Installation E

Control System 1(1)

D12-AUX
 Contents

Safety Information ................................................... 4

Safety directions for maintenance and service ...... 4
General Information ................................................. 6
Installation ............................................................. 6
Joint liability ........................................................... 7
Certified engines .................................................... 7
Special Tools ........................................................... 8
System overview ..................................................... 9
Control Panel ....................................................... 10
LCD screen ......................................................... 13
Shutdown system ................................................ 17
Components .......................................................... 19
Senders & switches – control system .................. 19
Senders & switches – shutdown system ............. 20
Fuel shut-off valve ............................................... 21
Interface Information .............................................. 22
Control and monitoring of the engine. ................. 22
GAC synchronization and load sharing ................ 27
Shutdown system overview ................................... 28
Configuration ....................................................... 30
Shutdown unit wire connections .......................... 33
Operating the engine ............................................. 34
Diagrams & Drawings ............................................ 35
D12-AUX System layout (combined mode) ......... 35
Wiring diagram EMS ............................................ 36
Wiring diagram CIU ............................................. 37
General Interface ................................................. 38
General Interface – Optional instruments ............ 39
EMS – GAC interface schematic ......................... 40
Safety information

Safety Information

Introduction Work Procedures

Read this Installation Manual carefully before installa-
tion. Improper installation may result in personal injury
or damage to property or the engine itself.
If you do not understand or are uncertain about any
operation or information in this Installation Manual,
please contact Volvo Penta organisation.
Refer to the specific Operator’s Manual for relevant in-
formation where necessary, especially regarding safe-
ty and engine operation.
The work must be performed at Volvo Penta’s service
workshops, boat builders or other authorized and suit-
ably equipped workshops with personnel who have ap-
propriate qualifications and experience.

Installation
This Installation Manual is produced for professional
use only and must be used in conjunction with the rel-
evant Operator’s Manual.
Volvo Penta will not assume any liability whatsoever
for damage to materials or personal injury, which may
result if the installation instructions are not followed or
if the work is carried out by non-professional person-
nel.
The installer is responsible for ensuring that the sys-
tem operates in accordance with this Installation Man-
ual.
Important!
The following special warning symbols are found in
this manual and on the engine.
WARNING! Possible danger of personal injury,
damage to property or mechanical malfunction if
the instructions are not followed.
IMPORTANT! Used to draw your attention to
something that can cause damage to or
malfunction of a product or damage to property.
NOTE! Used to draw your attention to important infor-
mation that will facilitate the work or operation in pro-
gress.

Safety directions for maintenance and service

WARNING! Installation, maintenance and service must be carried out with the engine stationary unless
stated otherwise in the instructions. Prevent inadvertent start of the engine by turning off the power with the
main switch, locking it in the off position. Disconnect primary and secondary power supply (positive(+) and
negative(–) leads) and disable auxiliary starters. Place warning signs stating that work is in progress in every
position from which the engine can be started.

Below is a summary of the risks and safety precautions you must observe or carry out when installing and calibra-
ting the D12-AUX Control System.

Before carrying out electric arc welding, these 1. Disconnect primary and secondary power supply
measures of precaution should be at taken. (positive(+) and negative(–) leads).

2. Remove the connector from the engine control

unit. Press in the lock tab (1), move the locking
brace (2) up and pull the connector (3) out. Refit
the connector to the engine control unit after
disconnecting the welding equipment.

3. Disconnect fuses in the electrical connection box

on the engine.

4. Disconnect the 8-pole connector positioned

below the auxiliary stop-button.

