Fal 5

Technical Publication
Field Automation Level

Assembly Catalog
FAL-5
Functional Description
Workshop Manual
Spare Parts Catalog
E531439/06E
Printed in Germany
© 2005 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung,
Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken
und Online-Diensten.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.
Printed in Germany
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.
Imprimé en Allemagne
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU
Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches,
la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.
Impreso en Alemania
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se
incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.
Stampato in Germania
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione,
alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici,
comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.
Impresso na Alemanha
A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a
autorização prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento,
tradução, microfilmagem, e a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line.
Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento
economicamente consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.
Salvo alterações.
Table of Contents 01
General Provisions ......................................................... 05

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
1.1 General conditions ....................................................... 07
1.2 Personnel and organizational requirements .................................. 08
1.3 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
1.4 Auxiliary materials, fire prevention and environmental protection ................ 12
1.5 Standards for warning notices in the publication .............................. 14
Functional Description ...................................................... 15

2 PIM – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Peripheral Interface Modules (PIMs) ......................................... 17
2.5 Overview of PIM printed circuit boards ...................................... 24
2.6 PIM – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 FIM – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Filter module 1 .......................................................... 31
3.2 FIM 1 – Technical data .................................................... 33
4 DIM – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Dimmer module 3 ........................................................ 35
4.2 DIM – Technical data ..................................................... 41
5 PSM – Purpose and Structure .................................................... 43
5.1 Power supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 PSM – Technical data ..................................................... 45
5.3 Power supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4 PSM – Technical data ..................................................... 49
5.5 Mechanical installation of PIMs, FIMs, DIMs and PSMs ......................... 51
6 MPU 23 – Purpose and Structure ................................................. 53
6.1 Printed circuit board MPU 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2 MPU 23 – Technical data .................................................. 58
6.3 Printed circuit board MPU 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4 MPU 27 – Technical data .................................................. 63
7 CCB – Purpose and Structure .................................................... 65
7.1 Printed circuit board CCB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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02 Table of Contents
7.2 CCB 1 – Technical data ................................................... 66

8 SCB – Purpose and Structure .................................................... 67
8.1 Printed circuit board SCB 2 ................................................ 67
8.2 SCB 2 – Technical data ................................................... 68
9 COB – Purpose and Structure .................................................... 75
9.1 Printed circuit board COB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.2 COB 1 – Technical data ................................................... 77
9.3 Printed circuit board COB 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10 PAB – Purpose and Structure .................................................... 83
10.1 Printed circuit board PAB 2 ................................................ 83
10.2 PAB 2 – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11 FCB – Purpose and Structure .................................................... 87
11.1 Printed circuit board FCB 1 ................................................ 87
11.2 FCB 1 – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
12 COB – Purpose and Structure .................................................... 93
12.1 Printed circuit board COB 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12.2 COB 17 – Technical data .................................................. 96
13 FCB – Purpose and Structure .................................................... 99
13.1 Display module FCB 2 .................................................... 99
13.2 FCB 2 – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
14 AIB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
14.1 Printed circuit board AIB 1 ................................................ 101
14.2 AIB 1 – Technical data .................................................... 106
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Table of Contents 03
15 BIB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

15.1 Printed circuit board BIB 1 ................................................ 127
15.2 BIB 1 – Technical data .................................................... 130
15.3 Printed circuit board BIB 2 ................................................ 131
15.4 BIB 2 – Technical data .................................................... 134
16 BOB – Purpose and Structure .................................................... 137
16.1 Printed circuit board BOB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
16.2 BOB 1 – Technical data ................................................... 140
17 EGB – Purpose and Structure .................................................... 149
17.1 Printed circuit board EGB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
17.2 EGB 1 – Technical data ................................................... 152
18 IIB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
18.1 Printed circuit board IIB 1 ................................................. 153
18.2 IIB 1 – Technical data ..................................................... 156
19 INB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
19.1 Printed circuit board INB 1 ................................................ 159
19.2 INB 1 – Technical data .................................................... 163
20 MFB – Purpose and Structure .................................................... 175
20.1 Printed circuit board MFB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
20.2 MFB 1 – Technical data ................................................... 179
20.3 Printed circuit board MFB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
20.4 MFB 2 – Technical data ................................................... 187
21 MOB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
21.1 Printed circuit board MOB 1 ............................................... 191
21.2 MOB 1 – Technical data ................................................... 196
21.3 Printed circuit board MOB 2 ............................................... 198
21.4 MOB 2 – Technical data ................................................... 202
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04 Table of Contents
22 SAB – Purpose and Structure .................................................... 205

22.1 Printed circuit board SAB 1 ................................................ 205
22.2 SAB 1 – Technical data ................................................... 210
23 ROB – Purpose and Structure .................................................... 213
23.1 Printed circuit board ROB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
23.2 ROB 1 – Technical data ................................................... 217
Workshop Manual .......................................................... 219

24 Malfunctions .................................................................. 221
24.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
24.1.1 Troubleshooting – LEDs on printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . 221
25 Work Descriptions ............................................................. 235
25.1 Power supply – Check .................................................... 235
25.2 Printed circuit board – Replacement ........................................ 236
25.3 Fuse – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
25.4 PIM – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
25.5 PIM – Replacement, screw-mounting ........................................ 239
25.6 Wiring – Repair .......................................................... 240
Appendix .................................................................. 241

26 Appendix ..................................................................... 243
26.1 Conversion tables ....................................................... 243
26.2 List of abbreviations ..................................................... 249
26.3 Index .................................................................. 252
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General Provisions 05
General Provisions
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06 General Provisions
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Safety 07
1 Safety
1.1 General conditions

General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or Conversions
Modifications made by the customer to the engine may affect safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.
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1.2 Personnel and organizational requirements

Personnel
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organization
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).
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Safety 09
1.3 Safety precautions when working on the engine

Safety precautions when putting the equipment into operation
Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Immediately after putting the device or system into operation, make sure that all control and display
instruments as well as the signaling and alarm systems work properly.
Safety requirements for operators
Procedures for cases of emergency must be practised regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the displays and monitoring units must be permanently observed with regard to present
operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Strict adherence to the maintenance and repair schedule is an essential safety factor.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed air line when air starters are fitted. Post
the "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Have maintenance and repair work carried out by qualified and authorized personnel only.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane. Always support by
suitable means which conform with the applicable regulations before commencing maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After completing
work on the engine, check that all protective devices/safety guards have been installed and that
all tools and loose parts have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage fuel lines during maintenance and repair work. To tighten the connections when installing
the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.
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Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposes
when exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in this
case. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals
if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable bonding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise
induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).
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Safety 11
Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies. Any measures requiring a power
supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.
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1.4 Auxiliary materials, fire prevention and environmental

protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible materials near the engine.
Do not carry out welding work on pipes and components carrying oil or fuel. Before
welding, clean with a noncombustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
sounds indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB (A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants, materials and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable,
which means work must only be carried out by authorized specialist companies (MTU is such a company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling hot,
chilled or caustic materials. When using inflammable materials, avoid sparks, flames and do not smoke.
Lead
• When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust!
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
Paints
• When painting anywhere other than in spray booths equipped with extractors, ensure good
ventilation. Make sure that adjacent work areas are not affected.
• No naked flames!
• No smoking.
• Observe fire prevention regulations!
• Wear masks providing protection against paint and solvent fumes.
Liquid oxygen
• Liquid oxygen is highly combustible.
• Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals)!
• Do not bring liquid oxygen in contact with the body (hands), as this causes frostbite and possibly the loss of tissue.
E531439/06E 05-09 © MTU

Safety 13
• No smoking, no naked flames, risk of explosion! Excessive oxygen in the air leads to explosive combustion.
• Do not store combustible substances, e.g. oils and greases, within 5 m of the working area!
• Under no circumstances should clothing be oily or greasy.
• Do not allow vapors to penetrate clothing! Oxygen enrichment in fabric can cause
working clothes to ignite suddenly!
• After working with liquid oxygen, do not smoke until clothing is free of vapors!
• Avoid all hard knocks and impacts when working with liquid oxygen.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and the loss of tissue.
• Wear protective clothing, including gloves, closed shoes and protective goggles!
• Ensure that the room is well ventilated. Nitrogen concentration exceeding 88% of
breathing air leads to suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Compressed air
Compressed air is air compressed at excess pressure and is stored in vessels from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air vessels and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Devices and equipment connected must either be designed for this pressure or, if the permitted
pressure for the connected elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
• Always wear protective goggles when blowing off tools or chips!
• The snout of the air nozzle should be provided with a protective disc (e.g. rubber disc), which prevents
air-borne particles being deflected and thereby prevents injury to eyes.
• First shut off compressed air lines before compressed air equipment is disconnected from the
supply line or before equipment or tools are exchanged!
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII
and B) out of containers, carries the risk of explosion!
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of shattering!
• Do not use compressed air to clean contaminated clothing whilst it is being worn.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.
E531439/06E 05-09 © MTU

1.5 Standards for warning notices in the publication

In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures
Note: This publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:
Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!
E531439/06E 05-09 © MTU

Functional Description 15
Functional Description
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16 Functional Description
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PIM – Purpose and Structure 17
2 PIM – Purpose and Structure
2.1 Peripheral Interface Modules (PIMs)
PIMs for use with processor printed circuit board MPU 23

Design of PIM 1
1 Module cassette 1
2 Basic module 1
3 Printed circuit board
PIM 1 comprises:
• Module cassette 1 (1) to accommodate one MPU 23 and one PIM printed circuit board.
• Basic module 1 (2) with printed circuit board COB 1-0X (3).
Slots and terminals
1 Slot 1
2 Slot 2
Slot 1 is reserved for the microprocessor board (MPU 23). All other slots may be
populated with PIM printed circuit boards.
E531439/06E 05-09 © MTU

