ADEC

Advanced Diesel Engine Controller

for Br.4000/2000 Generator Application

Series 2000/4000 Generator Application

Optional

MTU Display Power View Display

ECU 7

CAN Bus

SAM or SAM+
2
Series 2000/4000 Generator Application

Abbreviation

¾ ADEC Advanced Diesel Engine Control

¾ ECU 7 Engine Control Unit

¾ SAM Service Automations Module

¾ DILA Diagnostic Lamp

3
ADEC/MDEC Difference

ADEC (ECU7) MDEC (ECU4)

Injection triple single

Injector 24 - 48 V 24 V

Computing velocity 800 % 100 %

I/O 90 75
max. Housing Temperature 105 °C 75 °C
Box-Self test yes no

Features CAN-Bus for future extension

Adjustable Engine Monitoring
Adjustable Safety System
Torque Based Engine Management

4
Engine Control Unit ECU-7
Main difference MDEC/ADEC

Main difference MDEC to ADEC (service view):

- No internal 30A Fuse

- No pluggable Memory Modules „EDM“ and „IDM“
- No internal “Fault Code Display”
- The Parameter set is divided in Engine Parameter (MPS) and
Application-Parameter (APS) Æ update via EPROM Database possible
- New Parameter Structure (ZZ.KKKK.PPP)
- Extended Error Code List
- No Serial Interface for Dialog Unit. The Connection is only via CAN possible.
Attention! New service tools are required.
For the Dialog with ADEC the Diasys Version must be 2.32 or higher.
The hardware key needs to have the ADEC Authorisation

5
New Tools for Generator Application

USB to CAN Converter

PCMCIA to CAN Converter

Connection for
CAN Dialog Cable Dialog Cable
2m, 9pol. Sub D / 12pol. round Connector

6
ECU-7 Anschlüsse und Diagnose

Plug X1 Plug X2 Plug X3 Plug X4

System Cable Sensor Harness Power Supply Injector Harness

DILA (Diagnostic
Lamp)

7
ECU-7 Diagnostic Lamp (DILA)

The Diagnostic LED (DILA) shows the following Codes:

Zeit 0 Sec 1 Sec 2 Sec 3 Sec 4 Sec

Normal Operation

Applications Loader active

Offline-ITS Error

External RAM defect

External FLASH defect

No Firmware available

Application crashed

8
 Ein/Ausgänge Br.4000/2000 mit ECU 7

DIDI11 Engine
EngineStop
Stop
DIDI22 Droop
Droop22switch
switch TOP
TOP11 Yellow
YellowAlarm
Alarm
DIDI33 Idle
IdleMode
Mode TOP
TOP22 Red
RedAlarm
Alarm
DIDI44 Alarm
AlarmReset
Reset TOP 3 Lube Oil Pressure Stop
TOP 3 Lube Oil Pressure Stop
DIDI55 Speed
SpeedUp
Up Trans. Outputs TOP 4 Starter On
TOP 4 Starter On
DIDI66 Speed
SpeedDown
Down +24V switch
DIDI77 Engine
EngineStart
Start
Digital Input
DIDI88 Override
Override
+24V switch
AO
AO11 T T- -Coolant 0-10V
Coolant 0-10V
AI1
AI1 Speed
SpeedDemand
DemandUU 0-10V Analoger Output AO
0-10V AO22 PP––Lube
LubeOil
Oil 0-10V
0-10V
Speed
SpeedDemand
DemandI I 4-20mA
4-20mA
AIAI22 Engine
EngineTorque
TorqueDemand
Demand(LSG)
(LSG)0-10V
0-10V Analog Input
Freq.
Freq.InInSpeed
SpeedDemand
DemandFrequency
Frequency10
10-500
-500Hz
Hz

CAN1
CAN1
CAN2 PCS 5
CAN2

9
 Sensorik Br.4000/2000 mit ECU 7

Sensors Serie 4000 Sensors Serie 2000

Level
LevelCoolant
CoolantWater FF33 Level
LevelCoolant
CoolantWater
Water 33 F33
Water F33
Level
LevelIntercooler
IntercoolerWater FF57
Water 57
T T- -Coolant BB66 T T- -Coolant BB66
Coolant Coolant
T T––Charge BB99 T T––Charge
ChargeAir
Charge BB99
Air
T T––Rail
RailFuel BB33 T T- -Fuel BB33
Fuel 33 Fuel 33
T T––Coolant
CoolantIntercooler BB26
Intercooler 26
T T––Lube
LubeOil BB77 T T––Lube
LubeOil
Oil BB77
Oil
PP––Fuel
Fuelafter
afterFilter BB34
Filter 34
PP––Fuel
Fuel(Common
(CommonRail) BB48
Rail) 48
PP––Lube
LubeOil BB55 PP––Lube
LubeOil
Oil BB55
Oil
PP- -Charge
ChargeAir BB10 PP––Charge
ChargeAir
Air 10 BB10
Air 10
NN- -Crankshaft BB13 NN- -Crankshaft BB13
Crankshaft 13 Crankshaft 13
NN- -Camshaft B1 NN- -Camshaft B1
Camshaft B1 Camshaft B1

