ehb electronics MCflex Operating Instructions Manual

Engine controller

MCflex

Translation of the original operating instructions

Most recent revision: 08/05/2018

Version: 3.0

2

Device Engine controller MCflex

Serial number Enter the serial number of your device here:

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

ehb product
number

Publisher ehb electronics gmbh

ehb5200x

Hans-Böckler-Straße 20
30851 Langenhagen
GERMANY

Tel: [phone] - 0
Fax: [phone] - 77

E-mail: [e-mail]

www: www.ehb-electronics.de

www.ehbservice.de
www.ehbshop.de

The document is protected by copyright. All rights reserved. Copying, reproduc­tion, translation or conversion into an electronic medium or into a machine-read­able form, as a whole document or in partial sections, is not permitted without the
approval of ehb electronics gmbh.

Subject to change without notice.

Suggestions and
tips

... about this document or the device can be sent to the above address.

Last modification 08/05/2018

Version 3.0

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Table of Contents

1 DEVICE INFORMATION _________________________________________________________ 6

1.1 S

1.2 T

1.3 S

1.4 I

1.5 I

1.6 F

1.7 T

1.8 S

1.9 EU D

2 INFORMATION FOR THE READER _______________________________________________ 12

2.1 V

2.2 T

2.3 I

2.4 A

2.5 H

PECIFICATIONS ................................................................................................................... 6

YPE PLATE ......................................................................................................................... 6

COPE OF DELIVERY ............................................................................................................ 6

NTENDED USE...................................................................................................................... 7

MPROPER USE ..................................................................................................................... 7

UNCTIONAL DESCRIPTION.................................................................................................... 7

ECHNICAL DATA ................................................................................................................. 8

PARE PARTS ...................................................................................................................... 9

ECLARATION OF CONFORMITY .................................................................................... 10

ALIDITY ............................................................................................................................ 12

ARGET GROUP.................................................................................................................. 12

LLUSTRATIONS .................................................................................................................. 12

BBREVIATIONS USED ........................................................................................................ 13

IGHLIGHTING IN THE TEXT ................................................................................................. 14

2.5.1 P

2.5.2 N

2.5.3 S

2.5.4 W

2.5.5 H

ICTOGRAMS AND SYMBOLS ............................................................................. 14

AVIGATION PATH ............................................................................................ 15

AFETY INFORMATION ...................................................................................... 15

ARNINGS....................................................................................................... 15

ANDLING INSTRUCTION ................................................................................... 15

3

3 SAFETY _____________________________________________________________________ 16

3.1 S

3.2 D

3.3 L

3.4 Q

3.5 P

3.6 R

AFETY INFORMATION ........................................................................................................ 16

3.1.1 I

3.1.2 I

3.1.3 I

3.1.4 I

3.1.5 I

3.1.6 I

3.1.7 I

UTIES OF THE OPERATOR ................................................................................................. 18

OCAL REGULATIONS ......................................................................................................... 18

UALIFICATION OF PERSONNEL .......................................................................................... 19

ICTOGRAMS AND SYMBOLS ON THE DEVICE ....................................................................... 19

ESIDUAL RISK .................................................................................................................. 20

NFORMATION ABOUT OPERATIONAL SAFETY ...................................................... 16

NFORMATION ABOUT INITIAL COMMISSIONING .................................................... 16

NFORMATION ABOUT OPERATION...................................................................... 16

NFORMATION ABOUT DECOMMISSIONING AND STORAGE..................................... 16

NFORMATION ABOUT MAINTENANCE AND REPAIRS ............................................. 17

NFORMATION ABOUT ENVIRONMENTAL PROTECTION .......................................... 17

MPERMISSIBLE OPERATING CONDITIONS ........................................................... 17

4 PARTS OF THE DEVICE________________________________________________________ 22

4.1 F

4.2 D

4.3 R

4.4 B

RONT OF DEVICE .............................................................................................................. 22

ISPLAY VIEWS .................................................................................................................. 23

4.2.1 O

4.2.2 D

4.2.3 T

EAR OF DEVICE ................................................................................................................ 24