Example: The "n" in "n09" stands for the slot and "09" designates the terminal. "209" means: Slot 2, terminal 9.
E531439/06E 05-09 © MTU


Design of PIM 2
1 Module cassette 1
2 Module cassette 2
3 Basic module 2
PIM 2 comprises:
• Module cassette 1 (1) to accommodate one MPU 23 printed circuit board and one PIM printed circuit board.
• Module cassette 2 (2) to accommodate two PIM printed circuit boards.
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Slots and terminals
1 Slot 1 3 Slot 3
2 Slot 2 4 Slot 4
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Design of PIM 5
1 Module cassette 1
2 Basic module 1
PIM 5 comprises:
Slots and terminals
1 Slot 1
2 Slot 2
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Design of PIM 3
1 Module cassette 1
2 Module cassette 2
3 Basic module 2
PIM 3 comprises:
• Module cassette 2 (2) to accommodate two PIM printed circuit boards.
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Slots and terminals
1 Slot 1 3 Slot 3
2 Slot 2 4 Slot 4
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2.5 Overview of PIM printed circuit boards

MPU printed circuit boards (microprocessor systems)
Printed circuit board Function
MPU 23 • Single-chip processor with main and data memory

• 1 CAN interface as per ISO 11 898
• 1 slot for CCB 1, SCB 2 or SCB 4
• Power supply for PIM printed circuit boards
MPU 27 • Single-chip processor with main and data memory

• 2 CAN interface as per ISO 11 898
• Connector for FCB 2
• Power supply for PIM printed circuit boards
MPU 23 extension boards
CCB 1 • 1 additional CAN interface as per ISO 11 898
SCB 2 • 1 additional RS422 interface
SCB 4 • 1 additional RS232 interface
MPU 27 extension boards
FCB 2 • Display module
Connection printed circuit boards (motherboards)
COB 1-0X* • Connection printed circuit board between PIM 1

terminals and printed circuit board MPU 23 and
the printed circuit board in the second slot
• Used for processor printed circuit board MPU 23

the three printed circuit boards in slots 2, 3 and 4

the printed circuit board in the second slot

the three printed circuit boards in slots 2, 3 and 4
* 0X stands for the latest version of the printed circuit board (e.g. COB 3-03).
All printed circuit board versions are downward-compatible.
E531439/06E 05-09 © MTU

PIM printed circuit boards
AIB 1-0X* • 4 analog measuring channels to acquire

resistance, voltage and current signals
AIB 2-0X* • 2 analog input channels to acquire voltage and

current signals
• 2 analog output channels to output voltage and
current signals
AIB 3-0X* • 8 analog input channels to acquire current signals
AIB 4-0X* • 4 electrically isolated analog input channels to

acquire current signals (external power supply)
BIB 1-0X* • 8 electrically isolated binary inputs (external power

supply)
• Cable damage monitoring
BIB 2-0X* • 8 electrically isolated binary inputs (internal power

supply)
BOB 1-0X* • 4 independent relay outputs (changeover contacts)

BOB 1-0X/A* • 4 independent relay outputs (changeover contacts)

without cable damage monitoring
BOB 2-0X* • 14 transistor output stages (positive-switching)
BOB 3-0X* • 14 transistor output stages (positive-switching)
EGB 1-0X* • 8 analog input channels to acquire voltage signals

(for NiCr-Ni temperature sensor)
FCB 1-0X* • Display of alarms and fault codes

FCB 1-0X/A* • 2 transistor output stages (positive-switching)
• 2 transistor output stages (ground-switching)
• 2 independent relay outputs (changeover contacts)
IIB 1-0X* • 4 analog voltage outputs for instrument control

(0 VDC - 10 VDC)
• 4 electrically isolated binary inputs
INB 1-0X* • 4 outputs for instrument control (2 bipolar outputs

and 2 unipolar outputs)
• Dimmer (external power supply)
Produced and supplied as spare part only. INB 2-0X
used in new configurations.
INB 2-0X* • 4 outputs for instrument control (each output

bipolar or unipolar)
• Dimmer (internal power supply)
INB 3-0X* • 7 current outputs to control instruments (4 mA -

20 mA)
• 1 frequency output to control an instrument (0 Hz
- 1500 Hz)
• Use in conjunction with MPU 27 and MPU 29 only!
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MFB 1-0X* • 2 electrically isolated inputs for analog speed

signals with hysteresis control or 2 electrically
isolated inputs for binary speed signals or binary
signals (status interrogation) (only one speed
acquisition variant possible, either analog or
binary)
• Power supply (24 VDC) for electronic transmitters
or sensors
• 2 independent relay outputs (changeover contacts)
MFB 2-0X* • 2 analog input channels to acquire potentiometers

• 3 electrically isolated binary inputs (external power
supply)
• 5 transistor output stages (positive-switching) with
internal power supply (24 VDC)
• Power supply (24 VDC) for electronic transmitters
or sensors
• Use in conjunction with MPU 29 only!
MOB 1-0X* • 4 electrically isolated transistor output stages to

control two DC motors or dynamic/static control
of solenoid valves (for proportional valves or
positive/ground-switching valves), full step motors
only and in conjunction with printed circuit board
SMB 2-0X
• Use with MPU 23 only
MOB 2-0X* • 4 electrically isolated transistor output stages to

control two DC motors or dynamic/static control
of solenoid valves (for proportional valves or
positive/ground-switching valves)
• 2 current feedback channels
• Use with MPU 27 only
PAB 2-0X* • PIM node address and baud rate programming
SAB 1-0X* • 1 electrically isolated CAN interface as per

ISO 11 898
• 3 independent relays to output binary information
• 1 electrically isolated transistor output stage
(positive-switching)
• 1 electrically isolated binary input with cable
damage monitoring
SCB 3-0X* • 2 electrically isolated interfaces as per RS422 or

RS232 standard
ROB 1-0X* • 5 relay inputs with change-over switch, one of

which with 4 inputs (OR function)
• 1 relay input with four change-over switches
This printed circuit board is not bus-compatible and
can only be used in special PIMs with a suitable
motherboard. It cannot be used in type 1 and 2 PIMs
nor in type 5 and 3 PIMs.
* 0X stands for the latest version of the printed circuit board (e.g. AIB 1-02).
All printed circuit board versions are downward-compatible.
E531439/06E 05-09 © MTU

2.6 PIM – Technical data
Technical data of PIMs (screw terminals)

Term Unit Value
Installation position As desired
Operating voltage VDC 24, -50 %

to +30 %
Residual
ripple less
than 5 %,
as per
STANAG
1008
Power consumption Less than

PIM 1 or PIM 2 with MPU 23 A 0.2 (depend-
ing on
printed
circuit
boards
used)
Connecting-cable cross section mm2 Max.

2 x 2.5 solid
or
Max. 2
x 1.5
stranded
with
sleeve as
per DIN
64228
Degree of protection IP 20 as
per DIN
40 050
Shock 10g , 11
ms
Vibrostability
Top-hat rail mounting Hz 2 - 13.2:

Xpp = ± 1
mm
13.2 - 100:
a = ± 0.7 g
Screw mounting Hz 2 - 25:

Xpp = ±
1.6 mm
25 - 100:
a=±4g
EMC specification
Ambient temperature °C -30 - +70
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Term Unit Value
Storage temperature °C -35 - +85
Rel. humidity % 0 - 97,

non-con-
densing
Color Blue (RAL

5015)
Material Fiber-
glass-rein-
forced
polycar-
bonate
PIM 1
Dimensions (H x W x D) mm 75 x 70 x
90
Number of terminals 32
Weight kg Approx.
0.3 (pop-
ulated)
PIM 2
90
Weight kg Approx.
0.6 (pop-
ulated)
Technical data of PIMs (spring terminals)

Term Unit Value
Operating voltage VDC 24, -50 %

to +30 %
Residual
ripple less
than 5 %,
as per
STANAG
1008
Power consumption
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Term Unit Value
PIM 1 or PIM 2 with MPU 23 A Less than

0.2 (depend-
ing on
printed
circuit
boards
used)
PIM 5 or PIM 3 with MPU 27 A Less

than 0.35
(depend-
ing on
printed
circuit
boards
used)
Connecting-cable cross section mm2 Per

terminal:
2 x -2.5
per DIN
40 050
Shock 10g , 11
ms
Vibrostability

Xpp = ± 1
mm
13.2 - 100:
a = ± 0.7 g

Xpp = ±
1.6 mm
25 - 100:
a=±4g
EMC specification

non-con-
densing
Color Blue (RAL

5015)
Material Fiber-
glass-rein-
forced
polycar-
bonate
E531439/06E 05-09 © MTU

Term Unit Value
PIM 1
90
Weight kg Approx.
0.3 (pop-
ulated)
PIM 2
90
Weight kg Approx.
0.6 (pop-
ulated)
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FIM – Purpose and Structure 31
3 FIM – Purpose and Structure
3.1 Filter module 1
Purpose and structure

Design
1 Basic module 3
2 Printed circuit board FIB 1
Use
• Smoothing external operating voltages
• Overvoltage protection
• Overcurrent protection (self-restoring fuses)
• Reverse-battery protection
• EMC filter
Terminals
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The operating voltage is supplied (filter input) via terminals 101 to 116. The filtered operating
voltage is available at terminals 201 to 216 (filter output).
1 Self-restoring fuse
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FIM – Purpose and Structure 33
3.2 FIM 1 – Technical data
Technical data of FIM 1

Term Unit Value
90
Weight kg 0.3
Input voltage VDC 12 - 36
Output current A ≤ 6 at an
ambient
tempera-
ture of up
to 45 °C
≤ 4 at an
ambient
tempera-
ture of up
to 70 °C
Filter power consumption Less than