10
ADEC für Generator Anwendung

Robust und einfaches Design

9 Erhöhter Temperaturbereich von – 40°C bis +105C°

innerhalb der vorgeschriebenen Spezifizierung

9 Schock und vibrationsgeprüft bis 3,6 GRMS

9 Schutzklasse: IP69K

Wichtig !

ADEC wurde für härtere Rahmenbedingungen als

MDEC/DDEC Entwickelt.

11
ADEC für Generator Anwendung

Einfache Diagnostik

Der ADEC Regler führt einen Selbsttest während

des Einschaltens und im normalen Betrieb durch.
Das Ergebnis wird an einer LED am ADEC Regler
angezeigt (DILA).

LED An Æ ADEC ist OK

LED Blinkt Æ ADEC ist defekt.
LED Aus Æ Keine Spannungsversorgung

Interne Fehler können durch anliegen der Box Tausch

Spannungsversorgung und abgezogener
Reglerverkabelung erkannt werden.
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
SDMO/Kohler Switchgear
Cabinet
Configuration 2.
Diasys 2.xx
CAN 1.
CAN 1.
CAN 2. MAU

14
Br.2000/4000 Generator Anwendung

Customers with external Controller

Node Nr.6
(not SDMO/Kohler) External
CAN Open/J1939
Configuration 3. Controller
Customer
Switchgear
CAN 1. Cabinet
CAN 2.

Diasys 2.xx

CCB2 wird für Kunden

Schnittstelle benötigt
15
 ADEC & SAM
Übersicht der Einbindung des Kunden Schaltschranks

Customer Switchgear Cabinet

•Single Alarms Serial Interface CAN Open
•External Signals RS232/485 /422 SAE J 1939
Diasys 2.xx

Instrumente
• T - Coolant
• P - Lube Oil
SAM

ADEC

Inputs/Outputs for ADEC

16
Logistic Concept

LOP
Backup Engine management
Easy ADEC/SAM SAM
software + data:
Hardware change Backup Engine -
Application Software +
Application/Engine Data
Software + Data are
stored in both the SAM New ADEC
Application Software +data:
Memory as well as in Hardware
memory empty
the ADEC Memory. Engine management software + data:
memory empty
The download of the
complete software is
automatically initiated
after connecting a new
ADEC of SAM
hardware to the
remaining module. SAM Function

17
Data Storage Concept

¾ Life data storage SAM

Backup Engine life data
Engine life data is
stored continuously
every hour, after every
ADEC
engine stop or Engine life data:
• engine hours
emergency stop in the
• error log
SAM-Memory as a • load profile
backup.

SAM Function

18
SAM
Service Automation Module

19
SAM
Service Automation Module

Compact Flash
Memory Card Display for
Slots for additional Fault-Codes
for Application SW
I/O Plug-in Cards and Mini-Dialog

Pushbutton for
Mini-Dialog

Diagnostic-
Lamp

Plugs with spring

loaded terminal strips

Ethernet Interface Interface to Dialog-

for Remote Diagnostics Unit
and Web Based Monitoring

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 start
Engine on Engine stop
FAN 1 and 2 on Damper open En FAN1 off Damper off
gi
ne
st Roomtemp>lim1
Time delay 0-10min ar
t
or Engine stop

En
Coolant temp. > 85°C FAN1 off, Damper open

gin
e
sta
Roomtemp>lim2

rt
Engine on Engine stop
FAN 1 and 2 on Damper open Engine stop FAN1 and 2 on, Damper open

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

FAN1 = BR_OUT3
Default value: LIM1 = 28°C
LIM2 = 32°C
Hyst. LIM1 = 3°C
FAN2 = BT_OUT8
Hyst. LIM2 = 3°C
Damper = BR_OUT4

Ambient temperature. = A_IN8

SAM Function
22
Front mounted Fan radiator
driven by electrical engine

Generator Engine room

Engine GENO
Ambient temperature A_IN8

Damper
SAM
Engine Fan Control Mot

controls the FAN via the BR_OUT3

FAN1
engine coolant temperature

BR_OUT4

23
Roof mounted
Fan radiator

FAN2
Table radiator
TB_Version

Generator Engine room

Engine GENO
BR_OUT3
Mot

FAN1
Ambient temperature A_IN8

Damper
SAM
Engine Fan Control
BT_OUT8
control the FAN via the
engine coolant temperature

