MTU Series 1600 Diesel Generators Technical/Overview Manual

Documentation Functional Description Electronic governor ECU 8 for MTU Series 1600 Genset application E532291/01E

Printed in Germany © 2011 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, micro‐ filming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.

3 ❘ ECU 8 ❘ E532291/01E 2011-11 1 ........ General .......................................................................................................................................................... 6 1.1 General requirements ..................................................................................................................................... 6 1.1.1 General ..................................................................................................................................................................... 6 1.1.2 Intended use ............................................................................................................................................................. 6 1.1.3 Modifications or changes .......................................................................................................................................... 6 1.1.4 Spare parts ............................................................................................................................................................... 6 1.2 Safety regulations for maintenance and repair work ...................................................................................... 7 1.2.1 Safety regulations for commissioning ....................................................................................................................... 7 1.2.2 Safety regulations for operation ................................................................................................................................ 7 1.2.3 Engine operation ...................................................................................................................................................... 7 1.2.4 Maintenance and repairs .......................................................................................................................................... 7 1.2.5 Welding .................................................................................................................................................................... 8 1.2.6 Pressing and pulling work ......................................................................................................................................... 9 1.2.7 Work on electric/electronic assemblies..................................................................................................................... 9 1.2.8 Working with laser devices ..................................................................................................................................... 10 1.2.9 Operation of electrical devices................................................................................................................................ 10 1.3 Designation of the sides of the engine and the cylinders ............................................................................. 11 2 ........ Overview...................................................................................................................................................... 12 2.1 MTU Engine Control Unit ECU8 ................................................................................................................... 12 2.1.1 Overview ................................................................................................................................................................ 12 2.1.1.1 System devices................................................................................................................................................ 12 2.1.2 Design .................................................................................................................................................................... 13 2.2 Scope of delivery .......................................................................................................................................... 14 2.2.1 MTU basic equipment ............................................................................................................................................. 14 2.2.1.1 Engine sensors, actuators ............................................................................................................................... 14 2.2.1.2 Engine wiring + injection wiring ........................................................................................................................ 14 2.2.1.3 ECU8 Engine Control Unit ............................................................................................................................... 14 2.2.1.4 Engine Control Unit connecting cable to system/power supply........................................................................ 14 2.2.1.5 24V DC power supply ...................................................................................................................................... 14 2.2.1.6 Smart Connect ................................................................................................................................................. 14 2.2.2 OEM parts .............................................................................................................................................................. 14 2.2.2.1 External sensors .............................................................................................................................................. 14 2.2.2.2 Connecting cables/wires for external sensors.................................................................................................. 14 2.3 Customer interface/operator's devices ......................................................................................................... 15 2.3.1 System overview/customer interface ...................................................................................................................... 15 2.3.1.1 Instrument outputs ........................................................................................................................................... 15 2.3.1.2 Binary inputs .................................................................................................................................................... 16 2.3.1.3 Transistor outputs ............................................................................................................................................ 16 2.4 Diagnosis and tools ...................................................................................................................................... 17 2.4.1 Device's own diagnosis .......................................................................................................................................... 17 2.4.1.1 Flashing frequencies ........................................................................................................................................ 18 2.4.2 DiaSys .................................................................................................................................................................... 19 2.4.3 Smart Connect........................................................................................................................................................ 20 2.4.3.1 Functional description ...................................................................................................................................... 20 2.4.3.2 Description of Smart Connect hardware .......................................................................................................... 20 2.4.3.3 Overview of interfaces ..................................................................................................................................... 21 2.4.3.4 Settings ............................................................................................................................................................ 23 2.4.4 Engine Identification Label EIL ............................................................................................................................... 27 3 ........ Use and design ........................................................................................................................................... 28 3.1 Functions ...................................................................................................................................................... 28 3.2 Function of the ignition (IGI)/emergency stop (ESI) ..................................................................................... 29 3.2.1 Ignition input (IGI Tl.15) .......................................................................................................................................... 29 3.2.2 Emergency stop input (ESI) .................................................................................................................................... 29 3.3 Installation on engine.................................................................................................................................... 30 3.3.1 Specifications ......................................................................................................................................................... 30 3.3.2 Mechanical design/installation location................................................................................................................... 30 3.4 Technical data of ECU8................................................................................................................................ 31