0.05 A (at
24 VDC)
Connecting-cable cross section mm2 2 x -

2.5 per
terminal
per DIN
40 050
Shock 10g , 11
ms
Vibrostability

Xpp = ±1
mm
13.2 - 100:
a = ± 0.7 g
Screw mounting 2 - 25:

Xpp = ±1.6
mm
25 - 100:
a = ±4 g
EMC specification
E531439/06E 05-09 © MTU

Term Unit Value
Rel. humidity 0 % -
97 %,
non-con-
densing
Color Blue (RAL

5015)
Material Fiber-
glass-rein-
forced
polycar-
bonate
Reverse-battery protection Yes
Overcurrent protection Yes (self-

restoring
fuses)
E531439/06E 05-09 © MTU

DIM – Purpose and Structure 35
4 DIM – Purpose and Structure
4.1 Dimmer module 3

Design
1 Basic module 3
2 Printed circuit board DIM 3–01
Use
DIM 3 supplies a pulse-width-modulated 24 V output signal to supply background
illumination of dimmable instruments with power.
• PWM output signal (3 - 100 %), positive-switching (High side)
• Total output current at all terminals max. 2 A
• Input filter
• Various setpoint signal inputs:
• PWM input signal (e.g. from printed circuit board INB 2, which can control up to 10 DIM 3s in parallel)
• Potentiometer (5 kΩ)
• Analog voltage 7 0 28 V
• Analog voltage 0 - 10 V
• Adjustable basic brightness
• Wide input voltage range, controlled (typ. 17 - 29 V)
• Low power loss
E531439/06E 05-09 © MTU

Terminals
The supply voltage is supplied via terminals 101 and 102 (+24 VDC) and 103 and 104 (ground). 8 outputs are available
for lamp control at terminals 201 to 216. The dimming voltage is set by varying assignment at terminals 107 to 116.
1 Self-restoring fuse 2 Control unit
Circuitry for dimming voltage setting

Possible connection for dimming voltage setting.
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Connection is only established at terminals 107 to 116 respectively.
1 Control unit
1 Control unit
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1 Control unit
1 Control unit
1 Control unit
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1 Control unit
1 Control unit
1 Control unit
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1 Control unit
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4.2 DIM – Technical data
Technical data of DIM 3

Term Unit Value
90
Weight kg 0.3
Output current A ≤2
Filter power consumption W <1

2.5 per
terminal
per DIN
40 050
Shock 10g , 11
ms
Vibrostability

Xpp = ±1
mm
13.2 - 100:
a = ± 0.7 g

Xpp = ±1.6
mm
25 - 100:
a = ±4 g
EMC specification

non-con-
densing
Color Blue (RAL

5015)
Material Fiber-
glass-rein-
forced
polycar-
bonate
E531439/06E 05-09 © MTU

Term Unit Value

restoring
fuses)
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PSM – Purpose and Structure 43
5 PSM – Purpose and Structure
5.1 Power supply modules
Purpose and structure of PSM 3–01

Design
1 Basic module 3
2 Printed circuit board PSM 3–01
Use
• Input filter
• Electrical isolation of output voltages
• Self-restoring fuse
• Outputs 6 x 5 VDC (each 50 mA)
• Outputs 8 x 10 VDC (each 50 mA)
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Terminals
1 Slot 1
2 Slot 2
The primary voltage (supply voltage) is supplied via terminals 101 and 102 (+V) and 103 (ground). The controlled
output voltages are available at terminals 105 to 116 (+5 V voltage) and 201 to 216 (+10 V voltage) .
E531439/06E 05-09 © MTU

5.2 PSM – Technical data
Technical data of PSM 3-01

Term Unit Value
90
Weight kg 0.3
Output current mA ≤ 50 per 5

V output
≤ 50 per
10 V
output
Output voltage VDC 6x5 ±2

%
8x1 ±2
%

2.5 per
terminal
per DIN
40 050
Shock 10g , 11
ms
Vibrostability

Xpp = ±1
mm
13.2 - 100:
a = ± 0.7 g

Xpp = ±1.6
mm
25 - 100:
a = ±4 g
EMC specification

non-con-
densing
E531439/06E 05-09 © MTU

Term Unit Value
Color Blue (RAL

5015)
Material Fiber-
glass-rein-
forced
polycar-
bonate

restoring
fuses)
E531439/06E 05-09 © MTU

5.3 Power supply modules
Purpose and structure of PSM 3-01/A

Design
1 Basic module 3
2 Printed circuit board PSM 3-01/A
Use
• Input filter
• Electrical isolation of output voltages
• Self-restoring fuse
• Outputs +15 VDC and −15 VDC
Terminals
The primary voltage (supply voltage) is supplied via terminals 101 and 102 (+V) and 103 (ground).
The controlled output voltages are available at the terminals 105 and 107 (GND), 201 and 203 (+15
V voltage) and 106, 108, 202, 204 and others (−15 V voltage).
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E531439/06E 05-09 © MTU

5.4 PSM – Technical data
Technical data of PSM 3-01/A

Term Unit Value
90
Weight kg 0.3
Output current mA ≤ 50 per

output
Output voltage VDC 2 x +15 ± 2

%
2 x −15 ± 2
%

2.5 per
terminal
per DIN
40 050
Shock 10g , 11
ms
Vibrostability

Xpp = ±1
mm
13.2 - 100:
a = ± 0.7 g

Xpp = ±1.6
mm
25 - 100:
a = ±4 g
EMC specification

non-con-
densing
Color Blue (RAL

5015)
E531439/06E 05-09 © MTU

Term Unit Value
Material Fiber-
glass-rein-
forced
polycar-
bonate

restoring
fuses)
E531439/06E 05-09 © MTU

5.5 Mechanical installation of PIMs, FIMs, DIMs and PSMs
Mounting variants
Top-hat rail mounting
1 Mounting clip
2 Top-hat rail
3 End clip
Top-hat rail mounting involves automatic grounding by a spring in the mechanism of the PIM.
Screw mounting
1 Mounting screws
2 Mounting clip
Screw mounting involves grounding by means of a separate cable.
E531439/06E 05-09 © MTU

Mounting in a protective housing
The modules may be screw-mounted or mounted on top-hat rails in a protective housing for use in
extreme ambient conditions (degree of protection exceeding IP 20).
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MPU 23 – Purpose and Structure 53
6 MPU 23 – Purpose and Structure
6.1 Printed circuit board MPU 23
Purpose and structure of MPU 23

Design
1 Component side 6 LED (yellow) "Data receive on

2 Conductor side CAN1 or CAN2"
3 Plan view 7 LED (yellow) "Data transmit on
4 LED (green) "Power supply (+5 V)" CAN1 or CAN2"
5 LED (red) "Processor reset/fault" 8 Subprint for 2nd interface
Use
MPU 23 is only used in a PIM 1 (with printed circuit board COB 1) or PIM 2 (with printed circuit board COB 3)
Features
• Single-chip processor (68HC11E1) in HCMOS technology
• Integral Watchdog circuit (program run monitoring)
• 7.5 Kbyte RAM main memory
• 2 x 56 Kbyte FEPROM program and data memory
• 512 Byte EEPROM for dialog parameters
• I2C bus for communication with the serial EEPROM (configuration data)
• 8 interruptible 16-bit timer for PIM real-time processes
• Power consumption less than 100 mA
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• Wide supply voltage range (24 VDC, −50% to +30%)

• Electrical isolation of the power supply by DC/DC converter
• Internal voltage stabilization (5 VDC) for MPU 23 and the PIM printed circuit boards used
• CAN interface as per ISO 11 898, electrically isolated
• Extendable interface (option) by using sub-PCBs
• CAN: by printed circuit board MPU 23 with CCB 1
• RS422: by printed circuit board MPU 23 with SCB 2
• RS232: by printed circuit board MPU 23 with SCB 4
• Electrically isolated interface power supply
• Status indication by LEDs
• Temperature and operating voltage monitoring
Function
MPU 23 has the following tasks:
• Communication of PIM with higher-level systems.
• Process control, data acquisition and processing.
The standard software is stored in the FEPROM of MPU 23.
Application-specific data (e.g. configurations etc.) can also be transferred to the FEPROM via the CAN bus.
Dialog parameters (e.g. limit values etc.) can be stored in the internal EEPROM.
MPU 23 facilitates the control of the printed circuit boards of a PIM and the processing of their data.
The configuration of the PIMs used (e.g. the PIM printed circuit boards used, the baud rate, the field bus
identifier etc.) are stored in a serial EEPROM located on printed circuit board COB 1 or COB 3.
MPU 23 communicates with the serial EEPROM via the I2C bus.
MPU 23 communicates with the user via the CAN interface.
MPU 23 is equipped with one CAN interface (CAN1).
A second interface may be defined as an option by using a subprint inserted on MPU 23.
It is possible to choose between an RS232, RS422 or second CAN interface.
• MPU 23 with CCB 1, additional CAN interface (CAN2).
• MPU 23 with SCB 2, additional RS422 interface.
• MPU 23 with SCB 4, additional RS422 interface.
MPU 23 is available as a spare part with or without the initial program loader:
• MPU 23 with initial program loader (MTU order no. 504 530 87 97 / S0013).
The system and basic software is automatically loaded in the MPU 23 when a PPS
(Programmable Process Station) is available.
If no PPS is available, the software is loaded via the BDM (Backup Data Module).
• MPU 23 without initial program loader (MTU order no. 504 530 87 97).
Downloading realized by programming unit SST 1-01.
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Function of LEDs during download

Red LED indicator functions
LED State Meaning
Red LED Lit Lit after RESET until RAM and ROM test
(5) have been successfully completed.
Red LED Lit (after test) Serious fault encountered during one of
(5) the following tests:
• RAM test
• ROM test
• Overvoltage test
• Undervoltage test
• Overtemperature test
Watchdog tripped.
Red LED Flashing with 1 Hz System awaiting "System Software

(5) Enable" signal.
Requirements for yellow LED indicator functions:
LED State
Red LED (5) Dark
Green LED (4) Lit
Yellow LED indicator functions

Requirement:
"System Software Enable" signal received within the last 5 s.
LED State Meaning
Yellow Lit "System Software Download Response".