BR_OUT4

SAM Function
24
Preheater Control

BT_OUT18 Circulation pump on preheating system Power supply SAM

24V
Output is on when the engine not run.
Engine runs
0V
t
Engine stop Engine running - Signal

t
Circulation pump BT_OUT18
24V

0V
t

Coolant temperature
80°C Level Off 45°C

Level On 40°C

BT_OUT19 Preheating system on 0°C

Output will be controlled by the engine Preheating system BT_OUT19
coolant temperature.
24V
>45 Grad Off <= 40 Grad On.

0V
t
SAM Function
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 PV‘s via CAN Bus to ADEC

Is on SAM nothing connected than we send Rating 0 = no Limit.

RATING_SWITCH1 RATING_SWITCH2
Prepared for
B_IN 19 B_IN 20
future use

REQUESTED_TORQUE
Build active rating

MAX_TORQUE_CAN
Rating 0=no LIMIT

Max_torque_rating
Rating 1= Limit 1

Rating 2 = Limit 2
ENGINE SPEED

Rating 3 = Limit 3 Min

Requested Torque to
Combustion Management

SAM Function
27
PID Control 1 and 2 table

0 ECU Parameter 1

B_IN11
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 &

SAM
CAN J1939 TEST >=1
>=1
SAM B_IN2 BR_OUT 1-4
LAMP TEST SAM signal BT_OUT 1-20

ECU DIx LAMP TEST

CAN LAMP TEST

ECU TOP1-4
>=1

&
Default setting
Enable ( über Parameter)
>=1

ÉCU TOP via

I/O Config
software

SAM Function

31
 Default Test Switch Outputs

Eingnag Funktion Ausgang Funktion Defaultwert

B_IN 2 Test Switch Out BR_OUT1 Pre lube on 0
BR_OUT2 Fuel pump on 0
BR_OUT3 Fan 1 0
BR_OUT4 Damper 0
BT_OUT1 Overspeed alarm lamp 1
BT_OUT2 Coolant temp. warning lamp 1
BT_OUT3 Coolant temp. stop lamp 1
BT_OUT4 Charge air warning lamp 1
BT_OUT5 Charge air alarm lamp 1
BT_OUT6 Level intercooler stop Lamp 1
BT_OUT7 Level coolant stop lamp 1
BT_OUT8 Fan 2 on 0
BT_OUT9 Preheat not reached lamp 1
BT_OUT10 Lube oil press. warning lamp 1
BT_OUT11 Engine running 0
BT_OUT12 Alarm fuel pressure 1
BT_OUT13 Load assumption ready 0
BT_OUT14 Pre lube pres. reached 1
BT_OUT15 Governor temp. lamp 1
BT_OUT16 Subsedary excitation on 0
BT_OUT17 Generator Voltage 0
BT_OUT18 Circulation pump on 0
BT_OUT19 Downtime heating on SAM Function
0
BT_OUT20 Day tank min alarm 1 32
Pre Lube On Switch

Input B_IN4 activate for one times the pre lube output BR_OUT1

SAM Function

33
Manual Damper and Fan On Switch

The input B_IN10 activate manual the damper output BR_OUT4,

Fan1 BR_OUT3 and B_OUT8.

SAM Function

34
Turn Switch

The input P_IN7 activate the manual turn function.

SAM Function

35
Analogue Gauges Outputs SAM Basic

SAM Basic Description 0 - 10V to

V_OUT1 Engine Speed 0 - 2000rpm
V_OUT2 Coolant temp. 0 -120°C
V_OUT3 Lube oil temp. 0 -120°C
V_OUT4 Fuel press. after filter 0 - 10 bar
V_OUT5 Charge air press. 0 - 5bar
V_OUT6 Charge air temp. 0 -120°C
V_OUT7 Fuel temp. 0 -120°C
V_OUT8 Fan control 0 - 10V