OTTOM OF DEVICE............................................................................................................ 25

PERATING PARAMETERS................................................................................. 23

AILY OPERATING DURATION ............................................................................ 24

OTAL OPERATING DURATION ........................................................................... 24

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

4

5 UNPACKING, CONNECTING AND INSTALLING_____________________________________ 26

5.1 U

5.2 C

5.3 M

6 PARAMETRIZATION ___________________________________________________________34

6.1 D

6.2 N

6.3 P

7 MENUS IN PARAMETRIZATION MODE____________________________________________35

7.1 O

7.2 M

7.3 S

7.4 S

7.5 S

7.6 S

7.7 S

NPACKING........................................................................................................................ 26

ONNECTING ...................................................................................................................... 27

5.2.1 C

5.2.2 C

5.2.3 C

OUNTING ......................................................................................................................... 30

5.3.1 T

5.3.2 M

ESIGN OF THE DISPLAY IN PARAMETRIZATION MODE........................................................... 34

AVIGATING IN PARAMETRIZATION MODE ............................................................................. 34

ARAMETRIZING THE DEVICE ............................................................................................... 34

VERVIEW.......................................................................................................................... 35

AIN MENU ........................................................................................................................ 36

UBMENU – SETTINGS........................................................................................................ 36

7.3.1 [1] S

7.3.2 S

7.3.3 S

7.3.4 H

7.3.5 G

7.3.6 G

7.3.7 A

7.3.8 F

7.3.9 F

7.3.10 L

7.3.11 I

UBMENU – SERVICE.......................................................................................................... 61

7.4.1 [2] S

7.4.2 [1] S

7.4.3 [2] F

7.4.4 [3] F.L.

UBMENU – SAFETY........................................................................................................... 63

