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030303 DEC2 Tuning and calibration.pdf

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 ©  Scania CV AB, Sweden, 2001-06:2 Issue 2 en Part No. 1 588 739 Scania DEC2 control system V7.0 and V8.1 Tuning and calibration Dealer version 03:03-03
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 ©  Scania CV AB, Sweden, 2001-06:2

Issue 2 en

Part No.1 588 739

Scania DEC2 control systemV7.0 and V8.1

Tuning and calibration

Dealer version 

03:03-03

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2  ©  Scania CV AB, Sweden, 2001-06:2 03:03-03

Changes must not be made to the DEC2 control unit or sensors and wiring. Doing somay affect the control unit safety system and cause injuries to the operator anddamage to the engine or driven equipment.

• Never splice a damaged cable. Renew the entire cable, otherwise the safety andoperation of the system could be impaired.

• Sensors for the DEC2 control system are intended only for use in the DEC2.

The following points must be observed to ensure that the DEC2 controlunit is not damaged:

• Check that cables to the battery and generator are properly connected before the

engine is started.• Before disconnecting the cable to the control unit, switch off all power supply to the

unit.

• Disconnect the DEC2 control unit when rapid charging the battery.

• Disconnect the battery during electric welding and remove the control unit.

Important information

Contents

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Tuning: single speed or all speed engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Explanation of the other parameters shown on the Tuning screen . . . . . . . . . 6

Explanation of the function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Governor Configuration: All speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Explanation of the other parameters shown on the Configuration screen: . . . 8

Governor Configuration: Single speed engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Governor Calibration: All speed and single speed engines . . . . . . . . . . . . . . . . 10

Calibration procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Saving the calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Calibration has failed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Final check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Possible error messages that can occur during calibration . . . . . . . . . . . . . . 18

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03:03-03  ©  Scania CV AB, Sweden, 2001-06:2 3

Start-up procedure

Note: The PC should only be connected to the control unit using a special cable markedDEC at one end and PC at the other, after the cover over the COMM/DIAG PORT hasbeen removed. The cable part no. is 1434119 for length=4 m and 1413708 for

length=10 m. The program can only be started if the PC is connected to a poweredcontrol unit. However, the program menu below can be reached without poweringthe control unit.All Dealer  program versions with instructions are collected on a CD with part No.1589210 with subscription  and part No. 1588695 without subscription .

- Log in and open the file manager.

- Open the program for control unit with V7.0:

- 1002d701)  A. EXE  for all speed engines

- 1002d70S.EXE  for single speed engines

- or for control unit with V8.1:

- 1002d81 A. EXE  for all speed engines

- 1002d81S.EXE  for single speed engines

- When the program starts, it first states theapplication version and type: all speed or singlespeed.

- Press any key to continue.

1)  70 is the version number for the V7.0 program.All illustrations in this booklet show that programversion in the heading, but the illustrations are alsovalid for version V8.1.

V7.0:

V8.1:

GOVERNOR DIAGNOSTIC SYSTEM V4.0DEALER Version

ALL SPEED Application

or

GOVERNOR DIAGNOSTIC SYSTEM V4.0DEALER Version

SINGLE SPEED Application

GOVERNOR DIAGNOSTIC SYSTEM V4.1DEALER Version

ALL SPEED Application

or

GOVERNOR DIAGNOSTIC SYSTEM V4.1DEALER Version

SINGLE SPEED Application

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- In the Main Menu there are three alternativesfor adjusting the governor function: Tuning,Configuration and Calibration.

- Press the T , K  or C  key according to whichalternative is required.

- Alternative I (Maintenance Information)

contains the accumulated operating time andinformation from the factory, engine numberand date of test run.

- Under the heading PC Software, informationcan be stored about the specific OEM.

General

Once the required menu appears, the followingapplies when changing values:

- The Tab key is used to move the cursorforwards between the modifiable parameterfields. See illustration on next page.

- When the cursor hits a new field, this field ishighlighted.

- With Shift+Tab the cursor is moved backwardsbetween the modifiable parameter fields.

- When the space bar is pressed, the user isprompted to enter a new value.

- Enter the new chosen value.

- Confirm by pressing Enter .

- Save by pressing F2. See page 7 for adescription of the use of the function keys.