4 ❘ ECU 8 ❘ E532291/01E 2011-11 3.5 Connectors ................................................................................................................................................... 33 3.5.1 Connector X1/connector to ECU8 .......................................................................................................................... 33 3.5.1.1 Connector assignment ..................................................................................................................................... 33 3.5.2 Connector X2/engine wiring harness ...................................................................................................................... 36 3.5.2.1 Connector assignment ..................................................................................................................................... 36 4 ........ Sensors ....................................................................................................................................................... 40 4.1 Installation location of the sensors ............................................................................................................... 40 4.1.1 Sensors on Series 1600-6R engines ...................................................................................................................... 40 4.1.1.1 Series 1600-6R overview ................................................................................................................................. 40 4.1.1.2 Series 1600-6R top .......................................................................................................................................... 41 4.1.1.3 Series 1600-6R left side................................................................................................................................... 42 4.1.1.4 Series 1600-6R free end .................................................................................................................................. 43 4.1.1.5 Series 1600-8V overview ................................................................................................................................. 44 4.1.1.6 Series 1600-8V top .......................................................................................................................................... 45 4.1.1.7 Series 1600-8V free end .................................................................................................................................. 46 4.1.1.8 Series 1600-10V overview ............................................................................................................................... 47 4.1.1.9 Series 1600-10V top ........................................................................................................................................ 48 4.1.1.10 Series 1600-10V free end ................................................................................................................................ 49 4.1.1.11 Series 1600-12V overview ............................................................................................................................... 50 4.1.1.12 Series 1600-12V top ........................................................................................................................................ 51 4.1.1.13 Series 1600-12V PTO end, driving end ........................................................................................................... 52 4.2 Sensors used................................................................................................................................................ 53 4.2.1 Sensor types........................................................................................................................................................... 53 4.2.1.1 Pressure sensors ............................................................................................................................................. 53 4.2.1.2 Use .................................................................................................................................................................. 54 4.2.2 Speed sensors........................................................................................................................................................ 59 4.2.2.1 Use .................................................................................................................................................................. 59 4.2.3 Temperature sensors ............................................................................................................................................. 62 5 ........ Wiring........................................................................................................................................................... 64 5.1 Power supply ................................................................................................................................................ 64 5.1.1 Power supply .......................................................................................................................................................... 64 5.1.1.1 General ............................................................................................................................................................ 64 5.1.1.2 Example for power supply setup (recommendation) ........................................................................................ 66 5.1.1.3 Circuit breakers................................................................................................................................................ 66 5.1.1.4 Emergency stop ............................................................................................................................................... 66 5.1.2 Grounding concept ................................................................................................................................................. 67 5.1.2.1 Grounding concept .......................................................................................................................................... 67 5.1.3 CAN bus ................................................................................................................................................................. 68 5.1.3.1 General ............................................................................................................................................................ 68 5.1.3.2 Wiring requirements ......................................................................................................................................... 68 5.1.3.3 Block diagram .................................................................................................................................................. 68 5.2 Engine wiring harnesses .............................................................................................................................. 70 5.2.1 Sensor wiring harness ............................................................................................................................................ 70 5.2.1.1 Series 1600 6R (six-cylinder in-line engine)..................................................................................................... 70 5.2.1.2 Series 1600 8V (eight-cylinder V engine)......................................................................................................... 71 5.2.1.3 Series 10V (ten-cylinder V engine) .................................................................................................................. 72 5.2.1.4 Series 12V (twelve-cylinder V engine) ............................................................................................................. 73 5.2.1.5 Connectors XY39A1 ... XY39B2 ...................................................................................................................... 74 5.2.1.6 M8.1/M8.2 Connector ...................................................................................................................................... 74 5.3 System cable ................................................................................................................................................ 75 5.3.1 System wiring harness ........................................................................................................................................... 75 6 ........ Inputs and outputs of the system ............................................................................................................. 76 6.1 Overview of channel assignments................................................................................................................ 76 6.1.1 System-side ............................................................................................................................................................ 76 7 ........ Functions .................................................................................................................................................... 78 7.1 ECU8 signals ................................................................................................................................................ 78 7.1.1 Engine side - System side ...................................................................................................................................... 78 7.1.1.1 General information about the parameters ...................................................................................................... 78 7.1.1.2 Power supply ................................................................................................................................................... 78 7.1.1.3 Schematic circuit diagram ................................................................................................................................ 78