7.5.1 [3] S

7.5.2 S

7.5.3 S

UBMENU – DAILY OPERATING HOURS COUNTER ................................................................ 65

7.6.1 [4] D

7.6.2 S

UBMENU – OPERATING HOURS COUNTER .......................................................................... 65

7.7.1 [5] OHC

7.7.2 S

ONNECTION DIAGRAM AND PIN ASSIGNMENT .................................................... 27

IRCUIT DIAGRAM............................................................................................. 28

ONNECTING THE DEVICE ................................................................................. 29

ECHNICAL DRAWING........................................................................................ 30

OUNTING THE DEVICE..................................................................................... 30

ETTINGS.................................................................................................... 36

UBMENU LANGUAGE........................................................................................ 37

ENSOR SUBMENU ........................................................................................... 38

IGH-POWER OUTPUT SUBMENU ....................................................................... 40

LOW TIMES SUBMENU..................................................................................... 46

ENERATOR.ER SUBMENU................................................................................ 49

UTOSTART SUBMENU ...................................................................................... 49

AULT EVENT SUBMENU .................................................................................... 51

AULT TIMES MENU........................................................................................... 54

IMIT VALUES SUBMENU .................................................................................... 57

NPUTS/OUTPUTS SUBMENU .............................................................................. 59

ERVICE ..................................................................................................... 61

ERVICE SETTINGS ...................................................................................... 62

AULT LIST.................................................................................................. 62

DELETE ................................................................................................ 63

AFETY....................................................................................................... 63

UBMENU – PIN NUMBERS ............................................................................... 63

UBMENU – SELF-TEST .................................................................................... 64

AY COUNTER............................................................................................. 65

UBMENU – DAY COUNTER ............................................................................... 65

COUNTER ........................................................................................... 65

UBMENU – OHC – MENU ............................................................................... 66

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

8 CANBUS FUNCTIONS _________________________________________________________ 67

8.1 F

8.2 M

8.3 M

UNCTIONS AND DISPLAY DEVICES ...................................................................................... 67

ESSAGE ON DEN CANBUS ............................................................................................... 67

8.2.1 PGN 61444 E

8.2.2 PGN 65253 E

8.2.3 PGN 65262 E

8.2.4 PGN 65263 E

8.2.5 PGN 65271 (R) V

8.2.6 PGN 65269 A

8.2.7 PGN 65276 D

8.2.8 PGN 65278 A

8.2.9 A

CTIVE DIAGNOSTIC TROUBLE CODES (DM1) ................................................... 69

8.2.10 PGN 42496 (R) A

ESSAGE FROM CANBUS .................................................................................................. 71

8.3.1 PGN 57344 C

LECTRONIC ENGINE CONTROLLER 1 - EEC1 ............................... 67

NGINE HOURS, REVOLUTIONS - HOURS..................................... 67

NGINE TEMPERATURE 1 - ET1.................................................... 68

NGINE FLUID LEVEL/PRESSURE 1 - EFL/P1 ................................ 68

EHICLE ELECTRICAL POWER 1 - VEP1.................................. 68

MBIENT CONDITIONS – AMB....................................................... 68

ASH DISPLAY - DD..................................................................... 68

UX WATER PUMP PRESSURE- AWP ........................................... 69

UXILIARY INPUT/OUTPUT STATUS 3 - AUXIO3 ...................... 69

AB MESSAGE 1 - CM1 ............................................................... 71

9 OPERATION _________________________________________________________________ 72

9.1 S

9.2 I

9.3 O

9.4 S

9.5 C

9.6 S

9.7 O

ETTING PULSES PER ROTATION ......................................................................................... 72

9.1.1 S

9.1.2 S

NITIAL COMMISSIONING ...................................................................................................... 73

9.2.1 I

9.2.2 C

PERATING THE DEVICE ..................................................................................................... 74

ETTING THE DEVICE MODE ................................................................................................ 74

OMMISSIONING ................................................................................................................. 75

9.5.1 R

9.5.2 S

WITCHING OFF THE DEVICE ............................................................................................... 75

PERATIONAL FAULTS........................................................................................................ 76

PEED MEASUREMENT USING AN INITIATOR (PICK UP) ........................................ 72

PEED MEASUREMENT BASED ON THE PULSES OF THE "W” TERMINAL AT PIN 13. 73

NFORMATION ABOUT INITIAL COMMISSIONING .................................................... 73

ARRYING OUT INITIAL COMMISSIONING............................................................. 74

EQUIREMENTS FOR COMMISSIONING ............................................................... 75

WITCHING ON THE DEVICE .............................................................................. 75

5

10 MAINTENANCE, REPAIR AND DISPOSAL _________________________________________ 77

10.1 I

NFORMATION ABOUT MAINTENANCE AND REPAIRS .............................................................. 77

10.2 FAQ.................................................................................................................................. 77

10.3 R

10.4 C

10.5 C

10.6 D

EPAIR .............................................................................................................................. 77

LEANING .......................................................................................................................... 78

OMMUNICATION WITH PC (OPTIONAL) ............................................................................... 78

ISPOSAL .......................................................................................................................... 78

10.6.1 D

10.6.2 D

ISPOSAL OF DEVICES...................................................................................... 78

ISPOSAL OF BATTERIES AND RECHARGEABLE BATTERIES ................................. 79

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Specifications

6

Device information

1 Device information

1.1 Specifications

Enter the serial number of your device in the field with the dashed line.

Specifications of the device

Device name Engine controller

Device type MCflex

Serial number _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

ehb product number ehb5200x

1.2 Type plate

The type plate is located on top of the housing of the device.

Representation of the type plate

Legend

No. Designation Function

1 Serial number Represents a unique and unambiguous number for

identification of the device.

2 Date of manufacturer Represents the date of manufacturer in the "month -

year” format.

3 ehb product number Represents the ehb product number of the device

series.

4 Operating voltage Represents the operating voltage with which the device

may be operated.

1.3 Scope of delivery

The following parts are included in the scope of delivery of the device:

• one device "MCflex”

• two ignition keys

• one label "Do not clean with high-pressure cleaner”

• two mounting brackets

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Intended use

Device information

1.4 Intended use

This device is exclusively used to start and monitor mechanically controlled combustion
engines in machines.