4

Take care to avoid all moving parts of the engine
during testing and operation. Approaching an
engine which is operating is a hazard to personal
safety. Loose clothing or long hair can become
entangled in moving parts, and may cause
serious personal injury.
Never carry out work on an engine that is
suspended from a hoist.
Only start the engine in a well-ventilated area. If
operating the engine in a closed area ensure that
there is exhaust ventilation leading out of the
work area to remove exhaust gases and
crankcase ventilation emissions.
The engine must not be run in areas where there
are explosive materials or gases.
Never allow an open flame or electric sparks
near the batteries. Never smoke in proximity to
the batteries. The batteries give off hydrogen gas
during charging, which when mixed with air can
form an explosive mixture. This gas is easily
ignited and highly flammable. Incorrect
connection of the battery can cause a single
spark, which is sufficient to cause a gas explo-
sion. Do not alter the battery connections when
attempting to start the engine (spark risk) and do
not lean over any of the batteries. Refer to
instructions in the Engine Instruction Manual.
Safety information
Always ensure that the + (positive) and –
(negative) battery leads are correctly installed on
their corresponding terminal posts on the
batteries. Incorrect installation can result in
serious damage to the electrical equipment.
Refer to the wiring diagrams in the Engine
Instruction Manual.
Always use protective eyewear when charging or
handling the engine batteries. The battery
electrolyte fluid contains sulphuric acid which is
highly corrosive. If the battery electrolyte fluid
comes into contact with unprotected skin, wash
off immediately using copious amounts of clean
water and soap, then seek medical assistance. If
the electrolyte fluid comes in contact with the
eyes, flush the eyes immediately (preferable
using an eye bath) with copious amounts of
clean water, and obtain medical assistance
without delay.
IMPORTANT! AB Volvo Penta has developed
and tested the complete system and its
components. Non-original Volvo Penta
components or components installed in a way
that differ from the instructions may cause
malfunction of the system.
IMPORTANT! Use only Genuine Volvo Penta
Spare Parts.
Use of non-original AB Volvo Penta spare parts
will result in AB Volvo Penta being unable to
assume liability for the engine meeting engine
certification requirements. Any type of damage
resulting from the use of non-original Volvo
Penta replacement parts for the roduct will not be
covered under any warranty provided by AB
Volvo Penta.
5
General information
General Information
About the Installation Manual
This publication is intended as a guide for the installa-
tion of the D12-AUX Control system. The publication
is not comprehensive and does not cover every pos-
sible installation, but is to be regarded as recommen-
dations and guidelines applying to Volvo Penta stan-
dards.
IMPORTANT! Installation of electrical systems
shall only be carried out by a professional marine
electrician.
The recommendations in this manual are the result of
many years practical experience of installations all
over the world. Departures from recommended proce-
dures etc. can however be necessary or desirable, in
which case the Volvo Penta organisation will be glad
to offer assistance in finding a solution for your parti-
cular installation.
Installation manual for skilled professionals
This Installation Manual has been published for pro-
fessionals and qualified personnel. It is therefore as-
sumed that persons using this book have sufficient
knowledge of marine drive and monitoring systems
and are able to carry out related mechanical and elec-
trical work.
It is the sole responsibility of the installer to ensure
that the installation work is carried out in a satisfacto-
ry manner, that it is operationally in good order, that
the approved materials and accessories are used and
that the installation meets all applicable rules and re-
gulations.
Only parts delivered or approved by Volvo Penta
Only components, cables, connections etc, delivered
or approved by the manufacturer may be used. The
manufacturer will take no responsibility what so ever if
this requirement is violated.
6
Updates in Service Bulletins
Volvo Penta continuously upgrades its products and
reserves the right to make changes. All the informa-
tion contained in this manual is based on product data
available at the time of going to print. Notification of
any important modifications to the product causing
changes to installation methods after this date will be
made in Service Bulletins.
Installation
Great care must be taken in the installation of engines
and their components. Always make absolutely sure
that the correct specifications, drawings and any other
data are available before starting work.
Plan installations with care
The installation must be planned very thoroughly and
done with the greatest care. Plan the installation so
that it is easy to carry out routine service operations
involving the replacement of components (compare
the Service Manual with the original drawings showing
the dimensions).
IMPORTANT! Maximum permissible length of
cable from engine to panel, is 40 m [130 ft].
The connection cable between the engine and the in-
strument panel must be securely clamped. Remember
that the connectors must also be supported so that
they are not subjected to any tension. Cables must
not be run too close to hot components on the engine
or close to any other source of heat. Make sure that it
is protected from mechanical wear, sharp edges and
water splashes. If necessary, run the cable through
protective conduits.
IMPORTANT! Cables must also be run on a safe
distance from equipment that may disturb
communication signals, i.e. radio transmitters or
high current equipment.
Avoid making joints in the system as far as possible.
Cables and any joints must be accessible for inspec-
tion and service
NOTE! The connectors must be installed “dry”, they
must not be packed with Vaseline etc.
 General information

Joint liability
Each engine consists of many components working together. One component deviating from its technical specifi-
cation can cause a dramatic increase in the environmental impact of an engine. It is therefore vital that systems
that can be adjusted are adjusted properly and that Volvo Penta Genuine Parts as used.
Certain systems (components in the fuel system for example) may require special expertise and special testing
equipment. Some components are sealed at the factory for environmental reasons. No work should be carried out
on sealed components except by authorised personnel.

Environment
Remember that most chemical products damage the environment if used incorrectly. Volvo Penta recommends
the use of biodegradable degreasing agents for cleaning engine components, unless otherwise indicated. Take
special care when working on board boats to ensure that oil and waste are taken for destruction and not acciden-
tally pumped into the environment with bilgewater.

Certified engines
The manufacturer of engines certified for national and local environmental legislation pledges that this legislation
is met by both new and currently operational engines. The product must compare with the example approved for
certification purposes. So that Volvo Penta, as a manufacturer, can pledge that currently operational engines
meet environmental regulations, the following must be observed during installation:
• Service of fuel pumps, pump settings and injectors must always be carried out by an authorised Volvo Penta
workshop.
• The engine must not be modified in any way except with accessories and service kits developed for it by
Volvo Penta.
• Installation of exhaust pipes and air intake ducts for the engine compartment must be carefully planned as its
design may affect exhaust emissions.
• Seals may only be broken by authorised personnel.