LED (6) PDU received.
This state is maintained
• until downloading has been
completed;
• until the next 1 Kblock of data has
been received;
• if no data is received for 5 s.
Yellow Lit CAN bus transmitting

LED (6) • Alive messages;
• System messages;
• System Software Download
Response.
Yellow Flash Flash-EPROM cells are erased or

LEDs programmed.
(6 and 7)
Connection assignment
MPU 23
Relationship between MPU 23 and the terminals of the PIM.
E531439/06E 05-09 © MTU

MPU 23 is always located in slot 1 of the PIM.
Terminal Designation
101/102 Positive supply voltage (+24 VDC)
103/104 Supply voltage ground (GND)
105 Ground of CAN1 controller GND (CAN1)
107/108 CAN1 interface: Negative input CAN1(L)
109/110 CAN1 interface: Positive input CAN1(H)
111-116 Reserved for extension sub-PCBs.
MPU 23 with CCB 1

Relationship between MPU 23 with CCB 1 and the terminals of the I/O module.
MPU 23 with CCB 1 is always located in slot 1 of the I/O module.
The following terminals are additionally assigned on MPU 23 with CCB 1:
115/116 CAN1 interface: Positive input CAN1(H)
MPU 23 with SCB 2

Relationship between MPU 23 with SCB 2 and the terminals of the PIM.
The following terminals are additionally assigned on MPU 23 with SCB 2:
111 RS422 interface: Positive output A2 (TX)
112 RS422 interface: Negative output A2 (TX)
113/114 RS422 interface: Negative input E1 (RX)
115/116 RS422 interface: Positive input E2 (RX)
MPU 23 with SCB 4

Relationship between MPU 23 with SCB 4 and the terminals of the PIM.
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The following terminals are additionally assigned on MPU 23 with SCB 4:
111 RS232 interface: GND
112 RS232 interface: TXD
113/114 RS232 interface: RXD
E531439/06E 05-09 © MTU

6.2 MPU 23 – Technical data

General
Term Unit Value
17
Weight kg 0.050
Input voltage VDC 24, −50 %

to +30 %
Power consumption mA Less than

135 (with
one CAN
interface)
Less
than 185
(with an
additional
CAN
interface)
Power loss mW Less than

1675
Microcontroller Byte 8HC11E1

with
512 EEPROM
and
256 RAM
Memory Kbyte 7.5 RAM

112
FEPROM
Data transmission
Term Unit Value
CAN bus system As per

ISO 11
898
E531439/06E 05-09 © MTU

Term Unit Value
Baud rate kBd 50 to 1
Electrical isolation Yes, with

optocou-
pler
Term Unit Value
Bit serial As per

RS 232
/ RS 422
standard
Baud rate kBd 1.2 to 19.2

optocou-
pler
E531439/06E 05-09 © MTU

6.3 Printed circuit board MPU 27
Purpose and structure of MPU 27

Design
1 Component side 5 LED (yellow) "CAN communication 7 LED (green) "Power supply (+5 V)"
2 Conductor side CAN2" 8 Connector for mounting display
3 Plan view 6 LED (yellow) "CAN communication module FCB 2
4 LED (red) "Processor reset/fault" CAN1"
Use
MPU 27 may only be used in a PIM 5 (with COB 17) or in a PIM 3 (with COB 5)
The following printed circuit boards for signal input/output are not supported by MPU 27:
• Printed circuit board FCB 1
• Printed circuit board INB 1
• Printed circuit board MFB 2
• Printed circuit board MOB 1
MOB 2 may be used with MPU 27 instead of MOB 1.
Features
• Microcontroller C167 CS with 2 integral CAN controllers
• 1M x 16, offering a total of 2 Mbyte FEPROM
• 512K x 16, offering a total of 1 Mbyte RAM
• 5 channel A/D converter to acquire temperatures and supply voltages
• 4 x PWM channels
• 5 x Capture Register (DRZ speed input channels)
E531439/06E 05-09 © MTU

• Integral Watchdog circuit (program run monitoring)

• LED status indicators for operating voltage, reset and CAN communication
• Switched-mode power supply unit for 24 V/5 V-1A
• 2 x DC/DC converter for electrically isolated CAN power supply
• 2 x CAN interfaces as per ISO 11 898, electrically isolated
• Temperature and operating voltage monitoring (24 V/5 V)
Extended functionality available with pluggable LCD display interface (2*16 LCD and
4 keys for operation) (FCB 2 module).
Function
MPU 27 has the following tasks:
• Communication of PIM with higher-level systems.
• Process control, data acquisition and processing.
The standard software is stored in the FEPROM of MPU 27.
Application-specific data (e.g. configurations etc.) can also be transferred to the FEPROM via the CAN bus.
The configuration of the PIMs used (e.g. the PIM printed circuit boards used, the baud rate, the field bus identifier
etc.) are stored in a serial EEPROM located on printed circuit board COB 5 or COB 17.
MPU 27 communicates with the serial EEPROM via the I2C bus.
MPU 27 communicates with the user via the CAN interface.
MPU 27 is equipped with two CAN interfaces (CAN1 and CAN2).
MPU 27 includes an initial program loader.
The system and basic software is automatically loaded in the MPU 27 when a PPS is available.
If no PPS is available, the software is loaded via the BDM (Backup Data Module).
Function of LEDs during download
Red LED indicator functions
LED State Meaning
Red LED Lit/dark The red LED indicates the state of the
(4) processor printed circuit board.
This LED goes out after a
Power-On-RESET.
Red LED Lit Serious fault encountered

(4) (after Power-On-RESET) Watchdog tripped
• Printed circuit board to be replaced.
Red LED Flashing with 1 Hz System awaiting "System Software

(4) Enable" signal.
Requirements for yellow LED indicator functions:
LED State
Red LED (4) Dark
Green LED (7) Lit
E531439/06E 05-09 © MTU

Yellow LED indicator functions
LED State Meaning
Yellow Flash alternately with 4 Hz. Basic software download.

LEDs (5
and 6) Flash synchronously with 4 Hz. Project data download.
Flash irregularly. Data communication on the CAN buses.
An initial program loader program must be installed on the MPU 27 to execute the download feature.
MPU 27
Relationship between MPU 27 and the terminals of the PIM.
101/102 Positive supply voltage (+24 VDC)
103/104 Supply voltage ground (GND)
105 Ground of CAN1 (GND)
106 Shield
109/110 CAN1 interface: Positive input CAN1 (H)
111 Ground of CAN2 (GND)
112 Not used
113/114 CAN2 interface: Negative input CAN2 (L)
115/116 CAN2 interface: Positive input CAN2 (H)
E531439/06E 05-09 © MTU

6.4 MPU 27 – Technical data

General
Term Unit Value
17
Weight kg 0.050
Input voltage VDC 24, −50 %

to +30 %

350
(depend-
ing on
printed
circuit
boards
used)
Power loss mW Approx.

1200
Microcontroller C167 CS
Memory Mbyte 1 RAM

2
FEPROM
Data transmission
Term Unit Value

ISO 11 898
Baud rate kBd 125 to

250000

optocou-
pler.
E531439/06E 05-09 © MTU

E531439/06E 05-09 © MTU

CCB – Purpose and Structure 65
7 CCB – Purpose and Structure
7.1 Printed circuit board CCB 1

Design
1 Component side
2 Conductor side
Use
CCB 1 is only used in MPU 23.
Features
• CAN standard interface extension for MPU 23
• Directly pluggable on MPU 23
• Interface is electrically isolated
Function
CCB 1 is an interface extension for MPU 23.
It realizes a CAN standard interface (ISO 11 898).
Electrically connected to MPU 23 via a plug connector.
CCB 1 converts CAN level signals into TTL level signals.
Signal isolation is realized by optocouplers.
The TTL level signals are required for communication with the single-chip processor on MPU 23.
MPU 23 processes the data and controls the interface drivers.
The interface is connected by the terminal strip of the PIM.
E531439/06E 05-09 © MTU

7.2 CCB 1 – Technical data

General
Term Unit Value
4
Weight kg 0.002
Input voltage VDC +5 (±5 %)

from
MPU 23

50
Connection Spare
slot on
MPU 23
Data transmission
Term Unit Value

ISO 11 898
Baud rate kBd 3.78 to

1000

optocou-
pler
E531439/06E 05-09 © MTU

SCB – Purpose and Structure 67
8 SCB – Purpose and Structure
8.1 Printed circuit board SCB 2

Design
1 Component side
2 Conductor side
Use
SCB 2 is only used in MPU 23.
Features
• RS422 standard interface extension for MPU 23
Function
SCB 2 is an interface extension for MPU 23.
It realizes an RS422 standard interface.
SCB 2 converts RS422 level signals into TTL level signals.
E531439/06E 05-09 © MTU

8.2 SCB 2 – Technical data

General
Term Unit Value
4
Weight kg 0.002

from
MPU 23

50, via
MPU 23
Connection Spare
slot on
MPU 23
Data transmission
Term Unit Value

RS422
standard

19.2

optocou-
pler
E531439/06E 05-09 © MTU


Design
1 Component side 5 LED (green) "Ready" 7 LED (yellow) "Interface 2"

2 Conductor side 6 LED (yellow) "Interface 1" Receiving and transmitting
3 Plan view Receiving and transmitting line active"
4 LED (red) "Printed circuit line active" 8 Connector RS232 interface
board RESET"
Features
• 2 interfaces as per RS422 or RS232 standard
• Interface are electrically isolated
Use
SCB 3 is used as an interface extension (additional serial interfaces), as an interface converter or as an amplifier.
Function
SCB 3 is equipped with two serial transmission channels routed to the terminal strip of the PIM.
E531439/06E 05-09 © MTU