5 ❘ ECU 8 ❘ E532291/01E 2011-11 7.1.1.4 Ignition IGI input ............................................................................................................................................... 79 7.1.1.5 Schematic circuit diagram ................................................................................................................................ 79 7.1.1.6 Emergency stop input ESI ............................................................................................................................... 80 7.1.1.7 Technical data ................................................................................................................................................. 80 7.1.1.8 Schematic circuit diagram ................................................................................................................................ 80 7.1.2 Binary inputs DI 1 ... 8 ............................................................................................................................................ 81 7.1.2.1 Technical data ................................................................................................................................................. 81 7.1.2.2 Required settings ............................................................................................................................................. 81 7.1.2.3 Schematic circuit diagram ................................................................................................................................ 81 7.1.2.4 D1 - Engine stop .............................................................................................................................................. 81 7.1.2.5 DI 2 – Speed droop .......................................................................................................................................... 81 7.1.2.6 DI 3 – Increase idle speed/or switchover frequency ........................................................................................ 82 7.1.2.7 DI 4 – Reset alarm ........................................................................................................................................... 82 7.1.2.8 DI 5 – Increase engine speed (speed up) ........................................................................................................ 82 7.1.2.9 DI 6 – Decrease engine speed (speed down) .................................................................................................. 82 7.1.2.10 DI 7 – Engine start ........................................................................................................................................... 82 7.1.2.11 DI 8 – Override ................................................................................................................................................ 82 7.1.3 Analog inputs AI 1 ... 2 ........................................................................................................................................... 83 7.1.3.1 Technical data ................................................................................................................................................. 83 7.1.3.2 Required settings ............................................................................................................................................. 83 7.1.3.3 Schematic circuit diagram ................................................................................................................................ 83 7.1.3.4 AI 1 - Speed demand ....................................................................................................................................... 83 7.1.3.5 AI 2 – Torque request ...................................................................................................................................... 83 7.1.4 Transistor output TOP 1 to 4 .................................................................................................................................. 84 7.1.4.1 Channel specification/technical data ................................................................................................................ 84 7.1.4.2 Required settings ............................................................................................................................................. 84 7.1.4.3 Schematic circuit diagram ................................................................................................................................ 84 7.1.4.4 TOP 1 - Yellow alarm ....................................................................................................................................... 84 7.1.4.5 TOP 2 - Red alarm ........................................................................................................................................... 84 7.1.4.6 TOP 3 – Oil pressure too low (lube-oil stop) .................................................................................................... 85 7.1.4.7 TOP 4 – Starter on ........................................................................................................................................... 85 7.1.5 Analog outputs AO 1 to 2 ....................................................................................................................................... 85 7.1.5.1 Channel specification/technical data ................................................................................................................ 85 7.1.5.2 Required settings ............................................................................................................................................. 85 7.1.5.3 Schematic circuit diagram ................................................................................................................................ 85 7.1.5.4 AO 1 – Coolant temperature ............................................................................................................................ 85 7.1.5.5 AO 2 - Oil pressure .......................................................................................................................................... 86 7.1.6 CAN interfaces 1 to 2 ............................................................................................................................................. 86 7.1.6.1 Channel specification/technical data ................................................................................................................ 86 7.1.6.2 Required settings ............................................................................................................................................. 86 7.1.6.3 Schematic circuit diagram ................................................................................................................................ 86 7.1.6.4 CAN 1 .............................................................................................................................................................. 86 7.1.6.5 CAN 2 – J1939 ................................................................................................................................................ 87 8 ........ Fault message table ................................................................................................................................... 88

6 ❘ ECU 8 ❘ E532291/01E 2011-11 1 General 1.1 General requirements 1.1.1 General In addition to the notices in this brochure, the valid, country-specific, statutory regulations on accident prevention and environmental protection are to be observed. This engine is built according to the current state of the art standards and valid regulations and rules. Nevertheless dangers to persons and property are still present if this engine is:  • Not used properly  • Operated, maintained and repaired by non-trained and unauthorized personnel  • Modified or changed  • Safety notices are not observed 1.1.2 Intended use This engine is only to be used for the purpose stated in the contract or at the delivery. A different or additional use will be considered a “non-intended use”. The manufacturer assumes no responsibility for any damages resulting from a “non-intended use”. The user is solely responsible. Intended use also includes observing the operating instructions and the maintenance and repairs specifications. 1.1.3 Modifications or changes Any unauthorized modifications or changes to the engine affect safety. MTU assumes no responsibility and accepts no warranty claims for damages resulting from unauthorized modifications or changes. 1.1.4 Spare parts Only MTU original parts may be used when exchanging or replacing components or assemblies. Liability and warranty claims against the engine manufacturer for damage resulting from the use of non-OEM parts will be rejected.