IMPORTANT! Use only Volvo Penta Genuine Parts. Otherwise AB Volvo Penta will no longer take
responsibility for the engine meeting the certified design. All damage and costs caused by the use of
non-genuine replacement parts will not be covered by Volvo Penta.

7
Special tools

Special Tools

The tools below are intended for use in work on the cable harnesses of the engine. The tools are not included in
Volvo Penta’s range, they must be ordered from a local AMP or Deutsch dealer. If you experience problems in
contacting a dealer, please contact Volvo Penta Quality Action Center for advice.

HDT-48-00 AMP 725 840 AMP 58 495 AMP 726 534

AMP 726 519 AMP 825 514 AMP 725 938 AMP 825 582

Deutsch connectors Blades and sockets 3.5 mm (0.14")

HDT-48-00 Crimping tool 725 9380 Disassembly tool
0411-310-1605 Disassembly tool 825 582-2 Crimping tool

16-pin CPC connector, d=1.6 mm (0.063") 4.8 mm (0.19") and 6.3 mm (0.25") cable clamps.
725 840-1 Disassembly tool Tongues and socket terminals

58 495-1 Crimping tool 825 514-1 Crimping tool

JPT connector (42-pin EDC, 2 and 3-pin

Bosch etc.)
726 534-1 Disassembly tool 1.6 mm (0.063") pin
width
726 519-1 Disassembly tool 2.8 mm (0.11") pin
width
825 514-1 Crimping tool Multimeter
Special tool 9510060

8

System overview
PM – Power Module
The PM handles power distribution and management.
The power supply from the engine is distributed in the
network cable, which consists of eight wires. Four wi-
res are for communication, three are for power supply
and one is not used. The physical interface on the
engine is an 8-pole receptacle Deutsch connector.
EMS – Engine Management System
The EMS control unit handles engine speed and tor-
que governing and overall control of fuel injection and
emission control algorithms. The EMS unit also moni-
tors engine status. The EMS unit includes redundancy
functionality if external superior system fails.
CIU – Control Interface Unit
The CIU converts analogue and digital input informa-
tion from a control panel into data bus messages. It
also receives data bus messages and convert these
into analogue and digital output signals used for
alarms and gauges.
SDU – Shutdown Unit
The SDU is used for shutting down the engine by acti-
vating a fuel shut-off valve in a critical situation. The
shutdown system is completely separated from the
engine control system. The SDU does not contain
software, all functions are hard wired.
System overview
Network
The system has two communication buses.
IMPORTANT! Maximum permissible length of
cable from engine to control panel, 40 m [130 ft].
CAN bus
The CAN communication bus is the primary control
bus. It is a serial bus and complies with the CAN
Standard with J1939 protocol.
J1587 Communication bus
The J1587 communication bus is used as backup
control bus and also for aftermarket tools. It is a serial
communication bus and complies with the SAE J1708
standard.
NOTE! If the primary bus and redundancy bus fails
the engine will keep running at the same speed it had
before the malfunction.
VODIA
For software update on the field, Volvo Penta has de-
veloped VODIA, an after market tool used by certified
service personal. In addition to software download,
VODIA can perform system diagnostic.
9
System overview – control panel

Control Panel
Control panel for engine in auxiliary operation
This is the control panel used when the engine is configured for auxiliary use. The SDU comes with shutdown
functions for overspeed, high coolant temp, and low oil pressure. The system will also detect and indicate broken
wires.

1. Lamp test button 7. Engine page button (engine data) 13. Oil pressure shutdown indication
2. SDU Acknowledge button 8. Multi page button (operational data) 14. Coolant temp shutdown indication
3. LCD-display 9. Trip page button (fuel consumption) 15. Broken wire indication
4. Stop button 10. Graph page button (history graphically)
5. SDU Buzzer 11. Configuration page button (configuration)
6. Start button 12. Overspeed shutdown indication

10
 System overview – control panel

Control panel for engine in emergency operation

This is the control panel used when the engine is configured for emergency use. The SDU comes with shutdown
functions only for overspeed. The system will also detect and indicate broken wires.

1. Lamp test button 7. Engine page button (engine data)

2. SDU Acknowledge button 8. Multi page button (operational data)
3. LCD-display 9. Trip page button (fuel consumption)
4. Stop button 10. Graph page button (history graphically)
5. SDU Buzzer 11. Configuration page button (configuration)
6. Start button 12. Overspeed shutdown indication
13. Broken wire indication

11
System overview – control panel

Control panel for engine in combined auxiliary and emergency operation

This is the control panel used when the engine is configured for both auxiliary and emergency use. In auxiliary
mode the SDU includes shutdown functions for overspeed, high coolant temp, and low oil pressure. In emergency
mode all shutdowns except overspeed are disabled. The system will also detect and indicate broken wires.