The device is for the following use only:

• starting and monitoring the mechanically controlled combustion engines of mobile and

stationary construction machines

• starting and monitoring the mechanically controlled combustion engines of inland ships

Intended use also includes compliance with all specifications in these Translation of the orig­inal operating instructions.

1.5 Improper use

Any use not mentioned in section "Intended use" (Page 7) is considered improper and may
result in personal injury and property damage.

The device is expressly not intended for the following:

• starting and monitoring the mechanically controlled combustion engines of road vehicles

• starting and monitoring the mechanically controlled combustion engines of aircraft

• starting and monitoring the mechanically controlled combustion engines of helicopters

• starting and monitoring the mechanically controlled combustion engines of deep-sea

vessels

• Unauthorised structural changes

• Unauthorised repairs

7

Info

The manufacturer is not liable for damage caused by improper use of the device. The risk for
this is borne solely by the user or operator.
The guarantee expires in the event of improper use.

1.6 Functional description

The device offers a multitude of functions for the control and monitoring of conventionally
controlled combustion engines. You can individually configure the settings for very diverse
applications and different engine variants. The device is capable of pre-glowing, by-glowing
and after-glowing the engine to up to 70 A, using time or temperature variables. Oil pressure
and engine temperature can be monitored with switches or sensors. One additional input is
provided for monitoring the generator. The operating magnet is actuated by the outputs for
excitation and pick-up winding. There is also an alarm output available. The engine can be
switched off via an "external stop” input (hood switch , cover switch / housing switch, for
example).

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Technical data

8

Device information

In the event of a fault, the display returns a corresponding message after an adjustable delay
time and an LED illuminates. If a corresponding function is programmed, the engine is
switched off. The input lock allows the clear identification of the cause of error and requires an
active acknowledgement of the fault message.

By pressing the arrow keys of the device, the operating hours, oil pressure, temperature and
number of revolutions of the engine are displayed in sequence on the two-line display. Other
parameters can be displayed using customised software.

1.7 Technical data

Electrical data

Voltage range 6 V to 32 V (typically 12 V to 24 V)

Current consumption typically 50 mA (for UB 8 V to 24 V)

Operating temperature -20°C to+70°C

Storage temperature -30°C to+80°C

Inputs Inputs:

• PIN 01 | Oil pressure as NO/NC, programmable,

switching or analogue sensor

• PIN 02 | Generator monitoring, terminal D+

• PIN 03 | Temperature as NO/NC, programmable,

switching or analogue sensor

• PIN 04 | Diverse, NO/NC

• PIN 07 | Autostart, NO/NC

• PIN 09External stop, NO/NC

• PIN 13 | Speed monitoring, terminal W, sensor or

magnetic pick-up

Outputs Outputs:

• all outputs are short circuit-proof

• PIN 02 | Generator excitation, terminal D+, 0.5 A

• PIN 06 | Freely parametrisable, 7.5 A (maximum 1s)

/ 6.0 A

• PIN 08 | Freely parametrisable, 40 A (maximum 1s)

/ 20 A

• PIN 10 | Freely parametrisable, 70 A (maximum 1s)

/ 35 A

• PIN 11 | Freely parametrisable, 40 A (maximum 1s)

/ 20 A

• PIN 12 | Freely parametrisable, 70 A (maximum 1s)

/ 35 A

• PIN 15 | Freely parametrisable, 3.5 A (maximum 1s)

/ 3.0 A

• PIN 18 | Freely parametrisable, 40 A (maximum 1s)

/ 20 A

CAN bus interface PIN 17 / 19, CAN2.0B, 250kBit, SAE J1939, EEC1, ET1,

EFL/P1, VEP1, AMB, DM1 fault alarms/auto start, speed
adjustment, optionally adaptable