7 ❘ ECU 8 ❘ E532291/01E 2011-11 1.2 Safety regulations for maintenance and repair work 1.2.1 Safety regulations for commissioning The product must be properly installed and have passed the acceptance test according to the MTU regulations before it can be commissioned. Each time the device or system is put into commission make sure  • That all maintenance and repair work are finished  • That all loose parts have been removed from rotating parts  • That no one is in the danger zone of moving parts Right after placing the device or system into commission make sure that the controls and indicators and the monitoring, signaling and alarm systems are operating properly. 1.2.2 Safety regulations for operation Regularly train and practice the operating procedures in case of emergencies. The operator must be familiar with the controls and indicators. The operator must know the effects of each operating step performed. The operator must carry out each operating step according to the documentation. During operation the display instruments and monitoring groups must be constantly monitored with respect to the current operating states, the operating limits and any warnings and alarms. If a problem with the system is detected or if the system reports a problem:  • The person(s) responsible is/are to be informed  • The messages is to be evaluated  • Any emergency actions are to be taken, as necessary, e.g. emergency engine stop 1.2.3 Engine operation Always wear hearing protection when engine is running! Make sure engine room is well ventilated! Immediately wipe up any operating fluids that have leaked out or have been spilled; use a binding agent as necessary. A combustion engine's exhaust is poisonous. Inhaling the exhaust is hazardous to your health. Exhaust pipes must be air tight and routed to the open air. Do not touch or come into contact with any battery terminals, generator terminals or cables while engine is running! Improper insulation or grounding of electrical parts can lead to serious electrical shocks causing injury. Absolutely do not loosen or open any water, oil, brake fluid, fuel, compressed air or hydraulic lines while the engine is running! 1.2.4 Maintenance and repairs A major factor in safety is the compliance with the maintenance and repairs specifications. Do not perform any maintenance or repair work while the engine is running, unless it is explicitly permitted. Secure the engine from being accidentally started. If an electrical starter is installed, disconnect the battery. If a compressed air starter is installed, close the main valve of the compressed air system and release pressure in the air line. Place a sign “Do not operate” in the operating room or at the controls! Keep all nonessential persons away! Do not rectify any problems for which you do not have the proper knowledge or the special tools required! Maintenance and repair work should only be made by authorized and qualified personnel. Only use appropriate and calibrated tools.

8 ❘ ECU 8 ❘ E532291/01E 2011-11 Do not work on engines or components that are only being held up by lifting equipment or by a crane. Always properly support these components with suitable equipment before starting any maintenance or repair work. Before cranking engine make sure no one is in the danger zone of the engine. After finishing work on the engine, make sure all protective devices are reinstalled and that all tools and loose parts have been removed from the engine. Fluids exiting at high pressures can penetrate through clothing and skin and cause serious injuries. Before starting any work, release the pressure in those systems that are to be worked on! Never rebend any fuel injection lines and do not install any lines that have been rebent. Keep fuel injection lines and connections clean. When removing or opening lines, always close off the openings using suitable caps and plugs. Make sure to not damage the fuel lines during maintenance and repair work. When installing lines always use the correct tightening torque and make sure that all brackets and dampers are installed properly. Makes sure that all fuel injection lines and oil pressure lines have sufficient clearance so as to avoid any contact with other components. Do not install fuel or oil lines near hot components unless the design does not allow otherwise. Elastomers (e.g. Viton sealing rings) are safe at normal operating temperatures. If a fire occurs or if the temperature rises above 300 °C, the materials will start to melt setting off hydrogen fluoride fumes, which is an acid. If this acid comes into contact with the skin, serious burns can occur. If elastomer seals appear burnt or glassy, do not tough them with unprotected hands! Wear protective gloves! Be cautious with hot fluids in lines, pipes and spaces  Risk of burn injuries! Observe the cool off times of components that are heated up for installation/removal Risk of burn injuries! Do not touch or come into contact with the hot parts of the compressor and the exhaust system  Risk of burn injuries! Be careful when removing vent screws or screw plugs from the engine. To prevent the fluid from escaping, hold a rag over the vent screw or stop plug. The risk of injury is greater if the engine was just turn off and the fluids are still hot. Be careful when draining hot operating fluids.  Risk of scalding! Drain the operating fluids into a suitable container and clean up any spilled fluids using a binding agent as necessary. Make sure the engine room is well ventilated when changing any operating fluids or working on the fuel system! For any work above body height use safety gear and work platforms. Make sure engine parts are placed on stable surfaces! To avoid back injuries when lifting components, adults should only lift between 10 to 30 kg depending on age and gender, therefore:  Get help or use a lifting aid.  Make sure that all chains, hooks, loops, etc. are tested and approved and have sufficient payload rating and that the hooks are correctly positioned. Lifting lugs may not be loaded laterally. When carrying out maintenance and repair work on the engine, pay special attention to cleanliness. After finishing the maintenance and repair work, make sure that any loose parts have been removed. 1.2.5 Welding Welding is prohibited on the engine or on installed assemblies! Never use the engine as a ground connection for welding! This will prevent the welding current from being conducted through the engine causing burns to the mounts, bearings and gears, which in turn leads to bearing seizures or damage to the components.