1. Lamp test button 7. Engine page button (basic engine data) 13. Oil pressure shutdown indication
2. SDU Acknowledge button 8. Multi button(operational data) 14. Coolant temp shutdown indication
3. LCD-display 9. Trip button (fuel consumption) 15. Broken wire indication
4. Stop button 10. Graph button (history graphically) 16. Emergency mode key-switch
5. SDU Buzzer 11. Configuration button (configuration) 17. Emergency mode indicator
6. Start button 12. Overspeed shutdown indication

Combined auxiliary and emergency system

Turn the EMERGENCY MODE key-switch (16) clock-
wise to switch to emergency mode. This will disable
all shutdowns except for the overspeed shutdown.
The EMERGENCY MODE indicator (17) will be lit to
indicate that the control system is in emergency
mode.

IMPORTANT! When in emergency mode, vital

shutdown functions are disabled. Be sure to mo-
nitor engine data thoroughly.

12
 System overview – LCD-screen

LCD screen
The control unit is equipped with an LCD screen with adjustable lighting and contrast. Signals are displayed either
graphically or as numerical values. All alarms are displayed on the screen as text messages.

Contrast and lighting control

Push the CONFIGURATION button(11) to access the
lighting and contrast menu. Then push the correspon-
ding buttons to adjust levels. Push EXIT to store the
settings. The display has 4 lighting levels.
NOTE! Pushing all four white buttons simultaneously
will reset contrast and lighting to default values.

Configuration menu
To enter the CONFIG MENU, push the CONFIGURA-
TION button (11) for at least three (3) seconds.

Units
The displayed units are user-defined.
Pressure: kPa, PSI
Volume: LITRE, GAL Imperial GAL
Fuel rate: L/H, GAL/H, IGAL/H
Temperature: °C, °F

Settings
Language: 8 languages available
Bleep: Buttons are bleeping when pressed (On/Off)
Display: Set the range engine rpm gauge
Engine rpm: [2500 rpm:9000 rpm] step 500 rpm
Graph range: 2 MIN,10 MIN, 30 MIN, 60 MIN,
2 HRS, 4 HRS, 8 HRS

Alarm status
The alarm status page shows the current active
alarms list (same as when an alarm is first received).
Refer to section ”Alarm list”.

13
System overview – LCD-screen

System
In the system configuration page it is possible to reset
default values for viewing of the display.
Demo: Demo ON/OFF. Off = normal operation mode
Restore defaults: Reset configuration default values
Com viewer: Latest messages received on CAN port
About: Displays vital service information.

Views
There are four different display views:
Engine page (button 7)
Multi page (button 8)
Trip page (button 9)
Graph page (button 10)
Push any white button to display the pop-up menu,
then push the corresponding button to access wanted
page. Pushing the blue button will close the pop-up
menu.

Engine page
This page is always displayed after the start-up
screen, but can also be accessed by pushing ENGI-
NE PAGE button (11). This page shows the engine
rpm value and coolant temperature as standard gau-
ges. The lower part of the display window provides ac-
cess to fuel computer data and various data can be
displayed by repeatedly pushing the ENGINE PAGE
button (11).
Only metric units are shown but other units can be se-
lected in the configuration menu. Scale values for
engine rpm and coolant temp can also be changed in
the configuration menu.

Multi page
This page shows data parameters displayed in four
data windows either digitally or graphically. The dis-
play toggles between the two when MULTI PAGE but-
ton is pressed repeatedly.
NOTE! If a data parameter is not available, the unit
will display “—“ and the analogue gauge needle will
not be displayed.

14
 System overview – LCD-screen

Multi page display parameters

The page has an adjust mode which provides for any
available engine data to be displayed in any of the
four data windows.
The adjust mode is entered by pushing the CONFIGU-
RATION PAGE button (11) when the pop-up menu is
visible. The four white buttons will then adjust the dis-
played engine data in the corresponding window (as
highlighted in black).

Available engine data include:

Coolant pressure
Fuel pressure
Engine oil pressure
Turbo pressure
Coolant temp
Exhaust temp (optional)
Engine oil temp
Engine oil filter diff. pressure
Voltage
Engine rpm
Engine hours
NOTE! The voltage range will change automatically
depending on the current value.

Trip page
The page displays:
Trip fuel (fuel used since reset)(not yet available)
FUEL RATE (volume of fuel used per hours)
Trip engine hours (running hours since last reset)
Total engine hours (not re-settable)
NOTE! To reset the trip values just press and hold
TRIP PAGE button (9) for one second. The unit will
bleep and the values are reset.

Graph page
Pushing GRAPH PAGE button (10), will display engi-
ne data history graphically. Repeated pushing will
change to next available engine data history. If a data
is not available, that particular screen will not be se-
lectable. If the data is lost, whilst in the screen, the
graph line will just stop drawing but continue to scroll
across the screen.
NOTE! The maximum time range can be adjusted in
the configuration menu to either: 2mins, 10mins,
30mins, 1hr, 2hrs, 4hrs, 8 hrs.