Operating hours counter Integrated

Daily operating hours counter Integrated

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Spare parts

Device information

Visualisation

Display type Dot matrix LCD, transflective, dark-blue representation,

grey background

Resolution 16 x 2 characters, 5 x 8 dots per character

Brightness >1,000 cd/m²

Contrast ratio (CR) 8.24

Background lighting LED, white

Mechanical data

Housing dimensions (L x W) 72 mm x 72 mm

Installation dimensions (W x H x D)66 mm x 66 mm x 130 mm

Installation cut-out (W x H) 66 mm x 66 mm

Housing material PA 6 30 GB, black, UV-stabilised

Weight 340 g

9

Installation Mounting bracket or screw-fastening, 3 x M6

Protection class IP67

Connection Deutsch connector type HDP24-24-19PE

Test standards

Humidity DIN EN 60068-2-3

Vibration DIN EN 60068-2-6

Shock DIN EN 60068-2-27

CE marking According to Directive 2014/30/EU

Accessories

Connection cable, 19-pole, 3 m ehb2268

Deutsch plug set ehb1469

CANdongle with PC software
ehbTools

MCflex starter kit
CAN dongle, ehbTools,
connecting cable, power supply
unit

ehb5365

ehb5378

1.8 Spare parts

No spare parts are available for this device. If the device is faulty, contact the manufacturer.

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

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Device information

1.9 EU Declaration of Conformity

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Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

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Device information

11

EU Declaration of Conformity according to EMC Directive (2/2)

As soon as the device is improperly used, this declaration and the guarantee claim will expire.

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Validity

12

Information for the reader

2 Information for the reader

2.1 Validity

Safety information: Carefully read the Translation of the original operating instructions

Carefully read through these Translation of the original operating instructions before use.
Keep these Translation of the original operating instructions for future consultation.

These Translation of the original operating instructions contain information and rules of
conduct for the safe use of the device.

Please hand over the Translation of the original operating instructions when passing on the
device.

To operate the device effectively, the Translation of the original operating instructions provide
you with information on the following topics, among others:

• Connecting and mounting the device

• Putting the device into operation

• Making settings on the device

• Maintaining the device

• Disposing of the device

2.2 Target group

These Translation of the original operating instructions are intended for the operator, user and
service personnel of the machine with integrated device "MCflex”.

Info

The service personnel must have certain qualifications in order to work on or with the device.
You can find the qualification of personnel in chapter "Safety" > "Qualification of personnel"
(Page 19).

2.3 Illustrations

The illustrations in these operating instructions show the device in simplified form in some
cases.

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

2.4 Abbreviations used

The following abbreviations are used in these operating instructions:

Abbreviations used

°C Degrees Celsius

A Ampere

AW Pick-up winding

bar Unit of pressure [force/area]

OHC Operating hours counter

Cd Cadmium

ECU Electronic Control Unit

FMI Failure Mode Identifier

GND Ground

h hours

Hg Mercury

Abbreviations used

Information for the reader

13

HW Excitation winding

ID Identification

PPR Pulses per rotation

kg kilogram

LCD Liquid Crystal Display

LED Light Emitting Diode

mA Milliampere

NC Normally Closed

NO Normally Opened

NTC Negative Temperature Coefficient

Pb Lead

PC Personal Computer

PTC Positive Temperature Coefficient

s second

SPN Suspect Parameter Number

rpm revolutions per minute

V Volt

ZSS Ignition starter switch

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Highlighting in the text

14

Information for the reader

2.5 Highlighting in the text

In these Translation of the original operating instructions, important information is highlighted
with pictograms, symbols or special notations. The following examples show the most impor­tant highlights.

2.5.1 Pictograms and symbols

Pictograms and symbols

Pictogram /
symbol

Meaning

Further useful information.

Conditions that must be met to perform an action.

Tool or material required to perform an action.

The disposal of electrical and electronic equipment with household waste is
not permitted.

The disposal of rechargeable batteries and other batteries with household
waste is not

permitted.

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Highlighting in the text

WARNING

NOTICE

Information for the reader

2.5.2 Navigation path

The following representation helps you to navigate through the menus. Here you can see the
path of the menus that must be selected one after the other in order to reach the desired
submenu. In the digital version of the operating instructions, you can jump to the menu item
by clicking on the relevant path.

