System Description
Electronic Engine Governor
EMR 2
Chapter
EMR 2
Chapter Overview
Introduction
Important Notes
System Description
System Functions
Interfaces
Configuration and Parameter Setting
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Diagnostic Button and Fault Indicator Lamp
Replacement of System Components
Technical Data
Index of Specialist Terms
Index
Connection Diagams
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Chapter Overview
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EMR 2
Ta ble of Contents
Contents
1 Introduction
2 Important Notes
2.1 Operating instructions 67
2.2 Installation guidelines 67
2.3 Damage 67
2.4 Customer side wiring, plug connection 68
2.5 Remove plug 68
2.6 Electrical welding 68
3 System Description
3.1 Utilization of the EMR 2 69
3.2 System overview 69
3.3 Description of functions 70
3.4 Basic equipment 70
4 System Functions
4.1 Overview features 72
4.2 Function extensions 73
4.3 Speed control 74
4.4 Set point settings 76
4.5 Fuel quantity limitation (performance curve) 77
4.6 Droop control 78
4.7 Engine start/stop 78
4.8 Displays / Outputs (monitoring function) 79
4.9 LDA function 81
4.10 Temperature-dependent start control 81
4.11 Speed throttling (input F 7) 81
4.12 Engine protection functions 81
4.13 Altitude correction 82
4.14 Fuel volume control 82
4.15 Emergency running (limp home) 82
4.16 Cold start installation 82
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69
71
5 Interfaces
5.1 Diagnostic interface (basic function) 83
5.2 CAN-Bus interface 83
6 Configuration and Parameter Setting
6.1 Function overview, pin assignment and configuration example 86
7 Diagnostic Button and Fault Indicator Lamp
7.1 Self-diagnostic (without operating the diagnostic button) 87
7.2 Diagnostic with Button and Error Code 90
7.3 Diagnostic possibilities with the SERDIA software 98
8 Replacement of system components
8.1 Replacement EMR
8.2 Features of the Replacement of the Control Unit 99
8.3 Features of the Replacement of the Actuator 100
8.4 Combination EMR, EMR 2, Control Unit and Actuator 100
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Tab l e of C o n t e nt s
EMR 2
9 Technical Data
9.1 General Data 101
9.2 Signal Specification 102
9.3 Plug assignments 103
9.4 Sensor Data 105
10 Index of Specialist Terms
11 Index
12 Connection diagrams
Appendix
12.1 Connection diagram - Vehicle side / Unit side 115
12.2 Connection diagram Engine side (sheet 1) 116
12.3 Connection diagram Engine side (sheet 2) 117
12.4 Connection diagram for CAN-Bus and Diagnostic Line 118
101
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1 Introduction
EMR 2
Introduction
This system description provides an overview of the design and operation of the electronic engine governor
(EMR 2) as a control unit when used in engines of the model series 1012/1013/2012/2013/1015
In addition, an explanation is given of the functions of the EMR 2 and how problems with the EMR 2 can be
recognized and overcome.
The EMR 2 is a further development of the previously utilized EMR.
Basically, it has the same functionality as the EMR, but is equipped with additional functions and extensi-
ons that are summarized in Chapter 4.2.
Reference is made to Chapter 8 for information regarding replacements,
1) Same system with Bosch EDC-actuator (1015).
1)
.
General notes
It is our aim to permanently improve and extend the contents of this brochure. For this purpose, the experiences of the circle of users can be particularly helpful.
Should you desire changes, extensions, improvements, etc., we would welcome your input (Engine maintenance technology department, VS-TI). Please make as much use of this as you wish. In this way, you are
assisting in making the next version more up-to-date. We pay close attention to every message and will
prepare a new issue of the brochure at the appropriate time. We thank you in advance for your cooperation.
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Maintenance technology engines
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Introduction
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2 Important Notes
2.1 Operating instructions
☞
IMPORTANT!
The purpose of this document is the explanation and clarification of the design and functions
of engines, engine components and systems.
The information contained herein always corresponds to the technical conditions valid at the
time of going into print and are not subject to any immediate alteration service.
☞
IMPORTANT!
Applicable for the operation, maintenance and start-up are exclusively the information of the
published and currently valid technical documentation, corresponding to the scope of delivery and function (such as operating instructions, switching diagrams, workshop manual,
repair and adjustment instructions, technical circulars, service information, etc.).