15
System overview – LCD-screen

Alarm functions
The system includes to kinds of alarms, WARNING!
and STOP-alarm and a pop-up window will appear on
the display when there is a new alarm.
WARNING!: Indicates malfunction of the monitoring
system, e.g. broken wires, short-circuits, or sender-
failure. These faults will allow operation of the engine
but with impaired monitoring functions.
STOP-alarm: Indicates serious malfunction of the
engine that need to be rectified immediately. If such
an alarm occurs, stop the engine and do not operate it
until the fault has been rectified.

Alarm list
The alarm list contains all new unacknowledged
alarms (grey text on black background) and previously
acknowledged alarms (black text on grey backgro-
und). The screen cannot be exited until all alarms
have been acknowledged.
The alarm list will be scrollable if the list is longer than
the screen size and when faults have been rectified
the alarms will be cleared from the alarm list. All
alarms will be cleared when the system power supply
is turned off.
NOTE! The alarm list can be viewed, at any time,
from the configuration menu.

Data communication failure

If the system lose its signal from the engine, this will
be indicated by a flashing pop-up stating CONNEC-
TION LOST, and also the name of the lost link, J1939
or J1587. In both cases the engine can still be opera-
ted but with the loss of monitoring or alarm functions
respectively.
In the event of a communications failure, check all ca-
bles for lost connections and if that does not solve the
problem, contact a Volvo Penta Service Dealer.

16
 System overview – shutdown system

Shutdown system
The shutdown unit (SDU) will shut down the engine by cutting off the fuel supply. Shutdown functions include
shutdowns for OVERSPEED, COOLANT TEMP, and OIL PRESSURE, in auxiliary mode and for OVERSPEED
only, in emergency mode.

Lamp test
To make sure the lamps and the buzzer on the panel
are working, push and hold the LAMP TEST button (1).

Shutdown functions
When above mentioned engine data is not within set
limits the SDU will shut down the engine by cutting off
the fuel supply. This will trigger an alarm indicated by
light and sound on the control panel.
1. Push the ACKNOWLEDGE button (2) to silence
the buzzer. One of the lamps (12-14) indicating
the cause of the shutdown will be lit on the control
panel. A LED on the SDU in the electrical
connection box on the engine will also indicate the
cause of the shutdown.
2. Rectify the fault.
3. Push the SHUTDOWN RESET button (on the
electrical connection box on the engine). The LED
on the SDU and the lamp on the control panel
should go out if the fault no longer exists.
4. Restart the engine.

Broken wire
IMPORTANT! The BROKEN WIRE function only
detect lost connection due to cut off electrical
wires, not faulty or loose contacts.

The broken wire detection will set an alarm (light and

sound) if the shutdown system should somehow mal-
function, e.g. if connection to a switch is lost, or loss
of power supply to the shutdown unit itself (the
POWER LED on the SDU will no longer be lit in case
of power loss).
1. Push the ACKNOWLEDGE button (2) to silence
the alarm.
2. Check the SDU in the electrical connection box on
the engine, a yellow LED corresponding to the
broken wire will be lit:
S1 – Coolant temperature
S3 – Engine oil pressure
SS – Engine rpm
FV – Fuel shut-off valve
3. Rectify the fault.
4. Push the BROKEN WIRE RESET button (A) on
the SDU. If the fault is rectified the LED in the
SDU and the lamp on the control panel (15) will go
out.

17
System overview – shutdown system

Overspeed shutdown test

On a running engine, open the electrical connection
box on the engine and remove the SDU cover. Then
push and hold the OVERSPEED TEST button (A).
This will lower the overspeed setting by 25% and trig-
ger an overspeed shutdown.

18
 Components

Senders & switches – control system

19
Components

Senders & switches – shutdown system

Component locations – control system Component locations – shutdown system

1. Oil pressure sensor 16. Oil pressure switch
2. Speed sensor (camshaft) 17. Speed sensor (transmission)
3. Cooling water level switch 18. Coolant temperature switch
4. Crankhouse pressure sensor
5. Charge air press./temp. sensor
6. Cooling water temp. sensor
7. Tachometer sensor (flywheel)
8. Exhaust temperature sensor (optional)
9. Fuel pressure sensor
10. Water in fuel sensors
11. Oil level switch
12. Piston cooling pressure switch
13. Oil filter differential pressure sensor
14. Freshwater pressure sensor
15. Auxiliary stop

20
 Components

Fuel shut-off valve

1. I – to fuel Injection pump

2. F – from fuel filter
3. P – to feed pump
4. Signal from SDU
5. T – from fuel tank

21
Interface information

Interface Information
Control and monitoring of the engine.
To better match a specific installation the system can be configured using the VODIA. Which parameter to
change is described under “Configuration”.

Start
A startrequest is addressed by the startsignal, e.g. from a start switch (contact type: closing (NO), spring biased).
The engine will start to crank and continue to do so until one of the following conditions becomes true.
1. The startsignal goes inactive.
2. The engine speed exceeds 500 rpm.
3. The cranking time exceeds 20 s.