Governor<T> Tuning

<K> Configuration<C> Calibration<I> Maintenance Information

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Tuning: single speed or all speed engine

Changing parameters

In the Tuning menu the following parameters canbe changed.

For the governor there are three parameters whichregulates the engine control:

• Cntl Gain controls how much the fuel supplyis changed when there is a variation in speed.

• Cntl Stability adjusts the fuel flow to theengine until the speed error is eliminated.

• Cntl Deadtime which makes a rapid changeto the fuel supply when there is a rapidchange of speed.

•  Act Gain and Act Stability show the settingsof the actuator solenoid on the injectionpump and affect its sensitivity to the outputsignal from the control unit.

Approximate values for these five parameters are:

Single speed All speed Cntl Gain 15 6  

Cntl Stability 15 3  

Cntl Deadtime 1 1

Act Gain 7 4  

Act Stability 15 10  *) 

*) Minimum value 

- A higher value gives faster control.

- A lower value gives slower control.

Note: Make changes in small steps(normally 1 or 2), if a value has tobe changed.

Cntl Gain 15 CNTCntl Stability 15 CNTCntl Deadtime 1 CNT

Act Gain 7 CNTAct Stability 15 CNT

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Explanation of the other parameters shown on the Tuning  screen

Speed Droop = Calculated speed reductiondepending on current speed droop.

Velocity = Actual speed 

Starting Fuel = Maximum control rack travelduring startup (starting cycle).

Actual Fuel = Current control rack travel 

Operating Mode = Shows current operatingmode 

Air Temp = Air temperature in inlet manifold Engine Temp = Coolant temperature inengine 

Load = Shows actual load at current speed.

Speed Request = Requested speed signalfrom throttle position sensor.

Torque Limit = Shows maximum control racktravel in the torque limiter map at currentspeed.

Boost fuel = Shows maximum control racktravel in the smoke limiter map at currentspeed and boost pressure.

Oil Pressure = Oil pressure in engine.Displays the same value as long as theengine is running.

Atmospheric P = Shows the atmosphericpressure before the starting cycle. This valueis updated before each startup.

Boost Press = Absolute charge air pressureafter the turbocharger 

Atemp LOP  = Shows the limit value (warninglevel) for charge air temperature when operationcan be set to switch over to limited power level(POWER).

Etemp LOP  = Shows the limit value (warninglevel) for coolant air temperature when operationcan be set to switch over to limited power level(POWER).

Eng. Shutdn = Shows limit value (shutdownlevel) for coolant temperature when control unitshuts down the engine (if DIPswitch 4 on thecontrol unit is set in the OFF position).

OS Limit = Shows the overspeed value atwhich the engine will be shut down.

OS Time Limit = Shows the time delaybetween the overspeed and engineshutdown.

Speed Accel = Shows the acceleration timerequired for the control rack to reach itsprogrammed maximum travel.

Speed Decel = Same as Speed Accel butfrom maximum to minimum control racktravel.

The actual ramp time will be somewhatshorter than the value entered for SpeedAccel and Speed Decel.

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Explanation of the function keys 

F1 - Update = All recorded parameter valuesin the control unit are updated and displayed

on the screen F2 - Save = All the modifiable values shownon the screen are saved and stored in thepermanent control unit memory.

Each value is now retrieved at every reset(restart) until it is changed again. If aparameter value is not saved in this way aftera change, the last value saved will be shownat reset.

F3 - File = When this key is pressed, the useris prompted for a file name in order to store in

a separate file the parameters which can bemodified. This file can be printed and savedfor reference or troubleshooting.

F5 - Continuous updating = The screen isupdated approximately once every secondwhen this key is pressed. The function iscancelled if F5 is pressed again.

F6 - Log = Shows the error log menu 

ESC = This key will return the user to theprevious screen 

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Governor Configuration: All speed

Changing parameters

In the Governor Configuration menu thefollowing parameters can be changed.

- Low idle ( Min Spd Req). Actual low idle isgoverned by the speed droop.

- Speed droop ( Droop 1 and Droop 2)Values between 0-20 % are accepted for thespeed droop. Normally only map 2 is used togovern the speed droop.

- The limited operating power ( LOP power ) inpercent can be changed. It is normally 100% ondelivery.

In order to switch between Droop 1 and Droop 2,the position of DIPswitch 8 underneath the roundblack rubber cap on the control panel must bechanged.

Position OFF  means Droop 1.