1 Transmission channel 1 2 Connector 3 Module housing with SCB 3
The software of MPU 23 or MPU 27 determines which interface is active on which transmission channel.
Only one interface may be active for any one transmission channel.
• Transmission channel 1
is equipped with a connection for a serial RS422 interface and a serial RS232 interface.
The RS232 interface is connected via the terminals of the PIM or by a connector.
When connected by the connector, the terminals of the RS232 interface are automatically switched off.
• Transmission channel 2
is equipped with a connection for a serial RS422 interface and a serial RS232 interface.
MPU 23 or MPU 27 processes the data and controls the interface drivers.
E531439/06E 05-09 © MTU

Relationship between SCB 3 and the terminals of the PIM.
n01 Channel 1: O1 of RS422 interface
n05 Channel 1: Ground (GND) of RS422 interface
n07 Channel 1: I1 of RS422 interface
n11 Channel 1: TX of RS232 interface
n12 Channel 2: TX of RS232 interface
n15 Channel 1: RX of RS232 interface
n16 Channel 2: RX of RS232 interface
E531439/06E 05-09 © MTU


General
Term Unit Value
15
Weight kg 0.036

from
MPU 23
or MPU 27

100

425
Data transmission
Term Unit Value
Bit serial As per

RS422
standard

19.2
Electrical isolation With opto-

coupler.
Bit serial As per

RS232-
Standard

19.2
Electrical isolation With opto-

coupler.
E531439/06E 05-09 © MTU


Design
1 Component side
2 Conductor side
Use
SCB 4 is only used in MPU 23.
Features
• RS232 standard interface extension for MPU 23
Function
SCB 4 is an interface extension for MPU 23.
It realizes an RS232 standard interface.
SCB 4 converts RS232 level signals into TTL level signals.
E531439/06E 05-09 © MTU


General
Term Unit Value
Dimensions (H x W x D) mm 4 x 10 x 4
Weight kg 0.002

from
MPU 23

50, via
MPU 23
Connection Spare
slot on
MPU 23
Data transmission
Term Unit Value
Bit serial As per

RS422
standard

19.2

optocou-
pler
E531439/06E 05-09 © MTU

COB – Purpose and Structure 75
9 COB – Purpose and Structure
9.1 Printed circuit board COB 1

Design
1 Plan view
2 Terminal strip 1
3 Slot 1 (MPU 23)
4 LED green (+24 V DC OK)
5 Slot for serial EEPROM
6 Slot 2 (PIM printed circuit board)
7 Terminal strip 2
Features
• Establishes the connection between the module periphery and the printed circuit boards of the PIM
• Slots for one MPU 23- and one PIM printed circuit board
• Guard circuits in the power supply input circuit:
• EMC filter
• Guard circuits for CAN and serial interface:
• EMC filter
• Serial EEPROM for PIM module identification and configuration data
• Temperature sensor for terminal temperature
• Light-emitting diode green (supply voltage +24 VDC applied)
Function
COB 1 connects the terminals and the printed circuit boards in the PIM.
COB 1 is equipped with plug connectors for MPU 23 and a PIM printed circuit board.
There are two 2-tier terminal strips on COB 1.
Connections on terminal strip 1:
• PIM power supply
• CAN interface
(Option: 2nd CAN interface, RS232- or RS422 interface)
Connections on terminal strip 2:
• Depending on PIM printed circuit board used
E531439/06E 05-09 © MTU

PIM module configuration data are stored in a serial EEPROM.

The data are read via the I2C bus by the MPU 23 of the PIM.
EMC filters and overvoltage protection circuits safeguard the supply voltage of the printed circuit
boards in the PIM against short circuit and polarity reversal.
LED to indicate external +24 VDC supply voltage.
The bus interfaces for communication with other systems are equipped with EMC filters.
1 PIM printed circuit board 4 when SCB 2 used 7 Fuse

2 Self-restoring 5 when CCB 1 used
3 when SCB 4 used 6 Options
Sensor to monitor terminal temperature.

The sensor signal is evaluated by MPU 23.
COB 1 is supplied as a spare part assembly with PIM 1 (module housing, module cassette and COB 1).
The serial EEPROM on COB 1 is programmed with programming cassette SST 2-01.
E531439/06E 05-09 © MTU

9.2 COB 1 – Technical data
Term Unit Value
36
Weight kg 0.120
Input voltage VDC +24,

−50 % to
+30 %

3
Serial EEPROM Kbit 64 (8k x 8)

restoring
fuse F1,
F2 and
F3).
E531439/06E 05-09 © MTU


Design
1 Plan view 5 Terminal strip 4 9 LED green (+24 V DC OK)

2 Terminal strip 3 6 Terminal strip 2 10 Slot 1 (MPU 23)
3 Slot 3 (PIM printed circuit board) 7 Slot 2 (PIM printed circuit board) 11 Terminal strip 1
4 Slot 4 (PIM printed circuit board) 8 Slot for serial EEPROM
Use
COB 3 electrically connects the terminals and the printed circuit boards in the PIM.
Features
• Connection between the module periphery and the printed circuit boards of the PIM
• Slots for one MPU 23- and three PIM printed circuit boards
• Guard circuits in the power supply input circuit
• EMC filter
• Guard circuits for CAN and serial interface:
• EMC filter
• Serial EEPROM for PIM module identification and configuration data
E531439/06E 05-09 © MTU

Function
COB 3 is equipped with connectors for MPU 23 (slot 1) and max. three PIM printed circuit boards (slots 2 to 4).
There are four 2-tier terminal strips on COB 3.
Terminal strip 1 (terminals 101 to 116) establishes connection of:
• CAN interface power supply
(Option: 2nd CAN interface, RS232- or RS422 interface).
• PIM printed circuit board in slot 2.
PIM module configuration data are stored in a serial EEPROM.
The data are read via the I2C bus by the MPU 23 of the PIM.
1 PIM printed circuit board 4 when SCB 2 used 7 Fuse

2 Self-restoring 5 when SCB 4 used
3 when CCB 1 used 6 Options

E531439/06E 05-09 © MTU

The serial EEPROM on COB 3 is programmed with programming cassette SST 2-01.
E531439/06E 05-09 © MTU

Term Unit Value
36
Weight kg 0.230

−50 % to
+30 %

3
Serial EEPROM Kbit 64 (8k x 8)

restoring
fuse F1,
F2, F3, F4
and F5)
E531439/06E 05-09 © MTU

E531439/06E 05-09 © MTU

PAB – Purpose and Structure 83
10 PAB – Purpose and Structure
10.1 Printed circuit board PAB 2

Design
1 Component side 3 Not equipped

2 Conductor side 4 Plan view
Use
PAB 2 is only intended for use used in a PIM 1 (with COB 1 and MPU 23) or in a PIM 2 (with COB 3 and MPU 23)
Features
Programming adapter for setting the baud rate of the CAN bus and the node address of a PIM
Function
PAB 2 sets the node address and baud rate of the CAN interface of PIM.
Node address and baud rate are programmed with programming cassette SST 2-01 (comprising MPU 23 and PAB 2).
The node address (00 - 31) of the relevant PIM is set with the two rotary switches S1 and S2.
The two rotary switches S4 and S5 are used to select the baud rate at which data are
transmitted to the PIM via the CAN bus.
E531439/06E 05-09 © MTU

As two CAN buses can be connected to one PIM (MPU 23 with CCB 1), switch S4 is used to set the baud rate of the
CAN1 bus (MPU 23, always present) and rotary switch S5 to set the baud rate of the CAN2 bus (CCB 1, option). If one
of the rotary switches (S4 or S5) is set to 0, the baud rate set at the other switch when programming both interfaces.
Adjustable values as baud rates:
S1 Rotary switch node address 1st digit (tens)

S2 Rotary switch node address 2nd digit (ones)
S3 "Programming start" key
S4 Rotary switch baud rate CAN1 interface
S5 Rotary switch baud rate CAN2 interface
Rotary switch setting Baud rate
0 No baud rate, the value set at the other switch is used for both
interfaces
1 50 kilobaud
2 100 kilobaud
3 125 kilobaud
4 160 kilobaud
5 200 kilobaud
6 250 kilobaud
7 400 kilobaud
8 500 kilobaud
9 1000 kilobaud
• Press “Programming start” key

• Set values are used
E531439/06E 05-09 © MTU

PAB – Purpose and Structure 85
10.2 PAB 2 – Technical data
Term Unit Value
14
Weight kg 0.024
Supply voltage VDC +5 (±5 %)

from
MPU 23
Power consumption (5 VDC) mA Less than

10

50
E531439/06E 05-09 © MTU

E531439/06E 05-09 © MTU

FCB – Purpose and Structure 87
11 FCB – Purpose and Structure
11.1 Printed circuit board FCB 1

Design
1 Component side 4 Four-figure 7-segment display 7 Fuses

2 Conductor side 5 LED (yellow) "Relay K2 activated"
3 Plan view 6 LED (yellow) "Relay K1 activated"
Use
FCB 1 can only be used in devices with MPU 23.
Features
• Display of alarms and fault codes
• Output of binary information by transistor output stages
• Independent activation of two positive-switching and two ground switching transistor output stages by MPU 23
• Output current monitoring and short-circuit protection
• Electrical isolation of output stage circuits by optocouplers
• Operating voltage of output stages (+12 VDC - +36 VDC) is supplied separately
(protected by self-restoring fuse F3)
• Output of binary information by relays
• Independent activation of the two relays by MPU 23
• Indication of relay activation by LEDs (yellow)
E531439/06E 05-09 © MTU

• Short-circuit protection for each relay by fuse (F1 and F2)