15

Main menu (page 0)

> Submenu (page 0) > Current submenu (page 0)

2.5.3 Safety information

Safety information: Special note for an informative section.

Explanation of the note.

• This item indicates measures to take the note into account.

2.5.4 Warnings

Warning of serious injuries.

Failure to follow the warning may result in serious damage to health or even death.

► The arrow indicates a precautionary measure that you must take to avert the hazard.

Warning of material damage.

Failure to observe the warning notice can result in considerable damage to the device or its
surroundings.

► The arrow indicates a precautionary measure that you must take to avert the hazard.

2.5.5 Handling instruction

Complete the following work steps: = Start of a handling instruction.

1. First step in a sequence of actions.

Required settings . . . . . . . . . . . . . .

Setting values

2. Second step in a sequence of actions.

▼ Result of this step.

» Done Handling is completed, the goal is achieved.

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Safety information

16

Safety

3 Safety

3.1 Safety information

This safety information is addressed to the operator, user and service personnel of the
device.

3.1.1 Information about operational safety

The device is safe to operate. It was built according to the current state of science and tech­nology.

However, the device may constitute a hazard:

• if the device is used not as intended.

• if the device is improperly used.

• If the device is operated under impermissible conditions.

Safety information: Protect against unauthorised opening!

The device has a protective seal to prevent it being opened without authorisation. Note that
any unauthorised opening of the device will lead to it being irreparably damaged.

The following information applies to everyone who works on or with the device:

• Never insert any objects into the device openings not intended for this purpose. There is

a risk of interfering with the electronics.

• Protect the locking cylinder of the ignition starter switch from penetrating dirt and water.

• Only open a battery master switch in an emergency or when the engine is at standstill

and the device is switched off.

• When operating the device, comply with the general accident prevention regulations.

• Operate the device under the conditions specified by the manufacturer (see page 8:

Device information > Technical data).

• Never open the housing of the device. The device does not contain components that can

be serviced, replaced or repaired by the customer or third-party service personnel.

3.1.2 Information about initial commissioning

The following principles apply for initial commissioning:

• Make sure that the device is only connected and installed by personnel qualified for this.

• Make sure that no one can be injured when switching on the device.

3.1.3 Information about operation

Safety-conscious and precautionary behaviour of personnel avoids dangerous situations
during operation.

Observe the following points when handling the device:

• The device may only be connected and installed by personnel qualified for this. Observe

the information from the manufacturer of the plugs and cable harnesses.

• The environment must be free of interfering electrical installations (high frequency) and

electromagnetic compatibility (EMC Directive) must be observed.

• Never make any structural changes to the device.

• Only operate the device with accessories approved by the manufacturer.

3.1.4 Information about decommissioning and storage

The following principles apply for decommissioning and storage:

• Clean all dirt from the device.

• Store the device according to the specifications of the manufacturer (see page 8: Device

information > Technical data).

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Safety information

Safety

3.1.5 Information about maintenance and repairs

The following principles apply for maintenance and repairs:

• The device requires no maintenance and no special actions.

• Only clean the device with a mild cleaning agent.

• Never clean the device with a high-pressure cleaner.

• The device is to be shipped either in its original packaging or in suitable sturdy alternative

packaging. Improper packaging is regarded as negligence and results in any claims for
repair under guarantee being forfeited.

3.1.6 Information about environmental protection

Safety-conscious and precautionary behaviour of personnel avoids adverse effects on the
environment.

All packaging materials and devices are equipped with markings and test seals for proper and
professional disposal.

The following principles apply for environmentally-friendly actions:

• Always comply with the regulations for the prevention, disposal and recycling of waste.

• Always dispose of packaging materials and electrical devices and their components

through collection points or disposal companies authorised for this.

• Used electrical devices and electronic devices must not be disposed of with household

waste.

17

The devices comply with legal requirements, in particular the Electrical and Electronic Equip­ment Act and the REACH Regulation.

3.1.7 Impermissible operating conditions

Operational safety cannot be guaranteed under impermissible operating conditions. Always
avoid impermissible operating conditions.

Do not operate the device under the following conditions:

• Operation could injure persons.