9 ❘ ECU 8 ❘ E532291/01E 2011-11 Do not let the welding cables lie across or near the wiring harness of the MTU system. The welding current could cause a voltage to be induced in the wiring harness which could lead to damage to the electrical system. The ground connection of the welder must be connected within 60 cm of the spot to be welded. If parts of the engine have to be welded (e.g. exhaust pipe), they should be removed from the engine before welding. The connector and connections for the MTU electronics do not have to be removed for welding work, if the main power switch has been turned to “OFF” and the battery has been disconnected at both the positive and negative terminals. 1.2.6 Pressing and pulling work Only those devices specified in the work plan and the assembly instructions are to be used for pressing and pulling work. The maximum pressure of the pressing and pulling device must not be exceeded when pressing on parts. The high-pressure lines for the hydraulic pressing or pulling device have been tested with 3800 bar. Do not bend or apply pressure to the lines when they are under pressure! Before starting any pressing work, observe the following:  Bleed the pressing and pulling device and the pump and the lines at the designated positions for each system used (e.g. open the bleed screw, pump oil until it is free of air bubbles, close bleed screw).  When pressing parts on, install the device with the piston inserted.  When pulling parts off, install the device with the piston removed. On a pressing and pulling device with a central expansion supply line, screw the spindle into the shaft end until a sealing effect is reached. During hydraulic pressing and pulling of parts, make sure that no one is near the parts being pressed on or pulled off. When the system is under pressure, there is always the danger that the part being pressed on will suddenly “fly off”. Before the devices are used they are to be inspected and tested at regular intervals (crack tests). 1.2.7 Work on electric/electronic assemblies Before starting any maintenance or repair work or before shutting off any parts of the electronics, get the approval of the manager responsible. Turn off the power supply to the corresponding areas before starting any work on assemblies. If a specific measure requires a power supply, this is noted at the appropriate place in the document. Gases produced by the battery are explosive. For this reason avoid any sparks and open flames. Do not touch or come into contact with battery acid. Wear safety glasses. Do not place any tools on the battery. Before installing any cables on the battery, check for correct polarity. Crossing the polarity on the battery can lead to injuries caused by the sudden expulsion of acid or the bursting of the battery case. Do not damage wires and cables during removal work. Reinstall wires and cables so that they are not damages during engine operation by coming into contact with sharp edges or hot surfaces or chafing against other parts. Do not attached cables or wires to lines carrying fluids! After finishing the maintenance or repair work reattach and retighten any wires or cables that have come loose! A function check of the device or system must be made after any repairs. A check of just the repaired component is insufficient. The entire system connected must also be checked. If cables or wires are in contact with components and there is the risk that they will chafe, they should be attached with cable clamps!

10 ❘ ECU 8 ❘ E532291/01E 2011-11 Cable ties should not be used to mount wires or cables because if they are removed during maintenance or repair work, there is a chance that they will not be reinstalled when the work is finished. Spare parts must be properly stored before being used, i.e. especially protected against moisture. Faulty electronic parts or assemblies must be properly packaged for transport back for repairs, i.e. especially protected against moisture, shocks and wrapped in antistatic foil. 1.2.8 Working with laser devices When working with laser equipment wear special safety glasses for laser applications! Laser equipment can produce extremely intense, highly focused radiation by the effect of stimulated emission in the range of visible light or in the infrared or ultraviolet spectral ranges. The laser radiation can cause damage by photochemical, thermal or optomechanical effects. The main danger is of irreversible damage to eyes. Laser equipment must be equipped with the necessary protective equipment meeting the requirements of the class and application of the laser. Only the following laser equipment may be used for equisignal systems and survey work:  Class 1, 2 or 3A laser equipment  Class 3B laser equipment which only radiate in the visible wavebands (400 nm to 700 nm), have a maximum output of 5 mW and have a radiation axis or radiation surface that is set to prevent any hazards to the eyes. 1.2.9 Operation of electrical devices When electrical devices are in operation certain parts are electrified. Failure to heed the warnings for these devices may result in serious injuries or damage to property.

MTU Series 1600 Diesel Generators Technical/Overview Manual

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