• High switching capacity (50 W)
• All outputs equipped with EMC protective filter.
Function
FCB 1 is used to display alarms and fault codes and to output binary information.
Alarm display and storage
Alarm messages (fault codes) from a higher-level system are transmitted to MPU 23 via
a serial bus (RS422, RS232 or CAN).
MPU 23 processes and saves the alarm messages.
Alarm messages are displayed on the four-figure 7-segment display on FCB 1.
MPU 23 and FCB 1 communicate via the internal module bus.
Alarms are recorded over a period lasting 12 hours. They are categorized in four chronological groups:
Group Alarms
1 Current alarms
2 Alarms which occurred in the last hour
3 Alarms which occurred in the last 1 to 4 hours
4 Alarms which occurred in the last 4 to 12 hours
The first figure on the 7-segment display indicates the alarm group.
The alarm messages (second to fourth figure on the 7-segment display) in a group are
displayed in ascending order for 3 seconds.
Display is interrupted for 5 seconds when changing groups.
Output of binary information by MOS transistor output stages
The external operating voltage of the output stages is connected to the PIM via
terminals n09 (+UEXT) and n10 (GNDEXT).
It ranges between +12 VDC and +36 VDC and is independent of the operating voltage of the PIMs.
The output stage circuit is protected by a self-restoring fuse F3 (1.1 A) on printed circuit board FCB 1.
Printed circuit board FCB 1 is equipped with two positive-switching and two ground-switching MOS power transistors.
Electrical isolation between the output stages and the control logic is realized by optocouplers.
The MOS power transistors feature the following guard circuits:
allowing direct connection of inductive loads (relays etc.).
• Overcurrent protection
switches off the relevant output stage in case of short-circuit.
E531439/06E 05-09 © MTU

1 (self-restoring, 1.1 A)
2 Module housing with FCB 1
1 (self-restoring, 1.1 A)
2 Module housing with FCB 1
Output of binary information by relays

FCB 1 is equipped with two relays.
The relays are activated by MPU 23.
Relay activation is indicated by LEDs.
Two changeover contacts are provided at the terminals of the PIM. The relay changeover contacts
are connected in parallel to increase switching capacity.
E531439/06E 05-09 © MTU

1 Fuse, 3.15 A
Relationship between FCB 1 and the terminals of the PIM.
n01 Relay K1: NC contact
n02 Relay K1: NO contact
n03 Relay K1: Common connection
n07 Not used
n08 Transistor output 1 (positive-switching)
n09 External switching voltage (+UEXT)
n10 External switching voltage ground (GNDEXT)
n11 Not used
n13 Not used
n14 Not used
n15 Transistor output 3 (ground-switching)
n16 Transistor output 4 (ground-switching)
E531439/06E 05-09 © MTU

11.2 FCB 1 – Technical data

General
Term Unit Value
15
Weight kg 0.040

from
MPU 23

75

400
Display
Term Unit Value
Type 7-seg-
ment
display
(LED).
Binary outputs (relays)
Term Unit Value
Switching capacity per relay W Max. 50
Switching voltage VDC Max. 36
Switching current A Max. 2 (at

24 VDC)
Short-circuit protection A Fuse

(3.15) per
relay.
E531439/06E 05-09 © MTU

Term Unit Value
Relay switching time ms Max. 10
Relay actuation cycle Max. 20

times per
second.
Transistor outputs (MOS transistors)
Term Unit Value
Externe operating voltage VDC +12 - +36

(+UEXT))
Switching current per output mA Max. 250
Short-circuit protection A Self-

restoring
fuse (1.1)
Electronic
monitoring
with cutoff.
Electrical isolation Yes,

between
output
stage
circuit and
control
logic.
E531439/06E 05-09 © MTU

12 COB – Purpose and Structure

Design
1 Plan view
2 Terminal strip 1
3 Rotary switch, baud rate for both CAN interfaces
4 Rotary switch, node no. (Tens)
5 Rotary switch, node no. (Ones)
6 Terminal strip 2
7 Slot 2 (PIM printed circuit board)
8 Soldered serial EEPROM
9 LED green (+24 V DC OK)
10 Slot 1 (MPU 27)
Features
• Establishes the connection between the module periphery and the printed circuit boards of the PIM
• Slots for one MPU 27- and one PIM printed circuit board
• Guard circuits in the power supply input circuit:
• EMC filter
• EMC guard circuits for CAN interfaces
• Soldered serial EEPROM (128K x 8) for PIM module identification and configuration data
• Rotary switch for CAN node setting
• Rotary switch for baud rate setting (for both CAN interfaces)
Function
COB 17 connects the terminals and the printed circuit boards in the PIM.
COB 17 is equipped with connectors for MPU 27 (slot 1) and one PIM printed circuit board (slots 2).
There are two 2-tier terminal strips on COB 17.
Connections on terminal strip 1 (terminals 101 to 116):
• CAN interface
E531439/06E 05-09 © MTU

Connections on terminal strip 2 (terminals 201 to 216):

• Depending on PIM printed circuit board used
The module configuration data of the PIM (node address setting and baud rate at the rotary
switches) are read via the I2C bus by the MPU 27 of the PIM.
These data are subsequently written in the serial EEPROM of the motherboard (COB) by the MPU 27.
1 PIM printed circuit board 2 Self-restoring 3 Fuse
Rotary switches
PIM module identification data are set with the rotary switches on COB 17.
E531439/06E 05-09 © MTU

Node number
S1 Baud rate setting switch

S2 Node setting switch, tens
S3 Node setting switch, ones
The node setting is made as follows (node number "12" is set below by way of example):
• Set the tens of the node with switch S2 (for the example "12" to 1).
• Set the ones of the node with switch S3 (for the example "12" to 2).
Baud rate (transmission rate) of the two CAN interfaces
The baud rate is set to the following values at switch S1:
• Pos. 0: 1 MBaud
• Pos. 1: 500 kBaud
The setting defines the baud rate of both buses (CAN1 and CAN2).
Different settings for the two buses are not possible.
E531439/06E 05-09 © MTU

Term Unit Value
36
Weight kg 0.120

−50 % to
+30 %

3
Serial EEPROM K 128 x 8

restoring
fuse F1)
E531439/06E 05-09 © MTU

Term Unit Value
Dimensions (H x W x D) mm 84 x 135 x 36
Weight kg 0.230

−50 % to
+30 %

3
Serial EEPROM K 128 x 8

restoring
fuse F1,
F2, F3, F4
and F5)
E531439/06E 05-09 © MTU

E531439/06E 05-09 © MTU

13 FCB – Purpose and Structure
13.1 Display module FCB 2

Design
1 View in housing
2 Display
3 ENTER key
4 Up key
5 Down key
6 ESC key
Use
FCB 2 is only mounted on PIM cassettes with MPU 27.
Function
The LCD module comprises a two-line (2 x 16 figure) illuminated LCD display and 4 keys.
The display shows system information, parameters, data etc.
FCB 2 is supplied as a separate module or together with a PIM 5 or a PIM 3.
Versatile use with the following variants:
• PIM cassette with MPU 27 is used with display module
• PIM cassette with MPU 27 is used without display module (e.g. poor accessibility to terminal box)
• The display module is temporarily mounted for servicing (e.g. during initial startup).
Scrolling through the main menu is possible with the Up/Down keys (4 and 5).
The desired menu is then selected with the ENTER key (3). Scrolling in a sub-menu is
possible with the Up/Down keys (4 and 5).
On the "Password page" the ENTER key (3) selects the point and the Up/Down keys (4 and 5) select the characters.
Pressing the ESC key moves back.
E531439/06E 05-09 © MTU

13.2 FCB 2 – Technical data
Term Unit Value
24
Weight kg 0.035

from
MPU 27
Power consumption mA Approx.

35
Power loss mW Approx.

175
E531439/06E 05-09 © MTU

AIB – Purpose and Structure 101
14 AIB – Purpose and Structure
14.1 Printed circuit board AIB 1

Design
1 Component side 3 Plan view 5 LED (red) "Printed circuit

2 Conductor side 4 LED (green) “Power supply” (±12 V) board RESET"
Use
Printed circuit board AIB 1 is used to acquire resistance, current and voltage signals.
Features
• Four independent analog channels.
• Each analog channel is suitable for acquiring resistance, voltage and current signals.
• Software-configuration of analog channels.
• Automatic calibration of measuring amplifier and A/D converter.
• High resolution with 12-bit A/D converter.
• Internal reference voltage sources.
• All inputs equipped with EMC protective filter.
• LED status indication (not on AIB1-01)
E531439/06E 05-09 © MTU

Function
The various input signals are connected according to defined connection diagrams.
Configuration of the signal types connected to the various analog channels is realized by the software.
An analog channel has four input terminals with the following functions:
• The internal 10 VDC reference voltage is tapped at terminal A for resistance measuring
(e.g. for Pt100 resistance thermometer). The reference voltage (or reference current) is only
connected when channels are appropriately configured.
• Terminals B and C may be considered as differential voltage inputs of an operation
amplifier. A differential filter between the terminals offers optimum interference voltage
suppression and offers EMC protection at the same time.
• A reference potential (ground) is provided via terminal D . A resistor required for current measuring
(4 mA 0 20 mA) is connected between terminal D and PIM ground.
The input signals of the four analog channels are selected by a multiplexer and supplied to a measuring amplifier.
Measuring amplifier gain-time is controlled automatically by the measuring amplifier.
It depends on the configured signal source of the analog channel concerned.
A 12-bit A/D converter converts the amplified analog input signal into a data word for
digital processing by MPU 23 or MPU 27.
Relationship between AIB 1 and the terminals of the PIM.
The variable n in terminal designations stands for the slot used in the PIM.
Terminal Abbreviation Designation
n01 A Reference voltage Uref1 *)
n02 B Differential voltage input (−)
n03 C Differential voltage input (+)
n04 D Ground
n08 D Ground
n09 A Reference voltage input Uref3 *)
n12 D Ground
n16 D Ground
*) Depending on channel configuration.
E531439/06E 05-09 © MTU

Connection examples
1 Channel 1
2 Channel 2
3 Channel 3
4 Channel 4
5 Terminal strip for one PIM printed circuit board
Terminal assignment of printed circuit board AIB 1, the variable n depends on the slot used.
Connection of a 4-wire sensor, e.g.: Pt100, Ni100.
E531439/06E 05-09 © MTU

Connection of a 2-wire sensor, e.g.: Pt1000, Ni1000.
Connection of a NiCr-Ni sensor.
E531439/06E 05-09 © MTU

Connection of a current source.
Connection of a DC voltage source.
Connection of a potentiometer.
* This resistor (221 kΩ) is used for cable damage monitoring (faulty slider or cable connection disrupted).
E531439/06E 05-09 © MTU

14.2 AIB 1 – Technical data

General
Term Unit Value
15
Weight kg 0.030
Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

110

50

550
Electrical isolation Yes, to

module
bus
Common-mode voltage at inputs B and C VDC Less than

10 (to
ground).
Analog input temperature sensor
Term Unit Value
Sensor power supply Internal,

short-
circuit-
proof
Sensor current mA Approx.