Explanation of the other parametersshown on the Configuration screen:

Teeth = number of teeth on the flywheel gear

ring 

Max spd Req = In the unloaded mode thevalue displayed is high idle speed (DIPswitch7 in ON position, normal position) 

In the loaded position the value displayed isfull load speed (DIPswitch 7 in OFF position).

Surge time = shows the period over which theengine can be run at a higher power levelthan is programmed for this function(power/torque map 2) (OEM only) 

Recovery time = shows the period for whichthe engine must be run according topower/torque map 1 before the higher powerlevel (map 2) can be used again. (OEM only) 

Note: It is not normal to have two torquemaps. Normally Map 1= Map 2 

LOP power 79.69 % Min Spd Req 700 RPMDroop Map 1 4.0 %Droop Map 2 8.0 %

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Governor Configuration: Single speed engine

Changing parameters

In the single speed version, two operating speeds

can be adjusted.- The two most common speeds for generating

sets, 1500 or 1800 rpm can be preprogrammedby Scania. The minimum and maximum speedsare programmed at the same level whendelivered from Scania.

- If both 1500 and 1800 rpm are required, thismust be specified separately when ordering theengine.

If the speed needs to be switched, DIPswitch no. 6  

underneath the round black rubber cap on thecontrol unit must be changed.

- Normally the speed is 1800 rpm with theswitch in the ON  position and 1500 rpm in theOFF  position.

- Values of between 0-20 % are accepted for thespeed droop. When the engine is deliveredfrom Scania, Map 1 is used to set the speeddroop. The basic value is 4.0%

This applies if speed droop has been selected. For

further information on switching betweenisochronous and droop operation, see installationinstructions.

There is an option for externally switchingbetween low idle and operating speed with anextra switch connected to the control unit.

When the Run/Idle input on the control unit isswitched to Battery-, the engine runs at idle andwhen it is switched to Battery+ the engine willrun at the required operating speed. Seeinstallation instructions.

Max Spd Req 1800 RPMMin Spd Req 1500 RPMDroop Map 1 4.0 %Droop Map 2 2.5 %

LOP power 100.00 %Idle Speed 1000 RPM

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Governor Calibration: All speed and single speed engines

Calibration procedure

The menu for calibrating the governor ( A) givesan option to calibrate and match the injectionpump to the control unit.

This calibration must be carried out when thecontrol unit or injection pump have been replaced.

- Make sure that power to the control unit hasbeen switched off.

- Remove the round, black, rubber cap over theDIPswitches in the control unit. Set DIP switch

 3 in the OFF position. See illustrations on nextpage.

- Remove the red warning (Caution) label on thecontrol unit carefully, so that the label is notdamaged, to expose the calibration hole. Afterthe calibration the label should be put back tocover the hole.

- Remove the cover over the COMM/DIAGPORT and connect the computer cable with the DEC end to this port.

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DIP switch 3

DIP switch 3

Control unit, version V7.0 Control unit for single speed engines, version 8.1

Control unit for all speed engines, version V8.1

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V7.0:

- Connect a multimeter with + (plus) to themeasuring pin (1) in the control unit and with –(minus) to the brown cable marked TPSR( A7=pin 7 in row A, cable C36-11) in the mainconnector. See illustration below.

Note It is important to use a calibratedmultimeter in order to obtainaccurate voltage readings.

3

A

7

        1        2

        1        2

        1 1

12

Control unit, version V7.0 

1. Measuring pin (+) 

2. Trimpotentiometer 

3. Trimpotentiometer 

7. Pin 7 in row A (-) 

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V8.1:

- Connect a multimeter with + (plus) to themeasuring pin (1) in the control unit and with –(minus) to the yellow cable marked OPSR( B7=pin 4 in row B, cable C44-2) in the mainconnector. See illustration below.

Note It is important to use a calibratedmultimeter in order to obtainaccurate voltage readings.

Control unit for all speed engines,version V8.1

1. Measuring pin (+) 

2. Trimpotentiometer 

3. Trimpotentiometer 

4. Pin 4 in row B (-) 

Control unit for single speed engines,version V8.1

4

B

2 1

        1        2

        1        2

        1 1

        1        2

        1        2

        1   1

2 1

3

B

4        1        2

        1        2

        1   1

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The calibration procedure involves the adjustmentof two voltage levels:

- at control rack travel = 0 mm and

- at control rack travel = 20.3 mm.

