MOTIVLINE

ECU-7 / ADEC
Advanced Diesel Engine Control

for Series 4000 C&I Application

12.11.2007 MSAT 2
 ECU-7 /ADEC
Advanced Application
Diesel C&I
Engine
Control

20V 4000 C23

12.11.2007 MSAT 3
Examples: MOTIVLINE with ECU-7 /ADEC

12.11.2007 MSAT 4
ECU-7 characteristics

9 The ECU-7 governor or ADEC (Advanced Diesel Engine

Controller) has been in use for the BR2000CR since 2005. It
will be additionally used for BR4000-03 from the middle of
2008.

9 The ECU-7 has been designed for BR2000 CR (M92/M93)

series engines. It regulates and monitors the engine
sensors, the injectors and the solenoid valves at the
engine.

9 The ECU-7 communicates with the higher-level automation

systems of the vessel such as, e.g. SAM, or BlueLine
/SmartLine (Marine) via CAN bus.

12.11.2007 MSAT 5
ECU-7 Overview of functions

9 Monitoring and control of the injector system

9 Recording and evaluation of the engine operating values

9 Limit monitoring

9 If a limit is violated, power is reduced automatically, the engine is

stopped or an emergency stop is initiated (configurable)

9 Transmission of input signals from the vehicle control system to the

engine

9 Self-monitoring

9 Diagnostics can be run via the CAN interface using the DiaSys 2.xx
interactive system

12.11.2007 MSAT 6
Technical advantages

¾ Injection system:
• Common Rail
¾ Programmable injector control:
• One controller for 4 types of injector
¾ Multiple injection:
• 42V injectors for fast injection
• Improved emission values and low fuel consumption
¾ Control of up to 20 injectors
¾ Torque-based engine management with simplified power calibration
¾ Sequential turbo charger switching
¾ Flexible monitoring
¾ Interface available for exhaust gas recirculation (EGR)

12.11.2007 MSAT 7
Technical data of ECU-7

Term Value Unit

Dimensions (w x h x d) 360 x 314 x 65 mm
Weight 5.5 kg
Operating voltage Rated voltage: 24 VDC
Constant voltage: 20 to
32
Temporarily limited
operation:
16.8 to 20
Dialog mode: 11 to 16.8
Power consumption Max. 24 A
Dissipated power Maximum 35 W
Range of operating –40 to +75 °C
temperature
Storage temperature range –40 to +85 °C
Max. temperature of housing 105 °C
Relative air humidity 0 to 95 condensing % condensing
Degree of protection IP 69K (DIN 40 050)

12.11.2007 MSAT 8
ECU-7 Temperature tolerance

Improved temperature tolerance

ADEC works at housing temperatures

from -40°C to +105°C with the specified
accuracy

⇒ A cooling plate is not required

⇒ But for C&I available

12.11.2007 MSAT 9
Abbreviations related to the “ADEC System”

ADEC: Advanced Diesel Engine Control

ECU-7: Engine Control Unit

POM: Power Output Modul

SAM: Service and Application Modul

DILA: Diagnostics Lamp

12.11.2007 MSAT 10
ECU-7: Position on the engine

ECU-7

12.11.2007 MSAT 11
ADEC System Overview

System functions and system interface specific to the application

Genset C&I Railway Marine

BlueLine / BlueVision SmartLine

ECU-7

ECU 7 series/overview of application

BR 4000 Marine BR 2000 Marine
BR 4000 Genset BR 2000 Genset
BR 4000 C&I
BR 4000 Railway
12.11.2007 MSAT 12
 Overview of System MOTIVLINE

Control Stand
Future Vehicle
Electrical gauges Control
•Coolant temp.
•Lube-oil pres. J1939/ Binary In-/Outputs
•Engine speed CANopen Analog In-/Outputs

SAM
PCS-5 CAN

Hardwired
•Single alarms
•External signals

ADEC
PCS-5 CAN

I/O Signals

Diagnostic Tool
POM
12.11.2007 MSAT 13
Differences between ADEC / MDEC

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

Injection Triple Single

Injector 24 - 42 V 24 V

Clock frequency 800 % 100 %

I/O 90 75
Max. temperature of housing 105 °C 75 °C
Box self-test Yes No

Features CAN bus for future extensions

Programmable engine monitoring
Programmable safety system
Torque-based engine management

12.11.2007 MSAT 14
Differences between ADEC/MDEC
(aftersales view)

9 No internal fuse protection

9 No replaceable memory modules “EDM“ and “IDM“
9 No internal “Fault Code Display“
9 Dialog via CAN communication, no serial interface to the engine controller
(Attention: new accessory equipment required)
9 Parameter set has been divided into “Engine Parameters” (MPS) and
“Application Parameters“ (APS) Æ Update via EPROM
9 New parameter structure (ZZ.KKKK.PPP numbers)
9 Expanded fault/error list

12.11.2007 MSAT 15
Differences between ADEC/MDEC (aftersales
view)
Dialog via CAN communication, no serial interface to the engine controller
(Attention: new accessory equipment required)

X6 X4 X5 X2 X3 X1

No internal fuse

No replaceable
memory modules „EDM“ and „IDM“

No internal „Fault Code Display“

12.11.2007 MSAT 16
Photo of ECU-7 inside

Attention : No guarantee after opening.