EMR 2
Important Notes
1
2
3
2.2 Installation guidelines
☞
IMPORTANT!
For the mechanical installation of the apparatus, reference should be made to the applicable
issue of the “Installation Guidelines for electronic systems of DEUTZ diesel engines”. More
information can be obtained from the DEUTZ AG, dept. technical operation support.
H
REMARKS!
Sufficient ventilation of control unit and actuator must be ensured in order to prevent limitations of function and damage.
2.3 Damage
H
REMARKS!
Sensors and actuators may not be fitted individually to, or between, power sources for either
inspection or testing purposes but only in connection with the EMR 2, as there is a danger of
destruction!
H
REMARKS!
Despite polarity reversal protection in the control apparatus, it is necessary to prevent incorrect polarity. Incorrect polarity can damage control units!
H
REMARKS!
The plug connections of the control units are only dust and watertight when plugged into
mating connection! Until the mating connector has been plugged in, the control units must be
protected against spray water!
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EMR 2
Important Notes
2.4 Customer side wiring, plug connection
☞
IMPORTANT!
In order to attain the required protection class (IP 66) at the control unit, the individual wire
seals, plugs and sealing rings provided must be used.
1
☞
IMPORTANT!
The connection between pins and individual wires must only be carried out with the proper
pinching tools.
2
H
REMARKS!
The voltage supply for inputs and outputs for the users must be able to be switched in a deenergized manner via the key switch (terminal 15) - not via continuous positive.
3
2.5 Remove plug
4
H
REMARKS!
Removing the 25-pole equipment plug and engine plug when the control unit is on, i.e. when
the voltage supply is on (terminal 15 on) is not permitted.
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6
1. Voltage supply off
- only then -
2. pull out equipment plug and engine plug
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2.6 Electrical welding
H
REMARKS!
In order to prevent damage when carrying out ELECTRIC welding of the installation, the plug
connections at the control unit must first be pulled out.
H
REMARKS!
The ignition (terminal 15) must be switched off when working at the EMR 2.
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3 System Description
3.1 Utilization of the EMR 2
EMR 2
System Description
The purpose of the electronic engine governor (EMR 2) is the regulation of the speed of revolution of DEUTZ
Diesel engines of the model series 1012/1013/2012/2013/1015 for applications in agricultural and construction machinery as well as in generating sets. It is designed for heavy duty also under difficult environmental conditions and possesses the corresponding protection classes.
The governor fulfils all the functions of the mechanical governor (variable speed governing, torque limitations, LDA function) and makes further functions available.
3.2 System overview
Basically, the EMR 2 consists of the sensors, the control unit and the actuator.
Engine-side as well as vehicle-side or plant-side installation are connected by means of separate cable harnesses to the EMR control unit. The cabling on the plant side is carried out by the vehicle or plant manufacturer.
For arrangement on the engine and plant/vehicle side, see the following figure.
Engine-side equipment
Charge-air pressure
sensor (optional)
Control rod position sensor/
actuator
-Control unit
Set and vehicle-side equipment
Power supply
Multi function displays
1
2
3
4
5
6
Coolant temperature
sensor
2nd Speed sensor
(optional)
*with atmospheric pressure sensor (otional)
Lifting solenoid
(optional)
Camshaft speed
sensor
Oil pressure sensor
(optional)
Cold start aid
(optional)
Fuel temperature
(optional)
Charge air temperature
(optional)
Outputs (modifiable)
Inputs (modifiable)
(PWM/digital/analog)
Accelerator pedel
Hand operated throttle
(optional)
Functions changeover
switch
Start/Stop
Key-operated switch
Diagnostic button
Fault indicator
lamp
Diagnosis interface/
CAN-Bus
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EMR 2
System Description
3.3 Description of functions
The sensors attached to the engine provide the electronics in the control unit with all the relevant physical
parameters.
In accordance with the information of the current condition of the engine and the preconditions (accelerator
1
2
3
4
5
pedal etc.), the EMR 2 controls an actuator that operates the control rod of the injection pump and thus
doses the fuel quantity in accordance with the performance requirements.
