 2000/4000 05
PowerGen – Application (2)
Options
MTU Display 10 Power View
CAN 1
CAN 2 or
ECU-7
SAM
Node # 4
CAN 1
CAN 2

J1939 Interface

Node # 5
Node # 2 Dialog Unit and Diasys 2.xx

CAN

Node # 1

Page 71 | ECU-7/E2/G | Converse

 Series 2000/4000 05
PowerGen – Application (3)
Customer with external Controller
(not Onsite,SDMO/Kohler) Node # 6

External Controller
J1939 or CAN Open
Customer
ECU-7
Switchgear
Cabinet
CAN 1
Node # 5
CAN 2

Node # 2
SAM

Dialog Unit and Diasys 2.xx

Node # 1 CCB2 as an option for using the customer
CAN
Interface J1939 or CANOpen

Page 72 | ECU-7/E2/G | Converse

 06

SAM and MAU Wiring Diagram

Drawing # XZ00E50000006

Page 73 | ECU-7/E2/G | Converse

 07

Installation and Functions of DiaSys 2.71

Page 74 | ECU-7/E2/G | Converse

Series 2000/4000 07
PowerGen – Dialog System DiaSys

The MTU dialog system DiaSys® is required in order to set the electronic
engine governor and or read out data. The dialog system consists of the
following :

• Laptop with Windows™ operating system and a CAN convertor

• Installed software DiaSys® version 2.XX
• A connecting cable for connection to the system in which the engine
governor is integrated (e.g. MAU or SAM diagnostic connector)
• Dongle (Hardware Key)

Page 75 | ECU-7/E2/G | Converse

Series 2000/4000 07
PowerGen – Dialog System DiaSys

• The devices of a MTU system are connected with one another via a redundant
CAN bus (CAN1 and CAN2) CAN1 is the so-called „Default bus“ and CAN2 is the
so-called „Redundant bus“. The dialog unit requires a connection to this CAN bus
in order to access the engine governor.

• The structure of each MTU system is such that at least one device on the CAN
bus is equipped with a diagnostic interface. On Genset systems the diagnostic
interface is integrated in the MAU or SAM.

• The CAN Bus is terminated at both ends with 121 Ω resistors. Access to the CAN
bus is via the DiaSys Dialog cable. This cable must not be extended.

• Otherwise reflections on the bus could lead to malfunctions.

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Series 2000/4000 07
PowerGen – Dialog System DiaSys

SAM, phys. connection

Dialog cable (MTU)
CAN converter

DIASYS 2.71
Dongle (level 0, 1a, 1b, 1c)

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Series 2000/4000 07
PowerGen – DiaSys Kit # 23537104

USB to CAN Adaptor CAN-Dialogue Cable

Hardware key (Dongle)

Software DIASYS 2.70

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Series 2000/4000 07
PowerGen – MTU DiaSys Part Numbers
23537104 KIT MDEC/ADEC USB

PART NUMBER DESCRIPTION QTY

X00042159 DIASYS 2.xx AND 0 LEVEL USB DONGLE 1

X00041878 USB CAN ADAPTER ADEC S2000/4000 1

X00012797 CABLE DIALOG MCS/RCS/ADEC S2000/4000 1

5275300737 CABLE MDEC S2000/4000 1

X00042146 USB TO RS232 CABLE AND ADAPTER 1

23537701 Cable Set for ADEC Bench Programming 1

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Series 2000/4000 07
PowerGen – Dialog System DiaSys 2.71
Once the application has been launched a window with the version number of the
release is displayed. DiaSys software should be version 2.70

NOTE THAT INCORRECT HANDLING OF THE DIALOG SYSTEM CAN RESULT

IN SERIOUS DAMAGE TO HEALTH OR PROPERTY DAMAGE.

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Series 2000/4000 07
PowerGen – Dialog System DiaSys 2.71

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Series 2000/4000 07
PowerGen – Hardware Key (Dongle)
Dongle and levels of access:
In order to work with the DiaSys® dialog system, an access protection hardware
key (dongle) is required. There are dongles for various access rights:

• Level 0 (Customer) Read Only

• Level 1a (OEM) Limited Access to Parameters
• Level 1b (Service Technician) Access to most all Changable Parameters
• Level 1c (Test Stand) Access to outputs / inputs in the ECU
• Level 2 (Super-User) Access to all Parameters (MTU Service Engineer)

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Series 2000/4000 07
PowerGen – Hardware Key (Dongle)
Dongle and levels of access:
• Note: Your dongle has an expiration date!
• Level 0 Customer (5 years)
• Level 1a OEM (2 years)
• Level 1b Service Technician (2 years)
• Level 1c Test Stand (2 years)
• Level 2 Super-User (1 year)

• With in the DaiSys Software there is time clock that limits the Maximum time
change to 24 hours. If this time is exceeded your (dongle) will be locked!