12.11.2007 MSAT 17
Interactive communication with ECU-7

oder

COB 9-01
Rear Front

oder

Part-No.: 5295305612

12.11.2007 MSAT 18
 Tools for interactive communication

USB to CAN converter Part.-No.X00041878

CAN communication Cable

2m, 9pol. Sub D / 12 pin round connector
Part-No. X00012797

Software DIASYS 2.50

2.40 SP1
Part-No. 535 538 1280/S0012
1280/S0009

PCMCIA to CAN converter (V4.1)

Part-No. 000 538 2835

Attention: Diasys from Version 2.32 or higher is required for

dialog as well as a dongle (parallel/USB) released for ECU-7.

12.11.2007 MSAT 19
ECU-7 Software structure (simplified)

ECU-7
Governor

Engine- Plant-
Parameter Parameter
MPS APS

FSW FSW
(functional software) (functional software)

Engine
Plant

12.11.2007 MSAT 20
ECU-7 Structure of parameter numbers

zz.kkkk.ppp Assignment.Category.Parameter
Number of parameters/PV within this category
All parameter type (1D, 1D-Bit, 2D and 3D)
XX.XXXX.002

Category (e.g. 0120 Æ T-Coolant)

XX.0120.XXX

Assignment of the parameter

1 Æ Engine
2 ÆPlant
01.XXXX.XXX

12.11.2007 MSAT 21
ECU-7 Structure of parameter numbers

Example: 01.0120.002

Engine

T – Coolant Water

T-Coolant Water ECU Channel

12.11.2007 MSAT 22
 Extended error code list for ECU-7

MDEC/SAM
Error No.

ECU-7
Description/Information
Error No. with Diasys

Alarmtext

12.11.2007 MSAT 23
Engine Control Unit ECU-7
(Control Loop)

ECU-7
- Torque based
engine
management

ECU-7
- 4 Power Stage
- 24/42V Injector

12.11.2007 MSAT 24
 ECU-7 Connections and diagnostics

Connection Connection X2 Connection X3 Connection X4

X1 Sensor wiring Power supply Injector wiring
System wiring harness harness

DILA (diagnostics lamp)

-OFF
(no power supply)
- ON
(normal state – no fault)
- Flashes slowly
(incorrect data record /MPS, APS)
- Flashes quickly
(internal fault, e.g. defective RAM)

12.11.2007 MSAT 25
ECU-7 Overview of signals (X1)

9 X1 8 binary inputs (DI)

9 X1 1 frequency speed setting (FIP)
9 X1 2 analog speed settings (AI)
9 X1 1 ignition input (IGI)
9 X1 1 emergency stop input (ESI) X1 connection
9 X1 2 CAN connections (CAN_P, PCS-BUS)
9 X1 4 transistor outputs, plant (TOP)
9 X1 1 frequency channel (FO)
9 X1 2 analog channels (AO)

12.11.2007 MSAT 26
ECU-7 Overview of signals (X2 / X4)

9 X2 1 CAN connection (CAN_E, Engine Bus)

9 X2 4 engine transistor outputs (TOE)
9 X2 12 temperature inputs (TI)
9 X2 14 pressure inputs (PI)
X2 and X4
9 X2 3 level switch inputs (LSI)
connection
9 X2 2 speed inputs (ASI)
9 X2 4 frequency inputs (FI)

9 X4 20 injector channels (IO)

9 X4 4 PWM channels (PWM)

12.11.2007 MSAT 27
 Sensors Series 4000 with ECU-7 (X2)
maximum scope of supply
Temperature: Pressure:
Temperature: Pressure:
Lube
LubeOil
OilPressure
Temperature BB55
TemperatureAmbient
AmbientAir BB33 Pressure
Air
Pressure
PressureLube
LubeOil
Oilbefore
beforeFilter
Lube BB5.3
LubeOil
OilTemperature BB77 Filter 5.3
Temperature
Pressure
PressureCharge
ChargeAir
Coolant BB10
CoolantWater
WaterTemperature
Temperature BB66 Air 10
Pressure
PressureCoolant
CoolantWater
Temperature BB16
TemperatureCharge
ChargeAir BB99 Water 16
Air
Pressure
PressureFuel
FuelLine
Lineafter
afterFilter
T-Coolant BB34
T-CoolantIntercooler BB26 Filter 34
Intercooler 26
P-Coolant
P-CoolantIntercooler
Temperature BB43
TemperatureFuel BB33 Intercooler 43
Fuel 33
Pressure
PressureRail
RailFuel BB48
Fuel 48
Speed: P-Crankcase BB50
Speed: P-Crankcase 50
Engine
EngineSpeed
SpeedCamshaft B1
Camshaft B1
Engine Option:
EngineSpeed
SpeedCrankshaft BB13
Crankshaft 13 Option: ECU-7 (X2)
Speed
SpeedTurbo
TurboCharger
Charger(ETC) BB44
(ETC) 44
Priming
PrimingPump
Level: MM22
Level: Pump
Level
LevelWater
WaterininFuel
FuelPrefilter
Level F70
LevelCoolant
CoolantWater FF33 Prefilter F70
Water 33