The exact position of the regulating rod is reported back and, if necessary, is corrected, by means of the
control rod travel sensor, situated together with the rotation magnets in a housing of the “actuator”.
The EMR 2 is equipped with safety devices and measures in the hardware and software in order to ensure
emergency running (Limp home) functions (see Chapter 7.1).
In order to switch the engine off, the EMR 2 is switched in a de-energized fashion over the ignition switch. A
strong spring in the actuator presses the control rod in the de-energized condition into the zero position. As
a redundancy measure, an additional solenoid serves for switching off and this, independently of the actuator, also moves the control rod in the de-energized condition into the zero position.
After the programming, that is carried out over the ISO 9141 interface, the EMR 2 is possesses a motorspecific data set and this is then fixedly assigned to the engine. Included in this are the various application
cases as well as the customer’s wishes regarding a particular scope of function. The result of this is that any
later alteration must be reported back to the DEUTZ AG so that, in case of replacement anywhere in the
world, the new control unit can be programmed with the current data set.
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3.4 Basic equipment
Besides the control unit, the following components are required as minimum equipment for the operation
of the engine:
Vehicle side:
! Energy supply (battery)
! Diagnostic interface (ISO 9141)
! Fault lamp/diagnostic lamp
! Diagnostic button
! Set point selection
! Key operated switch
! Function change-over switch
! Cable harness
Engine side:
! Actuator (contains control rod travel sensor and positioning magnet)
! Speed sensor (camshaft)
! Coolant temperature sensor (NTC)
! Cable harness
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Further components and installation are possible depending on the application case or the desired
functions (see chapters 4 and 6). The combination can be selected from the DEUTZ pocket handbook.
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System Functions
4 System Functions
The EMR 2 makes a broad range of functions available and these can be activated by the applicationdependent configuration and the allocation of the inputs and outputs. It makes possible signal exchange
between the engine (via the engine plug) and the EMR 2, as well as between the vehicle (via the vehicle
plug) and the EMR 2. The signals can be transmitted as analog, digital, impulse modulated (PWM signals)
and as CAN-Bus messages.
Which functions are used, depends on the application conditions of the engine. Correspondingly, there are
different variations of the functions and the pin assignments of the plugs.
The functions of the EMR 2 refer to the speed control, quantity limitations (fuel injection), monitoring,
vehicle and apparatus functions and communication and diagnostic interfaces.
The EMR 2 offer a basic equipment on which all the optional variations can be structured.
1
2
3
Sensor inputs
Control rod travel
!
Speed
!
Coolant temperature
!
(Charge air pressure)
!
(Oil pressure)
!
(2nd speed)
!
(Coolant level)
!
(Charge air temperature)
!
(Fuel temperature)
!
(Tacho signal)
!
Actuator functions
Actuator
!
(Switch-off magnet)
!
:
EMR 2
(Atm pressure sensor)
Micro
processor
Memory for
operating
software
Set point input
Key-operated switch
!
(Pedal sensor)
!
(Throttle lever)
!
(Via CAN-Bus)
!
(Voltage 0 - 5 V)
!
(PWM signal)
!
Transfer switch for
functions
Interfaces
ISO 9141
!
CAN-Bus, SAE J1939
!
4
5
6
7
Energy supply
Memory for
Parameters
!
Char. curve
!
Char. diagram
!
Faults
!
Display functions /
outputs
Fault lamp
!
(Warning signals)
!
(Multi-function dis-
!
plays)
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The functions shown in brackets are optional.
© 06/02
Because of the numerous possibilities of combinations, DEUTZ has defined function ranges. These can be
crossed off in the DEUTZ pocket handbook. The switching diagram for each function range should also be
noted especially for the wiring required on the customers side.