Signal requirements
CIU: ....................................................... Active signal – shorted to Vbat
Inactive signal – disconnected

Stop
A stoprequest is addressed by the stopsignal, e.g. from a stop switch (contact type: closing (NO), spring biased)
and will stop the engine.

Signal requirements
CIU: ....................................................... Active signal – shorted to Vbat
Inactive signal – disconnected

Configuration
Signal logic can be changed with VODIA:
Default: .................................................
can be changed to: ...............................
Parameter: ............................................
Active signal – shorted to Vbat (energized to stop)
Active signal – disconnected (energized to run)
Stop function CIU

22
 Interface information

Synchronization/Loadsharing
The input is used for controlling the engine speed for synchronization and loadsharing (also refer to section GAC
synchronization and loadsharing).
CIU: ....................................................... Nominal speed (1500/1800): 2,75 V
(Nominal speed - 120 rpm): 1,17 V
(Nominal speed + 120 rpm): 4,3 V
GN/Y

Nominal engine
speed
+ 120 rpm SPEED
CONTROL
Nominal engine
speed
(1500/1800
rpm) GN/SB
GN/OR
Nominal engine
speed
– 120 rpm
1,17 V 2,75 V 4,3 V

Voltages lower than 0,3 V, or higher than 4,7 V are not

permissible.
2-10 kΩ

min max
-120 rpm +120 rpm

0,5-2 max 0,5-2

kΩ 2 kΩ (optional) kΩ

POT – POT SIGNAL POT +

Engine speed potentiometer

Frequency switch
The frequency switch (contact type, two-position, NO) is used for changing the nominal engine speed (i.e. swit-
ching between 1500 and 1800 rpm). For safety reasons the frequency can only be changed when the engine is
stopped. It is also possible to change the frequency using the VODIA.

Signal requirements
CIU: ....................................................... RPM as spec. at purchase – disconnected
Alternative RPM (1500 or 1800) – shorted to bat(+).
Use system supply FA (refer to wiring diagram).

Configuration
The frequency can be changed using VODIA.
Parameter: ............................................ Primary engine speed

23
Interface information

Idle switch
The idle switch (contact type: two-position, NO) is used for requesting idle speed. Closed contact gives idling
speed (900 rpm). For safety reasons, only possible if engine load is less than 700 Nm.

Signal requirements
CIU: ....................................................... Active signal – shorted to Vbat
Inactive signal – disconnected

Oil pressure alarm

The signal is activated by the engine if the oil pressure is too low.

Signal specification
CIU: ....................................................... Load max 125 mA
Voltage 24 V
Output from CIU is active low, mea-
ning that customer side of lamp or re-
lay* is to be connected to Vbat.
*Potential free

Oil temperature alarm

The signal is activated by the engine if the oil temperature is too high. The alarm will go inactive if the temperature
drops below alarm temperature.

Signal specification
CIU: ....................................................... Load max 125 mA
Voltage 24 V
Output from CIU is active low, mea-
ning that customer side of lamp or re-
lay* is to be connected to Vbat.
*Potential free

Coolant temperature alarm

The signal is activated by the engine if the coolant temperature is too high. The alarm will go inactive if the tempe-
raturedrops below alarm temperature.

Signal specification
CIU: ....................................................... Load max 125 mA
Voltage 24 V
Output from CIU is active low, mea-
ning that customer side of lamp or re-
lay* is to be connected to Vbat.
*Potential free

24
 Interface information

Coolant level alarm

The signal is activated by the engine if the coolant level is too low. The alarm will be active until next start-up of
the engine.

Signal specification
CIU: ....................................................... Load max 125 mA
Voltage 24 V
Output from CIU is active low, mea-
ning that customer side of lamp or re-
lay* is to be connected to Vbat.
*Potential free

Fuel pressure alarm

The signal is activated by the engine if the fuel pressure is too low.

Signal specification
CIU: ....................................................... Load max 125 mA
Voltage 24 V
Output from CIU is active low, mea-
ning that customer side of lamp or re-
lay* is to be connected to Vbat.
*Potential free

Common Alarm
The signal is activated by the engine when any of the monitored operational data exceeds the set limit.

Signal specification
CIU: ....................................................... Load max 125 mA
Voltage 24 V
Output from CIU is active low, mea-
ning that customer side of lamp or re-
lay* is to be connected to Vbat.
*Potential free, normally connected to a relay, refer to wiring diagram.

Run Indication
The engine will activate a signal when the nominal rpm is achieved. The signal can be used as an indication of
that the engine is prepared to take load.

Signal specification
CIU: ....................................................... Load max 125 mA
Voltage 24 V
Output from CIU is active low, mea-
ning that customer side of lamp or re-
lay* is to be connected to Vbat.
*Potential free

25
Interface information

Instruments

Tachometer
Use Volvo Penta’s universal tachometer.
0–2600 rpm.