SAM Function
36
Analogue Gauges Outputs SAM Plus SAM Function

SAM Plus
V_OUT1 Nominal Speed 0 - 2000rpm
V_OUT1 Feedback Speed Demand 0 - 2000rpm
V_OUT1 Feedback Speed Demand Eff. 0 - 2000rpm
V_OUT1 Engine Speed Crankshaft 0 - 2000rpm
V_OUT4 Pressure 1 0-10bar
V_OUT4 Pressure 2 0-10 bar
V_OUT6 T-Coolant Intercooler 0-120°C
V_OUT8 Speed Demand 0-10V
V_OUT8 Engine Power Reserve %
V_OUT8 Injection Quantity Act.DBR % %
V_OUT8 Injection Quantity 0-120% %
V_OUT8 Nominal Power kW
V_OUT8 Tank Level Daily Tank 0-100000 Litre
V_OUT8 Tank Level Main Tank 0-100000 Litre
V_OUT8 Exhaust temp. A 0-800°C
V_OUT8 Exhaust temp. B 0-800°C
V_OUT8 Gen. Winding Temperature. 1 0-200°C
V_OUT8 Gen. Winding Temperature. 2 0-200°C
V_OUT8 Gen. Winding Temperature. 3 0-200°C

37
 SAM Function
Binary Outputs SAM Basic

Input Function Output Function

B_IN 2 Test Switch Out BR_OUT1 Pre lube on SAM Basic
BT_OUT1 Overspeed alarm lamp SAM Basic
BT_OUT2 Coolant temp. warning lamp SAM Basic
BT_OUT3 Coolant temp. stop lamp SAM Basic
BT_OUT4 Charge air warning lamp SAM Basic
BT_OUT5 Charge air alarm lamp SAM Basic
BT_OUT6 Level intercooler stop Lamp SAM Basic
BT_OUT7 Level coolant stop lamp SAM Basic
BT_OUT9 Preheat not reached lamp SAM Basic
BT_OUT10 Lube oil press. warning lamp SAM Basic
BT_OUT11 Engine running SAM Basic
BT_OUT12 Alarm fuel pressure SAM Basic
BT_OUT14 Pre lube pres. reached SAM Basic
BT_OUT18 Circulation pump on SAM Basic

38
 SAM Function
Binary Outputs SAM Plus

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 Function
SAM Functions

SAM Basic SAM Plus

Redundant Data Storage Fuel Level Monitoring

Life Data Storage Day Tank / Storage Tank Control

CAN BUS Communication Fuel Pump Control

Fan Control
Operating Signals
Shutter Control
Warnings / Alarms
Fuel Pre- Filter Monitoring
Fault Codes
Generator Excitation Control
Web server Access Generator Winding Temp. Monitoring
Remote Control 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
 SAM Function
Transistor Output SAM Plus

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

ANALOG- Output is switch Tank curve via DIASYS adjustable

OUTPUT able Standard curve linear 0-100% = 4-20mA
SAM V_OUT8
Skalierung [l/%]
PCS5
Yellow alarm

MINIDIALOG
Exchange BR_OUT2
Tankanzeige [liter] Alarm High +Pump off

A_IN_ISO2
4-20 mA Level4 95%Level > Level4 Level < Level4-Hyst

BR_OUT2
Level3 90%
Fuel Pump off
Tank Monitoring
scale Analoges
Tanklevel [0-100%] Level2 60%
Level > Level < Level2
Default: Lineare Tankcurve Level3
10 Points BR_OUT2
Level1 40%
Fuel Pump on

LEV1 to Level4 Level > Level < Level1

is adjustable via Level1+Hyst1
Diasys BR_OUT2
Min Alarm, Fuel Pump on

At LEV < LEV1 => Combined alarm yellow

+ BT_OUT20 „Alarm
Daytank“
+ Minidiag screen
SAM Function 43
Generator Monitoring

L1 Temp. Limit 1
B_OUT15
L2 Temp.
>=120°C
L3 Temp.

SAM Function

44
Exhaust Temperature A and B Side

A_IN1 and A_IN2

Exhausttemp.1 and 2
PT100 0-800°C

SAM Function

45
Logistic Concept

LOP
Backup Engine management
Easy ADEC/SAM SAM
software + data:
Hardware change Backup Engine -
Application Software +
Application/Engine Data
Software + Data are
stored in both the SAM New ADEC
Application Software +data:
Memory as well as in Hardware
memory empty
the ADEC Memory. Engine management software + data:
memory empty
The download of the
complete software is
automatically initiated
after connecting a new
ADEC of SAM
hardware to the
remaining module. SAM Function

46
Data Storage Concept

¾ Life data storage SAM

Backup Engine life data

Engine life data is

stored continously Engine life data:
ADEC
every hour, after every • engine hours
engine stop or • error log
emergency stop in the • load profile
SAM-Memory as a
backup.

SAM Function

47
WEB PAGE SAM

SAM Function

48
Dialog SAM and ADEC

USB to CAN Converter

PCMCIA to CAN Converter

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

SAM Function

49