© 06/02 Seite 71
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EMR 2
System Functions
4.1 Overview features
Feature Chapter Description
As variable speed, idling/end or fixed speed governor; choice
1
Speed control 4.3
of switchable governor features during operation, freezing
the current speed, fixed speed governor for network
synchronization or load distribution, overdrive speed
2
Set point input 4.4
3
4
Torque limitation 4.5
Governor behaviour (speed
droop)
4.6
By means of
! Pedal sensor and/or hand throttle
! External voltage signal (0 - 5 V)
! CAN Bus (remote electronics)
! Fixed speed signal (genset operation)
! Pulse width modulation (PWM)
! Touch control operation Up/Down (digital)
Optimal adaptation to different applications
Up to three performance curves can be set independently of
each other within the framework of the engine limits
Constant, variable or switchable speed droop from 0 - 80 %
for adaptation to the application
5
Engine Start/Stop 4.7
6
7
8
Monitoring and signal
output functions
LDA function 4.9
Temperature-dependent
start control
4.8
4.10
Engine switch-off by means of EMR actuator (additional
safety using switch-off solenoid possible)
Coolant temperature and level, oil pressure, charge air
temperature, fuel temperature → fault display and/or
performance reduction or engine switch-off for engine
protection
Smoke limitation through charge air pressure and/or
temperature-dependent limitation of the adjustment speed of
the injection
Improving the starting ability, gentle cold start without smoke
ejection
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Altitude correction 4.13 Engine protection because of reduced air pressure
Fuel volume correction 4.14 Compensation for loss of performance due to fuel heating
Emergency running after failure of set point signal (e.g. using
Emergency running 4.15
Selection of cold
start help installations
Data communication 5 Interfaces, diagnostics and programming
Output of fault
fault blink codes
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4.16
7.2 Simplified fault diagnosis
accelerator pedal), the charge air sensor or the vehicle speed
signal
Failure of auxiliary control units, EMR 2 controls a selection
of heating flange, glow plugs or flame starting apparatus
EMR 2
System Functions
4.2 Function extensions
The EMR 2 has the same functions as the EMR but possesses extended and new functions.
The new functions in detail are:
! Improved speed control
! Third performance curve
! Smoke limitation = function of the charge air temperature
! Monitoring the charge air temperature, coolant level
! Altitude-referenced fuel quantity
! Control of an engine brake
! Special set point parameter for genset applications
! Special vehicle speed evaluation to DIN 11786
! New functions via the diagnostic button:
- fault blink codes
- clearing the fault memory 1
! 2 Independent fault memories (mirroring the first fault memory)
! Acquisition of a load collective
! Baud rate alteration for ISO communication possible
! Possibility of a software update for the operating software via the
ISO interface
! Newly introduced or changed commands in ISO communication
! CAN Bus protocol to SAE J1939 has been greatly extended,
but is upwards compatible to the present EMR applications.
Caution!
EMR and EMR 2 are separate systems. An exchange of control units and actuators is not possible (see
Chapter 8).
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System Functions
4.3 Speed control
Provision is made for various variations of speed control that must be programmed in advance (at the end
of the programming) depending on the application case (power generation, building or agricultural machines) and usage conditions. The variations depend on the type of programmed and the selected functions.
1
The following types of speed regulation (switches) are optional and are programmed at the works depending on the variant (pin assignment see Chapter 6.1):
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Function Variant Description Remarks
Variable speed
control
Genset
applications
Variable speed-,
Min/Max-control
Min/Max-control
1) Types of speed control
Variable speed control
For this type of control the speed of the engine is governed or kept constant with reference to the desired speed of revolution.
For changes of load, the new required amount of fuel is set in accordance with a PID control. The desired value can be
determined through various variants.
Min/Max control
For this type of control, the fuel injection quantity is determined on the basis of the desired value. the result of this is that, for
this type of control, a speed of revolution depending on the load situation is set. The idling (= Minimum) and the end
revolutions (= Maximum) are controlled taking into account the control parameter speed droop 1 and speed droop 2. The
basis for this type of control is the drive characteristic field.
2) Change-over switching see point 4.3.1.
Variable speed
governor
Fixed speed governor Variable speed governor with fixed, pre-defi-
Change-over
switching speed 1 /
2)
2
Change-over switching speed fixed/
variable
Speed variable /
freeze
Speed memory
function
Power generation
governor with adjustable speed range
Power generation for
network synchronisation or Load distribution
Power generation
governor with adjustable speed and
switchable overdrive
speed
Variable speed,
Min/Max governor
Min/Max governor
1)
2)
2)
Pure variable speed governor without addition and switch-over functions
ned speed for gensets (1,500 or 1,800 rpm),
desired speed of rotation is defined in the
scope of customer supply (KLU).
Variable speed governor with change-over
switching possibility between two speeds.