1.2
Sensor connection 2 or 4-wire

possible
Sensor monitoring Short

circuit and
disruption
Measuring ranges
Ni100 °C −60 - +180
E531439/06E 05-09 © MTU

Term Unit Value
Pt100 °C −200 -
+850
Ni1000 °C −60 - +180
Pt1000 °C −200 -
+850
Input filter Hz fg = 22
(RC
low-pass)
with
6 dB/decade
Measuring error K ±1.2

(without
sensor)
< 1 % over
the entire
measuring
range.
Analog input current source
Term Unit Value
Sensor power supply; VDC 16.8 - 32,

Note on ground distribution. external,
module
ground
terminal
103 or
104 nec-
essary.
Sensor monitoring
Signal: 4 mA - 20 mA mA Sensor
fault at
/ < 2 and
/ > 22
(config-
urable)
fault at /
> 22 (con-
figurable)
Measuring range mA 0 - +25
(RC
low-pass)
with
6 dB/decade
Resolution Bit Internal 12
E531439/06E 05-09 © MTU

Term Unit Value
Measuring error % Less

than 0.5
absolute
(without
sensor).
Sampling rate Hz fa > 20
Compliance voltage VDC Less than

4
Input resistance Ω 50
Analog input voltage source
Term Unit Value
Measuring range VDC -0.25 -

+10.25
(RC
low-pass)
with
6 dB/decade
Input resistance kΩ Greater

than 50
Resolution Bit 12 internal

than 0.5
absolute
(without
sensor).
Analog input potentiometer
Term Unit Value
Power supply VDC 10,

±0.5 %,
internal
Measuring current mA Max. 10,

short-
circuit-
proof
Source resistance kΩ 1 ≤ R ≤ 10
Measuring range− VDC -0.25 -

+10.25
Sensor monitoring Short

circuit and
disruption.
E531439/06E 05-09 © MTU

Term Unit Value
(RC
low-pass)
with
6 dB/decade

than 50

than 0.5
absolute
(without
sensor).
Analog input thermocouple
Term Unit Value
Measuring range mV −5 - +50
Sensor monitoring Disruption
(RC
low-pass)
with
6 dB/decade

than 50

than 0.5
absolute
(without
sensor).
Terminal temperature compensation Yes with

tempera-
ture sen-
sor.
E531439/06E 05-09 © MTU


Design
1 Component side 3 Plan view 5 LED (yellow) "Output 2 active"

2 Conductor side 4 LED (yellow) "Output 1 active"
Features
• Two independent electrically-interconnected analog input channels respectively for the acquisition of:
• One voltage signal (0 VDC to +10 VDC) or
• One current signal from 4 mA to 20 mA (two-wire connection)
• Two independent analog output channels respectively for the output of:
• One voltage signal (0 VDC to +10 VDC) or
• One current signal from 4 mA to 20 mA (two-wire connection)
• Software-configuration of analog channels
• Electrically isolated inputs/outputs
• All inputs/outputs equipped with EMC protective filter.
Function
AIB 2 acquires and outputs current and voltage signals. Configuration of the signal type connected to
an analog channel is realized by the software and appropriate circuitry.
Input channels
Two analog input channels acquire current and voltage signals. Each input channel acquires voltage or current signals
E531439/06E 05-09 © MTU

1 Module housing with AIB 2

2 Input signal 1

2 Input signal 1
The input signals are filtered and digitalized by a 12-bit A/D converter. The input circuit is
electrically isolated from the electronics by optocouplers.
Data are processed and evaluated by MPU 23 or MPU 27.
Both input channels are referenced to the same ground, i.e. terminals n02 and n06 are connected internally.
Output channels
Two analog output channels output current and voltage signals. Each output channel outputs voltage or
current signals. Mixed operation (current output and voltage output) is not possible.
Operational availability of output channels 1 and 2 is indicated by two LEDs.
E531439/06E 05-09 © MTU

1 Output signal 1
1 Output signal 1
The operating voltage of the external voltage (+ UEXT) must be filtered by filter module FIM 1 before supply.
E531439/06E 05-09 © MTU

n01 Input channel 1: Positive input voltage (0 VDC - 10 VDC)
n02 Input channel 1: Ground (GND), internally connected to n06
n03 Input channel 1: Current input (4 mA - 20 mA)
n05 Input channel 2: Positive input voltage (0 VDC - 10 VDC)
n06 Input channel 2: Ground (GND), internally connected to n02
n07 Not used
n08 Not used
n09 Output channel 1: Positive output voltage (0 VDC - 10 VDC)
n10 Output channel 1: Current output (4 mA - 20 mA)
n11 Output channel 1: Positive external supply voltage (+ UEXT) via filter module
FIM 1
n12 Output channel 1: External supply voltage ground (GNDEXT )
n13 Output channel 2: Positive output voltage (0 VDC - 10 VDC)
n14 Output channel 2: Current output (4 - 20 mA)
n15 Output channel 2: Positive external supply voltage (+ UEXT) via filter module
FIM 1
n16 Output channel 2: External supply voltage ground (GNDEXT )
E531439/06E 05-09 © MTU


General
Term Unit Value
15
Weight kg 0.030

from
MPU 23
or MPU 27
Power consumption (5 VDC) A Less than

80

400
Input channels
Term Unit Value
(RC
low-pass)
with
6 dB/decade

than 0.5
absolute
(without
sensor)

between
electron-
ics and
outputs,
no,
between
inputs
channel
1 and
channel 2.
Analog input current signal
Signal monitoring
E531439/06E 05-09 © MTU

Term Unit Value
Signal: 4 mA 0 20 mA mA Sensor
fault at
/ < 2 and
/ > 22 (con-
figurable)
Signal: 0 mA 0 20 mA mA Sensor
fault at /
> 22 (con-
figurable)

4
Input resistance Ω Approx.

120
Analog input voltage signal
Measuring current mA Less than

1
Measuring range VDC 0 - +10.25

than 25
Output channels
Term Unit Value
Analog output current signal
Power supply VDC 7.5 - 32,

external,
Compliance voltage VDC 7.5
Output current of current source mA 4 - 20
Resolution Bit 12

than 0.5
absolute
Electrical isolation Yes
Analog output voltage signal
Power supply VDC 16.8 - 32,

external,

15
Output voltage VDC 0 - 10
E531439/06E 05-09 © MTU

Term Unit Value
Output current of voltage source mA Less than

10
Resolution Bit 12

than 0.5
absolute
Electrical isolation Yes
E531439/06E 05-09 © MTU


Design
1 Component side 6 LED (red) "Printed circuit

2 Conductor side board RESET"
3 Plan view 7 LED (green) "Operation"
4 LED (yellow) "Spare" 8 LED (green) "Power supply (+15 V)"
5 LED (yellow) "Spare" 9 LED (green) "Power supply (−15 V)"
Features
• 8 analog channels for the acquisition of current signals
• Automatic calibration of measuring amplifiers and A/D converter
• High resolution with 12-bit A/D converter
• Internal reference voltage sources
E531439/06E 05-09 © MTU

Function
1 Analog channel 1
AIB 3 acquires max. eight current signals (4 mA - 20 mA).
Function is described for one analog channel. All other analog channels are identical in structure.
Each analog channel is equipped with an input for the acquisition of the current signal and a voltage
output for sensor supply (the output voltage depends on the supply voltage of the corresponding PIM).
The output voltage is protected by one fuse for each analog channel.
The current signal is selected by a multiplexer and subsequently amplified.
A 12-bit-A/D converter digitalizes the current signal. Data are processed and evaluated by MPU 23 or MPU 27.
E531439/06E 05-09 © MTU

n01 Analog channel 1: Output voltage 1 (+24 VDC)
n02 Analog channel 1: Current input 1
E531439/06E 05-09 © MTU


General
15
Weight kg 0.030

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB
Power consumption (5 VDC) mA < 50
Power consumption (24 VDC) mA < 200
Power loss mW < 660
Analog channel

internal
(−50 %
to +30 %,
depending
on the
supply
voltage of
the PIM)
Signal monitoring
fault at
/ < 2 and
/ > 22
(config-
urable)
fault at /
> 22 (con-
figurable)
(RC
low-pass)
with
6 dB/decade
Resolution 12 bit
E531439/06E 05-09 © MTU

Measuring error % < 0.5

absolute
Compliance voltage VDC <4

80
Overcurrent limitation mA Approx.

50 - 70
E531439/06E 05-09 © MTU


Design
1 Component side 4 LED (red) "Printed circuit

2 Conductor side board RESET"
3 Plan view
Features
• Four independent electrically isolated analog channels to acquire current signals
(4 mA - 20 mA, two-wire connection)
• Overcurrent protection for analog channels
• All inputs and outputs equipped with EMC protective filter.
• Provision of +24 VDC for power supply of current sources
• Fault indication by LED
Function
AIB 4 acquires current signals ranging between 4 mA - 20 mA. The four input channels are
electrically isolated from each other and from the electronics.
Each input channel is equipped with:
• Overcurrent protection circuit
• EMC protection filter
Input signals digitalized by a 12-bit-A/D converter.
E531439/06E 05-09 © MTU

Data are processed and evaluated by MPU 23 or MPU 27.