• Objects could be damaged or destroyed unintentionally during operation.

• Malfunctions have been detected.

• Damage has been detected.

• Impermissible changes to operating parameters have been made.

• For example, the device has been modified.

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Duties of the operator

18

Safety

3.2 Duties of the operator

This chapter contains information on the duties of the operator of the machine in which the
device is installed.

It is the operator’s duty of care to plan safety measures and to check their implementation.
The following principles apply to minimise the risk of injury:

• Make sure that damaged devices are no longer used.

• Make sure that the device is installed and connected by authorised specialist personnel.

The following principles apply for faultless operation:

• Only use the device for its intended purpose.

• Only operate the device when it is in a perfect and functional condition.

• Make sure that the device is never opened by personnel. Damage caused by opening the

• Make sure that the device is properly transported and stored by personnel.

• Make sure that the device is never cleaned with a high-pressure cleaner. Give the service

Info

device will void the warranty.

personnel comprehensive instructions that cleaning with a high-pressure cleaner will
cause damage and that the warranty will be excluded.

Carry out regular checks. This allows you to ensure that these measures are actually
followed.

3.3 Local regulations

In addition to these instructions, correct operation of the device is regulated by laws and regu­lations.

The following regulations also apply for the operation of the device:

• Regulations for operating machines in which the device is installed (laws and regulations

not expressly mentioned here as well).

• Accident prevention regulations.

• Internal company regulations.

• Information on the device.

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Qualification of personnel

Safety

3.4 Qualification of personnel

All work on the device requires special training of the personnel.
Everyone working on the device must meet the following requirements:

• Persons between the ages of 14 and 18 may only work on and with the device under the

supervision of a person trained to use the device.

• Personally suitable for the respective activity.

• Sufficiently qualified for the respective activity.

• Trained to handle the device.

• Familiar with these operating instructions, especially with safety information and with the

sections that are relevant for the activity.

• Familiar with basic occupational safety and accident prevention regulations.

These operating instructions distinguish between the following user groups:

User groups

Personnel Qualification

19

Operating
personnel

Service
personnel

Training by the operator of the machine in which the device is installed.
The following topics must be covered in this training:

• Intended operation of the device

• Correct behaviour in the event of malfunctions, errors, damage

• Cleaning the device

• Competences and responsibilities for the activity

The required knowledge for the operating personnel is given in these
operating instructions. The operator must train the user to use the
machine in which the device is installed. Operating personnel must have
read and understood the operating instructions.

Training as a mechatronics engineer or at least equivalent training.
The tasks of the service personnel include the following activities:

• Connecting the device

• Mounting the device

• Parametrizing the device

Service personnel must have sound knowledge of the design and func­tion of the device and must have read and understood the operating
instructions.

3.5 Pictograms and symbols on the device

Pictograms and symbols are attached to the device. The following table explains the mean­ings of the pictograms and symbols.

Pictograms and symbols on the device

Pictogram /
symbol

Meaning

Prohibited: Cleaning with a high-pressure cleaner is prohibited.

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Residual risk

20

Safety

3.6 Residual risk

The device is built according to the currently valid rules of technology and is safe to operate.
The device has been tested and has left the factory in a perfectly safe condition.

Residual hazards cannot be completely ruled out. Safety-conscious and precautionary behav­iour of personnel avoids dangerous situations. Read and observe the safety information and
warnings to prevent risks.

Residual risks at the device and measures

Danger Cause Measure

Material damage due to
missing protective func­tion of the starter!

Material damage due to
incorrect wiring of the
outputs!

Risk of injury due to
misuse of pin 9
(external stop) for the
emergency stop func­tion of the engine!

Material damage due to
incorrect type of instal­lation!

The starter of the
engine can be damaged
due to the missing
signal. The signal is
required for the inte­grated protective func­tion of the starter.

If the outputs are
connected in parallel,
there is a risk that tran­sistors may blow.

Misuse of pin 9
(external stop) for the
engine emergency stop
function may cause
serious injury at parts of
the engine. The input is
not designed for this
purpose. This can result
in delays of up to one
second.