Variable speed governor with change-over
switching possibility between a fixed programmed and a variable speed of revolution.
Variable speed governor with change-over
switching possibility between:
freezing a current desired speed as set point
independent of the pedal setting, and a variable revolution.
Customer-specific solution for storing and
calling up two speeds of revolution.
As for change-over switching fixed/variable
speed. Without Load the speed can be adju-
sted in the speed range.
As for change-over switching fixed/variable
speed. The variable revolutions can be adjusted in the revolution range for network synchronization or load distribution.
As for change-over switching fixed/variable
speed the power generator, in fixed speed
mode, can be used as the overdrive speed
without loading, in variable mode or for
parallel switching.
Switching over between variable speed and
2)
Min/Max control.
1)
Idling and end revolutions for vehicle
applications.
Only one variant can be
selected
See also
system description
EMR Genset,
TN 0297 9939
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EMR 2
System Functions
4.3.1 Switchable speed functions
The conditions for the switchable variants are selected by means of a switch (Input pin 18, GND pin 17
V plug). The switch closes a contact to -U
The following is applicable for the switchable speed functions:
Switchable speed functions
(for a selectable)
Batt
.
Switch open
(1/HIGH)
1)
Switch closed
(0/LOW)
1
Speed 1/ speed 2 Speed 1
Fixed / variable speed Variable Fixed
Speed variable / freeze Variable
Variable speed governor / Min/Max
governor
1) With an open switch, the underlined conditions above are activated as preset values (default values).
The switching condition can be displayed with the aid of the SERDIA diagnostic software (see Chapter 7.3)
4.3.2 Second speed input (optional)
This input can be used as a redundant speed input. If a second speed sensor has been installed, then the
engine will not be switched off on failure of the first speed sensor but will switch over to the second one.
The failure of a speed sensor is indicated by the continuous burning of the fault lamp. The operation of the
engine can be limited by defining a lower desired speed (see also Chapter 7.1).
4.3.3 Excess speed protection
when the speed limit is exceeded, the EMR 2 moves the control rod into the Stop position. The output,
engine switch off (Digital 3, M 2) is activated (if it is programmed) and a fault message is generated.
With applications in mobile machines the thrust mode is programmed as a safety measure.
Exceeding of the revolution limit can occur in thrust mode. In this case the control rod is moved to the zero
position and the fault lamp lights up. The engine is protected against excess revolutions also in this type of
operation.
After falling below the programmed recovery limit, the governing is again taken up and the fault lamp is
extinguished. The parameters “Above speed limit” and “Recovery limit” are adjustable.
Variable speed governor
Speed 2
Freeze
Min/Max regulator
2
3
4
5
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System Functions
4.4 Set point settings
The following variants for the set point settings of the governor can be configured:
1
Function Variant Description Remarks
Set point setting Accelerator
value sensor
(SWG 1)
Setting with potentiometer (5 V reference
voltage, max. 30 mA
input pin 24, GND pin 23, V-plug
1)
, typ. 1 kΩ linear, pin 25,
2)
)
2
Voltage Setting by means of external voltage (0.5 -
4.5 V, input pin 24, GND pin 23, V-plug)
3
Hand throttle
(SWG 2)
4
Memory
function
Setting with hand throttle. The set point in the
EMR 2 is determined by means of a maximum
function (5 V reference voltage, max. 30 mA
typ. 1 kΩ linear, pin 25, input pin 20,
GND pin 23 V-plug)
Freezing the current engine speed Only possible in con-
5
CAN Setting via the CAN interface
(see Chapter 6.1)
6
Internal (fixed
speed)
Setting via internal parameters.
The parameter is determined in the customer
scope of supply (KLU).
Replacement for
pedal value sensor
1)
,
nection with the
pedal value sensor
(SWG 1)
CAN = Controller
Area Network
For gensets
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PWM signal 1
PWM signal 2
1) PIN 25: I
2) V*plug = Vehicle plug / GND = Ground.
=30 mA (Pedal value sensor and hand throttle combined).
max
The desired value is set by means of an external PWM signal (frequecyz=100 Hz) with a
modulation of 5 % to 95 %
(see Chapter. 9.2) Input pin 18 or 20, GND pin
17 V-plug
Auxiliary for pedal
value sensor
12
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