Oil pressure instrument

Use Volvo Penta oil pressure instrument.
0-10 bar (0-145 PSI).

Oil temperature instrument

Use Volvo Penta oil temperature instrument.
40-150 °C (104-302 °F).

Coolant temperature instrument

Use Volvo Penta coolant temperature instrument,.
40-120°C (104-248 °F).

26
 Interface information

GAC synchronization and load sharing

The D12-AUX control system is designed to suit the GAC synchronization and load distribution system. Interface
module EAM 122 must be used to connect to the GAC system.

Interface module – EAM122

The EAM122 is an electronic interface module desig-
ned for use with the D12-AUX control system. The
module accepts a nominal 5V DC input signal and
converts this signal to a 2.9V DC analog signal for the
EMS control across a galvanic isolated barrier. Typi-
cal usage is as a signal conditioner between a GAC
auto-synchronizer / load sharing system and the EMS
engine control. The power to operate the interface co-
mes from the 24V DC on the engine side (EMS) of the
application.

Wiring
refer to EMS – GAC interface schematic.
NOTE! The common battery minus connection bet-
ween the control system, EAM122, and the synchroni-
zation and load sharing system should be as direct as
possible electrically (minimum voltage difference).

Specifications
Input impedance (Terminals 6 & 5) ....................... 200 kΩ
Input DC voltage (nominal) (Terminals 6 & 5) ...... 5.0 V
Output impedance (Terminals 3 & 4) .................... 100 Ω
Nominal output voltage (Terminals 3 & 4) ............ 2.9 V DC
Output voltage range (Terminals 3 & 4) ............... 2.4 to 3.4 V DC
Transfer function ................................................... -0.2 volts/ volt
DC supply voltage range (Terminals 1 & 2) ......... 15 - 32 V DC
Supply current (Terminals 1 & 2) .......................... 75 mA
Temperature range ................................................ -40 to +85 °C
Isolation barrier rating (Terminals 2 & 4) .............. 1 kV DC

27
SDU
Shutdown system overview
Shutdown unit (SDU)
The SDU for D12-AUX has 2 shutdown channels and
one overspeed shutdown.
S1 Cooling water temp
S3 Lube oil pressure, Engine
S1 and S3 has a ~1 second delay and are enabled or
disabled in accordance with the engine specification.
Broken wire
All channels are equipped with a broken wire detection
(SF output) that indicates if any wire in the system is
broken. The broken wire reset button (refer to picture
”SDU indications”,E) is used to reset the SF. Each
broken wire function has a yellow LED (refer to picture
”SDU indications”, A–D).
Run detection
To avoid alarms when starting and stopping the engi-
ne an interlock for the shutdown pressure switches
(run detection) is implemented (speed sender signal
inputs 65,66). The run detection must be set at an
appropriate level before using the SDU. A green LED
indicates run detection for S2, S3 and yellow LED in-
dicates S4 (refer to picture ”SDU indications”, 3&4).
Overspeed shutdown
The overspeed function shuts down the engine in
case of overspeed. A red LED indicates overspeed
(refer to picture ”SDU indications”,2).
28
Overspeed test
To test the overspeed function push the overspeed
test button (inside the SDU). When pushed the over-
speed limit drops 25%.
Shutdown reset
An activated shutdown must be manually reset (acti-
vating SR input) before a new start of the engine can
be made. As standard the shutdown reset button is
placed on the lid of the engine connection box.
Shutdown system buzzer
The buzzer, output SB, is activated if shutdown or
broken wire detection is activated. The shutdown ack-
nowledge, input SA, is used to de-activate the buzzer
(when installed on output SB).
Emergency mode (shutdown override)
The system can be overridden by activating the OR
input (the Emergency mode lamp, when installed on
output SL, will be activated). Override does not inclu-
de overspeed.
Other information
The T1 input controls the alarm output test and acti-
vates all outputs 7, 9, OS, SB, SL and SF when acti-
vated.
A green LED indicates power on (refer to picture ”SDU
indications”, 1).

SDU indications.
1. Green – Power
2. Red – Overspeed
3. Yellow – Run detection S4
4. Green – Run detection S2, S3
5. Red – S3 Shutdown
6. Red – S1 Shutdown
SDU
A. Yellow – Fuel valve Broken wire
B. Yellow – Speed sender Broken wire
C. Yellow – S3 Broken wire
D. Yellow – S1 Broken wire
E. Broken wire reset button
29
SDU

Configuration
General
Remove the cover by gently pushing and pulling in the direction of the arrows. The cover has a ”snap-on” on each
side (A).

Channel set-up
1. Locate the channel on/off jumper pins on the SDU
card (1).
2. Disable all the S1–S6 channels before configuring
run detection and overspeed.
A. Channel disabled
B. Channel enabled

30
 SDU

Shutdown system run detection configuration

The first configuration is for S3 run detection.
NOTE! Factory setting – 1500 Hz.