Installation with
mounting brackets is
intended exclusively for
locations without the
influence of vibrations. If
the device with
mounting brackets is
mounted at locations
subject to vibration,
there is a risk of serious
damage to the device!

Make sure that a speed signal is
connected to pin 13 (terminal "W”).

Make sure that the transmission ratio
(PPR) and the maximum start speed are
set correctly.

Never connect the outputs in parallel.

Never use pin 9 (external stop) for the
emergency stop function of the engine!

Mount the device at locations subject to
vibration with rubber-bonded metals
(accessories).

Only carry out installation with mounting
brackets if you can ensure that no vibra­tions can have an effect! (For example,
in a switch cabinet)

Material damage due to
load on ignition starting
switch!

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

If weight is attached to
the ignition key (e.g.
heavy keychain,...),
there is a risk of
damaging the ignition
lock.

Do not hang any other weight or other
objects on the ignition key.

Residual risks at the device and measures (cont.)

Danger Cause Measure

Residual risk

Safety

21

Material damage due to
the ingress of water!

If the device is cleaned
with a high-pressure
cleaner, there is a risk
that water ingresses in
the housing and
damages the device.

Never clean the device with a high-pres­sure cleaner.

Information for the operator: Instruct your
service personnel about the conse­quences of using high-pressure
cleaners.

Apply the supplied label "Do not clean
with high-pressure cleaner” visibly in the
immediate vicinity of the device at the
installation site.

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Front of device

22

Parts of the device

4 Parts of the device

4.1 Front of device

Front of device

Legend

No. Designation Type Setting Function

1 Operation LED LED off shows that the device is switched off.

Green shows that the device is switched on.

Red shows that an error message is present on

the device.

2 Display LCD - The two-line display shows messages and

parameters during operation. Each line has
16 characters.

The following display views can be viewed
during operation:

• Operating parameters

• Daily operating hours counter

• Total operating hours counter

You can find the functions in the para­metrizing mode in chapter "Parametriza­tion" > "Design of the display in
parametrization mode" (Page 34).

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Legend (cont.)

set

ì

ì

No. Designation Type Setting Function

Display views

Parts of the device

23

3 Ignition lock Ignition

starter
switch

4 Pushbutton press Used to confirm messages.

5 Pushbutton press Used to navigate through the

6 Pushbutton press Used to navigate through the

0 The device is switched off.

1 The device is supplied with power.

The "ignition” is switched on.
A connected diesel engine pre-glows.

2 The connected engine starts.

You can find the functions in the para­metrizing mode in chapter "Parametriza­tion" > "Navigating in parametrization
mode" (Page 34).

menus/display views.
The next menu item is displayed.
You can find the functions in the para-

metrizing mode in chapter "Parametriza­tion" > "Navigating in parametrization
mode" (Page 34).

menus/display views.
The previous menu item is displayed.
You can find the functions in the para-

metrizing mode in chapter "Parametriza­tion" > "Navigating in parametrization
mode" (Page 34).

4.2 Display views

4.2.1 Operating parameters

Operating parameters

Legend

No. Function

1 Displays the current state of the engine temperature.

2 Displays the current state of the oil pressure.

3 Displays the current engine speed. (only when engine is running)

4 Displays the current daily operating duration.

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Rear of device

24

Parts of the device

4.2.2 Daily operating duration

Daily operating duration

Legend

No. Function

1 Displays the current set operating mode of the device.

2 Displays the current daily operating duration.

4.2.3 Total operating duration

Total operating duration

Legend

No. Function

1 Displays the total operating duration.

2 Displays the current engine speed. (only when engine is running)

4.3 Rear of device

Rear of device

Legend

No. Designation Function

1 Device connection –

Deutsch connector

Translation of the original operating instructions • Engine controller MCflex • 08/05/2018 • 3.0 • GB

Used as a connection point for a Deutsch connector
socket housing.

You can find an example or the pin assignment in
chapter "Unpacking, connecting and installing" >
"Connection diagram and pin assignment" (Page 27).