Actor:
Actor:
High
HighPressure
PressurePump M8
Pump M8

12.11.2007 MSAT 28
ECU-7 Diagnostics

Straightforward diagnostics

The ECU-7 controller carries out a self-test during

switch-on and in normal operation. The result is Diagnostics Lamp
displayed by an LED (DILA). (DILA)

Permanent light Æ ECU-7 is OK

Flashing light Æ ECU-7 malfunction
No light Æ No power supply

Internal faults can be detected by applying the

power supply and disconnecting the controller
cable.

12.11.2007 MSAT 29
Integrated Test System (ITS)

Integrated Test System (ITS) functions

The ITS runs extensive internal system tests after switch-on.
It monitors all important functional areas of the governor
and the connected electrical components:
• The electronics within the actual governor
• Sensors
• Actuators
• Bus communication
• Power supply
The ITS detects faults that occur, pinpoints these and reports them by means of combined
alarms. Additionally, a fault report is output at a higher-level monitoring system
(if present) via the CAN bus and can be made visible to the operator there.

12.11.2007 MSAT 30
ECU-7 LED function

The diagnostics LED (DILA) can display the following codes :

Time 0 Sec 1 Sec 2 Sec 3 Sec 4 Sec

Normal operation

Loader application active

Offline-ITS fault

External RAM defective

External FLASH defective

No firmware

Application has crashed

12.11.2007 MSAT 31
 SAM
Service
and
Application
Modul

Application
C&I
12.11.2007 MSAT 32
SAM - Service and Application Module

¾Evaluation of additional binary and analog signals (e.g. additional

sensors, control signals etc.)
¾Analog and binary Outputs to drive Instruments and Lamps installed in
customers´ dashboards
¾Processing of additional customer or application related functions
¾Display of ADEC and SAM Fault Codes
¾Intergrated gateway adaption of MTU CAN Bus to several existing
customer bus systems (i.e. CANopen/J1939)
¾Backup of all ECU data and Functional Software
¾Interface for Dialog-Unit

12.11.2007 MSAT 33
SAM - Service and Application Module

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

Pushbutton for
Mini-Dialog

Diagnostics-
Lamp
Plugs with spring
loaded terminal strips

Future functionality
Ethernet Interface Interface to Dialog-
for Remote Diagnostics Unit
and Web Based Monitoring

12.11.2007 MSAT 34
SAM - Service and Application Module

High I/O Capability Onboard

9 24 Channel Binary Output

9 3 Channel PWM Output
9 8 Channel Instrument output
9 28 Channel Binary Input
9 10 Channel Analog Inputs
(e. g. PT100, 4-20mA, 0-10V,
etc.)
9 4 Frequency inputs (Speed)
9 1 CANopen or J1939 Interface
Expansion of I/O and
9 1 Ethernet interface
Interfaces via plug in cards
9 1 Serial interface
9 Interface plug for Diasys

12.11.2007 MSAT 35
SAM: Diagnostics

The ADEC and SAM performs a self test

during power initialisation and during
operation. The result is indicated via the
Diagnostic lamp (DILA).

Permanent light Æ ADEC / SAM is ok.

Flashing light Æ ADEC / SAM malfunction
Diagnostics Lamp
No light Æ Power supply failure

Internal faults can be detected with power on

at disconnected harness.

SAM offers an additional fault code display.

Fault Code Display

12.11.2007 MSAT 36
Data Storage Concept
„Field Data Handling“ (FDH)
SAM
¾ Life data storage 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.

prelim
inary
12.11.2007 MSAT 37
Logistic Concept

Easy ADEC/SAM LOP

Backup Engine management SAM
Hardware change software + data:
Backup Engine -
Application/Engine Application Software +
Software + Data are Data
stored in both the SAM
Memory as well as in Application Software +data: ADEC
memory empty
the ADEC Memory.
Engine management
The download of the software + data:
complete software is memory empty
automatically initiated
after connecting a new
ADEC or SAM prelim
hardware to the
remaining module. inary
12.11.2007 MSAT 38
ECU7: Ignition

¾ Ignition input

+ 9No data loss at Emergency stop

IGI
9Shut down fuel injection without
controller shut down
9CPU saves alarm codes

ECU 7 power up
Ignition on = 24V
ECU 7 Engine stop
Ignition off = 0V

12.11.2007 MSAT 39
Summary

ADEC (Advanced Diesel Engine Controller) is an integrated

Engine Control System for the harsh reality and advanced
technical demands
The SAM (Service and Application Module) design allows a
flexible custom-made solution

12.11.2007 MSAT 40