1. Connect the removable cable terminal sections to 7. Turn (A) counter-clockwise (–) until the green LED
the SDU. (1) switches on. The run detection limit is now
configured.
2. Connect terminal 1 to 18-32V and terminal 2 to
0V. 8. Ramp the frequency from 0 Hz to the run
detection level to make sure that correct limit is
3. Switch on the supply and make sure the green
configured.
LED (POWER – 1) lights on the SDU. Some
alarms can be activated, ignore these. *Engine (pulses/rev.) ........................................ 38
4. Connect a sinusoidal frequency generator (Y) to Run detection S3 (rpm/Hz) ....................... 550/348
the 65,66 inputs.
5. Connect a multimeter in parallel (X)with the NOTE! Freq.(Hz) = rpm x pulses/rev.
frequency generator to measure the frequency 60
(use a multimeter that is specified to measure
frequency up to 10 kHz).
6. Set the frequency generator (Y) to the run
detection frequency*.

31
SDU

Shutdown system overspeed configuration

NOTE! Factory setting – 7000 Hz overspeed limit.

1. Connect the sinusoidal frequency generator to the *Engine (pulses/rev.) ........................................ 38

65,66 inputs.
Nominal speed (rpm) ............................ 1500/1800
2. Connect the shutdown reset button according to Maximum speed (rpm) ......................... 1620/1920
(Z).
Overspeed (rpm) ................................... 1863/2208
3. Connect a multimeter (X) in parallel with the Overspeed freq (Hz) ............................. 1180/1400
frequency (Y) generator to measure the frequency
(use a multimeter that is specified to measure
frequency up to 10 kHz). NOTE! Freq.(Hz) = rpm x pulses/rev.

4. Set the frequency generator to the overspeed 60

frequency*.
5. Turn (C) counter clockwise until the red overspeed
LED (3) is lit. The overspeed limit is now
configured.
6. Set the frequency generator to 0 Hz and then
push the shutdown reset button.
7. Ramp the frequency from 0 Hz to the overspeed
limit to make sure that correct limit is configured.
9. If the S6 channel is used, proceed with the
exhaust temp. configuration.
10. Enable the channels S1–S6 according to the
engine specification (refer to section ”channel set-
up”). Mount the SDU cover.

32
 SDU

Shutdown unit wire connections

Terminal wire connections
1. Remove the terminal sections from
the SDU by pulling in the direction of
the arrows.
NOTE! section 4 does not need to be
removed

2. Connect wires according to the list:

1. Emergency stop
2. Emergency mode lamp
3. Broken wire alarm
4. SDU Buzzer
5. Overspeed shutdown
6. Oil pressure shutdown
7. Coolant temp. shutdown
8. Emergency mode switch
9. Emergency mode switch
10. Shutdown reset switch
11. Lamp test switch
12. SDU acknowledge switch

3. Reinsert the terminal sections (1, 2, &

3) in the the SDU.

33
Operation

Operating the engine

Learn how to handle the engine, controls and other equipment in a safe and correct manner before taking it into
operation.

Start the engine

1. Turn on the main power supply to the engine, this
will also power up the panel (not indicated).
2. Push and hold the LAMP TEST button (1) to
make sure the Control panel is active and that the
lamps and the buzzer are working.
3. Select AUXILIARY or EMERGENCY mode (if
applicable).
4. Push the START button (6).

Operation
Check the control panel
Check the LCD screen and indication lamps regularly
during operation to make sure that all is normal. For
information on engine data values under normal opera-
ting conditions, refer to chapter ”Technical Data”.

Alarm
If an alarm occurs this will be indicated by a flashing
pop-up window (refer to section ”alarm functions”) on
the display and a high-pitched bleep will sound. Push
any button to open the alarm list. Push the display
ACKNOWLEDGE button (9) to silence the alarm. Rec-
tify the fault.

Shutdown
If a fault that triggered an alarm gets worse, the SDU
will shut down the engine by cutting off the fuel supp-
ly. This is indicated by light and sound on the control
panel.
1. Push the ACKNOWLEDGE button (2) to silence
the buzzer, refer to section”shutdown functions”.
2. Rectify the fault.
3. Push the SHUTDOWN RESET button, refer to
section”shutdown functions”.
4. Restart the engine.

Stop the engine

Let the engine run without load for at least three minu-
tes before turning it off. This will keep the engine tem-
perature in balance and prevent it from overheating.
IMPORTANT! The above procedure is
specially important if the engine has been
heavily loaded.
1. Push the STOP button (4).

34
 Drawings & Diagrams

D12-AUX System layout (combined mode)

35
Drawings & Diagrams

Wiring diagram EMS

36
 Drawings & Diagrams

Wiring diagram CIU

37
Drawings & Diagrams

General Interface

38
 Drawings & Diagrams

General Interface – Optional instruments

39
Drawings & Diagrams

EMS – GAC interface schematic

40
7743206-0 English 06-2003