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Series 2000/4000 07
PowerGen – Hardware Key (Dongle)
Dongle and levels of access:
• Depending on the definition by MTU, it may be possible to display parameters via
DiaSys® that can-not be changed. The display fields of these parameters are
shaded grey. Values that the user can change with the help of a dongle are
always shaded white.

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 08

Parameter Structure and Function

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Series 2000/4000 08
PowerGen – Principle of Software Structure

• The complete data set

ECU-7
(software and parameters)
Governor Data Set
are available in the Central
Database.
• It is made available via the
Engine Plant MTU Business Portal and
parameters parameters the Central Database prior
MPS APS to commissioning and,
following commissioning,
saved in the Central
FSW FSW Database.
(Functional Software) (Functional Software)
Engine Plant

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Series 2000/4000 08
PowerGen – Parameter Structure and Function
• What are parameters?
Parameters are all setting possibilities of the electronic engine governor. These
parameters can be altered using the dialog system DiaSys® .
This allows the adaption of an engine, the entire governor behavior and the
adaptation to a plant to be changed.

• What are process variables?

Process variables (PV) are changeable values, created inside or calculated by the
application. Process variables have designations like parameters (i.e. a name and
a number). However, no external influence can be exerted on process variables.
They are used as interface values between different application parts.

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Series 2000/4000 08
PowerGen – Parameter Structure and Function
• 1D parameter (one-dimensional)
• Parameters can only assume values (e.g. On or Off (Binary 1D parameter) or
numeric value (analog 1D parameter).

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Series 2000/4000 08
PowerGen – Parameter Structure and Function
• 2D parameter (two-dimensional)
• The value of a parameter depends on another value (e.g. on speed). Such parameters
are specified as function Pvalue = f (variable). Such a parameter is designated as a
2D-parameter.

Pressure

Speed

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Series 2000/4000 08
PowerGen – Parameter Structure and Function
• 3D parameter (three-dimensional)
• The value of a parameter depends on two other values (e.g. engine speed and
torque). Such parameters are specified as function Pvalue = f (variable1, variable2).
Such a parameter is designated as a 3D-parameter.
This function (area) is set via predefined support points.

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Series 2000/4000 08
Parameter Structure of the ZKP Number
• Each parameter has a number, the so-called „ZKP number“. A ZKP number is
always structured according the following pattern:

ZZ.KKKK.PPP

KKKK = Kategorie
ZZ = Zuordnung
(Category) Parameter/Measuring Point
(Assignment)
xx.0120.xxx Parameter types (1D, 2D, 3D)
01 Î Engine
02 Î Plant T-Coolant Example: xx.xxxx.002
Example: 01.xxxx.xxx Example: xx.0120.xxx (Hardware input of the ECU)

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Series 2000/4000 08
Structure of the ZKP Number: ZZ

ZZ = Number allocation

The „ZZ" denotes the allocation, i.e. these digits provides information as
to whether the parameter concerns the plant-side or the engine side.
• ZZ = 01*: Engine-related parameter
• ZZ = 02*: Plant-related parameter

* The leading 0 (zero) is suppressed in DiaSys and therefore is not

displayed.

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Series 2000/4000 08
Structure of the ZKP Number: KKKK
KKKK = Category
The K-numbers denote the category a parameter belongs to. Categories are used
to provide a user-friendly overview of parameters and PVs. A category contains
parameters / PVs that are closely related, e.g. that all belong to the same function.
There are categories that form a group, e.g. all measuring points. Based on their
function all parameters are assigned to specific areas, e.g. to the measuring
points category or to the monitoring / protection category.

• Measuring points use the number range from 0100 to 0299

• Monitoring modules use the number range from 0300 to 0309
• Protection modules use the number range from 0310 to 0399
• Beyond 0400 no groups have been defined.