This is done with the two trim pots located atpositions 2 and 3 in the control unit illustrationson pages 12 and 13.

Both trim pots are adjusted in the same way.When they are turned clockwise the voltagereading will increase and vice versa.

However, the resulting effects are different.

- trim pot 2 shifts the entire measuring range, i.e.both values are increased or decreased.

- trim pot 3 increases or decreases the measuringrange between the two values.

Normally only very small adjustments arerequired.

20.3

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Important! Turn on the power to the controlunit. Check that DIP switch 3 is in

 the OFF position. If there is aRun/Stop switch, it should be set in

 the Run position.

In the first screen (page 11), the control unit willask for a value for "control rack travel".

- First read off the voltage value on themultimeter with control rack travel = 0. Thevoltage should be 0.454 (0.450-0.458) voltsDC.

- Then insert the value 20.3 (maximum controlrack travel) and press Enter. Refer toillustration on page 11.

- The control unit now moves the control racktwice to maximum and back to zero. At thesame time Sending fuel rack travel .... isdisplayed on the screen.

- Read off the highest voltage value when thecontrol rack reaches maximum travel (twice).

- The voltage should be 4.54 (4.50-4.58) voltsDC.

- Adjustment to reach these values is carried outwith calibration screws 2 and 3.

- Repeat the procedure and check that the correctvalues have been obtained.

Note: The control unit may switch toShutdown  during the calibration. Byturning off power to the control unitmomentarily, the function is reset tonormal and the calibrationprocedure can be resumed.

Summary of calibration data:

Control rack

travel mm

Voltage value

Volts DC

0 0.454 ± 0.004

20.3 4.54 ± 0.04

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Saving the calibration

When the calibration procedure has beencompleted and accepted, the message Calibration

has passed  appears.Save the calibration as follows:

- Press the space bar so that the text Enter choice appears.

- Save the required Calibration by pressing F2.

- Check that a green text is flickering in thebottom left hand corner, which confirms thatthe save function is working.

- Set DIPswitch 3 in the control unit to the ON  position (standard position).

- Press ESC twice and confirm by pressing Y to Exit.

Note: If an non-approved calibration issaved, the engine cannot be starteduntil an approved calibration iscarried out and saved.

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Calibration has failed

- If the calibration values are outside theapproved range, the message Calibration has

 failed  will appear.

- If this happens, the calibration procedure mustbe repeated from the beginning.

Note: The calibration may fail even if thevoltage values are correct. In thiscase it is also necessary to repeatthe calibration procedure.

Final check 

Turn off the power to the control unit and thenturn on the power again.

- Open the Calibration window and check thevalues for Act F/B Offset  and Act F/B Range.

-  Act F/B Offset should be within 81-102CNT (RV=0).

-  Act F/B Range should be within 921-942CNT (RV=20.3).

Note: If the voltage values are correct butthe CNT values are outside the limitvalues, the voltage values must bechanged to obtain the correct CNTvalues and an approved calibration.

- Press F3 if you wish to store this data in aseparately named PC file.

- Exit the program as before and turn off thepower.

- Disconnect the computer cable and restore thecontrol unit to normal.

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Possible error messages that can occur during calibration

• If the calibration fails although both high andlow voltage values are correct and the CNT

values are within the tolerance range,proceed as follows:

- Exit the DEC2 calibration program.

- Turn off the main switch for powering thecontrol unit.

- Put DIPswitch 3 back in the ON  position.

- Resume the calibration procedure from thestart on page 11.

• If Shutdown occurs and the LED lights up onthe control unit, momentarily turn off powerto the control unit and then resume thecalibration procedure.

• If the following text appears on the screen:Press any key to continue (blue text) and

 Error communication failure, Status:(e.g.) E000 (red text):

- Press the space bar.

• If the following text appears on the screen:Press any key to continue (blue text) and

Sending fuel rack travel.......0 (green text):- Press the space bar.

• If the following text appears on the screen:Press any key to continue (blue text) andCalibration has failed (green text):

- Press the space bar.

• If the following text appears on the screen:Would you like to ( R)etry, ( D)isable, or(Q)uit  (blue text) and Comm Error while

reading byte/word, data (e.g.) CCEF,status = 10 (green text)

- Press the Q key and restart the calibration procedure from the start on page 11.


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