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Series 2000/4000 08
Example for ZKP Number: Yellow Alarm
Sensor defect Monitoring module
Engine Wiring PV T-Coolant (Limit 1) / ZKP No.: 02.0312.218
(Alarmparameter)
Categorie 8004 Par-No. : ZKP No. 1.0300.603 (Value) = 102 degC
Par-No. : ZKP No. 1.0300.606 (Hysterese) = 1 degC
ZKP No.: 01.8004.570
Par-No. : ZKP No. 1.0300.607 (Monit. Act.) = (x)

GENERATING WARNING
Protection module
PV T-Coolant (Limit 1) / ZKP No.: 02.0312.218
Sensor Type
Par-No. : ZKP No. 2.0312.201 (Prot. Mod. Act.) = (x)
(1D parameter)
Sensor B6 ZKP 01.9901.xxx
Par-No. : ZKP No. 2.0312.205 (Alarm Supp Stop) = ()
T-Coolant ZKP 02.9901.xxx Par-No. : ZKP No. 2.0312.206 (Alarm Supp Selft) = ()
ZKP No.: 01.9901.119 Par-No. : ZKP No. 2.0312.207 (Alarm Supp Func) = ()
Sensor type Input TI1 Par-No. : ZKP No. 2.0312.208 (Alarm Del Aft Start) = ()
Î 0 (Pt1000) Par-No. : ZKP No. 2.0312.231 (Alarm On Del) = 3 s
Par-No. : ZKP No. 2.0312.232 (Alarm Off Del) = 1 s

Alarmparameter
Pt 1000

ECU input channel

(1D parameter) of Warning Alarm output
ZKP No.: 01.0120.002 HI T-Coolant
T-Coolant ECU Channel
Î 002 (19-digit) 02.0120.931

Sensor definition Sensor evaluation

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Series 2000/4000 08
Example for ZKP Number: Red Alarm
Sensor defect Monitoring module
Engine Wiring
(Alarmparameter) PV T-Coolant (Limit 2) / ZKP No.: 02.0312.258
Categorie 8004 Par-No. : ZKP No. 1.0300.623 (Value) = 104 degC
Par-No. : ZKP No. 1.0300.626 (Hysterese) = 1 degC
ZKP No.: 01.8004.570
Par-No. : ZKP No. 1.0300.627 (Monit. Act.) = (x)

GENERATING RED ALARM

Protection module
Sensor Type PV T-Coolant (Limit 2) / ZKP No.: 02.0312.258
(1D parameter) Par-No. : ZKP No. 2.0312.241 (Prot. Mod. Act.) = (x)
ZKP 01.9901.xxx
Sensor B6 ZKP 02.9901.xxx Par-No. : ZKP No. 2.0312.243 (Override Poss.) = (x)
T-Coolant only shown with level Par-No. : ZKP No. 2.0312.244 (Delayed Stop) = (x)
1b and 2 Par-No. : ZKP No. 2.0312.245 (Alarm Supp Stop) = ()
ZKP No.: 01.9901.119 Par-No. : ZKP No. 2.0312.246 (Alarm Supp Selft) = ()
Sensor type Input TI1
Par-No. : ZKP No. 2.0312.247 (Alarm Supp Func) = ()
Î 0 (Pt1000)
Par-No. : ZKP No. 2.0312.248 (Alarm Del Aft Start) = ()
Par-No. : ZKP No. 2.0312.268 (Shutd Del Time) = 180 s
ECU input channel Par-No. : ZKP No. 2.0312.271 (Alarm On Del) = 3 s
Pt 1000

(1D parameter) Par-No. : ZKP No. 2.0312.272 (Alarm Off Del) = 1 s

only shown with level 2 Alarm output
ZKP No.: 01.0120.002 Alarm Parameter
T-Coolant ECU Channel SS T-Coolant Action output
Î 002 (19-digit) 02.0120.932 ES or PR

Sensor definition Sensor evaluation

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 9/10
ECU-7 Hands on Workshops:
Installation of DiaSys (New Version 2.71)
Wire up System: ECU-7 / SAM / MAU.
ECU-7 Self Test.
Create Project in DiaSys and connect to govorner.
ECU-7 Reset to Stock.
ECU-7 Reprograming Offline (Replace)
ECU-7 Reprogram On Line (Update)
Make a Recording of all engine sensors.

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 9/10

SAM Hands on Workshops:

SAM Self Test
CF Card Programming
SAM Configuration
SAM Erasing
SAM Dialog

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Thank you very much for your attention.