Failure of one or more A/D converters leads to a fault message (summary alarm), indicated by red LED on AIB 4.
Operation of current sources with external or with the internal power supply possible due to
electrical isolation of the four analog channels.

2 Input signal 1
Two outputs are provided for use of the internal power supply of AIB 4.
Each output is protected by a self-restoring fuse (200 mA) and is equipped with an EMC filter.

2 Input signal 1
However, both outputs may only be loaded with a total current of max. 250 mA. The
current is otherwise limited by the COB.
E531439/06E 05-09 © MTU

n02 Input channel 1: Ground of input channel 1
n05 Not used
n06 Not used
n11 Not used
n12 Not used
n13 Positive output voltage (+24 VDC)
n14 Output voltage ground (GND)
n15 Positive output voltage (+24 VDC)
n16 Output voltage ground (GND)
E531439/06E 05-09 © MTU


General
Term Unit Value
15
Weight kg 0.034

from
MPU 23
or MPU 27
Power consumption (5 VDC) A Less than

80

400
Input channels
Term Unit Value

between
electron-
ics and
outputs,
Yes,
between
the inputs
of a
channel.

120

4
(RC
low-pass)
with
6 dB/decade
A/D converter
Resolution Bit 12

than 0.5
absolute
(without
sensor)
E531439/06E 05-09 © MTU

Term Unit Value
Signal monitoring
fault at
/ < 2 and
/ > 22
(config-
urable)
fault at /
> 22 (con-
figurable)

internal
(−50 % to
+30 %,
depending
on the
supply
voltage of
the PIM).
Power consumption mA Max. 250

for both
channels
together.
E531439/06E 05-09 © MTU

BIB – Purpose and Structure 127
15 BIB – Purpose and Structure
15.1 Printed circuit board BIB 1

Design
1 Component side 8 LED (yellow) "Channel 3 active" 14 LED (yellow) "Channel 6 active"
2 Conductor side 9 LED (red) "Cabling damage 15 LED (red) "Cabling damage
3 Plan view channel 3" channel 6"
4 LED (yellow) "Channel 1 active" 10 LED (yellow) "Channel 4 active" 16 LED (yellow) "Channel 7 active"
5 LED (red) "Cabling damage 11 LED (red) "Cabling damage 17 LED (red) "Cabling damage
channel 1" channel 4" channel 7"
Features
• 8 electrically isolated binary channels in two-wire technology
• Status indication of binary channels by LEDs (yellow)
• Cable damage monitoring of binary channel connecting lines
• Indication cabling damage by LEDs (red)
• Wide input voltage range (36 VDC) of binary channels
• Constant input current (approx. 4 mA) in the input voltage range between 8 VDC and 36 VDC
• RF filter, reverse-battery protection
E531439/06E 05-09 © MTU

Function
Function of BIB 1 is described for one binary channel. All other binary channels are identical in structure.
Each binary channel is equipped with two inputs (two-wire technology) and is activated by an external voltage.
The optocoupler on BIB 1 is activated when the switch is closed. The current which then flows is
limited to approx. 4 mA regardless of the external switching voltage used.
1 (cable damage monitoring)

2 Module housing with BIB 1
3 Binary channel 1
The admissible input voltage range of the binary channel is 36 VDC.
The following applies to the input voltage (Ui) of the binary channel:
• Ui ≥ 8 VDC is interpreted as binary channel activated (logic "1").
• Ui ≤ 4 VDC is interpreted as binary channel deactivated (logic "0").
• 4 VDC v Ui ≤ 8 VDC must be avoided (inadmissible range).
The input signal of the corresponding binary channel is electrically isolated by an optocoupler. The
channel is sampled cyclically by MPU 23 or MPU 27. Each binary channel is assigned an LED (yellow).
The relevant LED lights up when a binary channel is activated (logic "1").
A resistor (33 kΩ) is connected in parallel to the switching contact for cable damage monitoring. The
quiescent current which thus flows is evaluated by a separate optocoupler and sampled cyclically
by MPU 23 or MPU 27. Each binary channel is assigned an LED (red). The relevant LED (red) of
the affected binary channel flashes in case of cabling damage.
E531439/06E 05-09 © MTU

n01 Binary channel 1: Positive binary input
n02 Binary channel 1: Negative binary input
E531439/06E 05-09 © MTU

15.2 BIB 1 – Technical data

General
Term Unit Value
15
Weight kg 0.026

from
MPU 23
or MPU 27

30

150
Binary inputs
Term Unit Value
Input voltage range VDC Less than

36
Input voltage for logic "1" VDC Min. 8
Input voltage for logic "0" VDC Max. 4
Input current for logic "1" mA Approx. 4
Input current for logic "0" mA Max. 1

(for cable
damage
monitor-
ing)
Sensor connection Two-pole

optocou-
pler
Input filter Low-pass

(RC) with
6 dB/decade
Sampling cycle of binary inputs ms Approx.

50
Cable length for sensor connection m Max. 5

(unshielded)
twisted.
Max. 50
(shielded)
twisted.
E531439/06E 05-09 © MTU

15.3 Printed circuit board BIB 2

Design
1 Component side 8 LED (yellow) "Channel 3 active" 14 LED (yellow) "Channel 6 active"
2 Conductor side 9 LED (red) "Cabling damage 15 LED (red) "Cabling damage
3 Plan view channel 3" channel 6"
Features
• 8 electrically isolated binary channels
• Cable damage monitoring of binary channel connecting lines
• Indication of cabling damage by LEDs (red)
• Constant input current (approx. 4 mA) in the input voltage range between 8 VDC and 36 VDC
• Failure of +24 VDC (switching voltage) indicated by LED.
Function
Function of BIB 2 is described for one binary channel. All other binary channels are identical in structure.
E531439/06E 05-09 © MTU

Each binary channel is equipped with a binary input and a voltage output (+24 VDC). The switching voltage
(+24 VDC) is provided by the PIM and is protected by the fuse on the COB.
All red LEDs light up in case of switching voltage failure. All binary inputs are electrically isolated by optocouplers.
1 (cable damage monitoring)

2 Module housing with BIB 2
3 Binary channel 1
An optocoupler on BIB 2 is activated when the switching voltage (24 VDC) is applied to the binary
input. The current which then flows is limited to approx. 4 mA.
The following applies to the switching voltage:
• 4 VDC v Ui ≤ 8 VDC must be avoided (inadmissible range).
channel is sampled cyclically by MPU 23 or MPU 27. Each binary channel is assigned an LED (yellow).
The relevant LED lights up when a binary channel is activated (logic "1").
A resistor (33 kΩ) is connected in parallel to the switching contact for cable damage monitoring. The quiescent
current which thus flows is evaluated by a separate optocoupler. Each binary channel is assigned an LED
(red). The relevant LED (red) of the affected binary input flashes in case of cabling damage.
E531439/06E 05-09 © MTU

n01 Binary channel 1: Switching voltage (+24 VDC)
n02 Binary channel 1: Binary input 1
E531439/06E 05-09 © MTU

15.4 BIB 2 – Technical data

General
Term Unit Value
15
Weight kg 0.026

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

30

32

280
Binary inputs
Term Unit Value
Input voltage range VDC Max. 36

optocou-
pler.

(RC) with
6 dB/decade
E531439/06E 05-09 © MTU

Term Unit Value

50

(unshielded)
twisted.
Max. 50
(shielded)
twisted.
E531439/06E 05-09 © MTU

E531439/06E 05-09 © MTU

BOB – Purpose and Structure 137
16 BOB – Purpose and Structure
16.1 Printed circuit board BOB 1

Design
1 Component side 5 LED (yellow) "Relay K2 activated" 8 LED (red) "Printed circuit
2 Conductor side 6 LED (yellow) "Relay K3 activated" board RESET"
3 Plan view 7 LED (yellow) "Relay K4 activated" 9 Fuses
4 LED (yellow) "Relay K1 activated"
Features
• Output of binary information by relays
• Separate activation of the four relays by MPU 23 or MPU 27.
• Four free changeover contacts with overvoltage protection circuit, on changeover contact
(K4) designed as double contact (K4.1 and K4.2)
• Indication of relay activation by LEDs (yellow)
• Short-circuit protection for each relay by fuse
• Monitoring of relay switching states and fault indication by LED (red)
• Cable damage monitoring and fault indication by LED (red) (BOB 1-02 only, no function on BOB 1-02/A)
• High switching capacity (50 W)
Function
BOB 1 is equipped with four relays (K1, K2, K3 and K4) to output binary information.
E531439/06E 05-09 © MTU

The relays are activated by MPU 23 or MPU 27. Relay activation is indicated by LEDs (yellow).
Five changeover contacts are available to the user at the terminals of the PIM:
• Relay K1: One changeover contact with cable damage monitoring for NC and NO contacts
• Relay K4: One changeover contact with cable damage monitoring for NC and NO contacts (K4.1)
One changeover contact without cable damage monitoring (K4.2)
The changeover contacts of relays K1 to K3 are connected in parallel to reduce contact loading.
1 Fuse
Relays K1, K2, K3 and K4.1 are equipped with double cable damage monitoring for NC and NO
contacts. Monitoring is realized by loading the external switching voltage with a constant current (typ.
0.5 mA). The monitoring current also flows when the contact is open.
A fault message is generated (LED Fault lights up red, not on BOB 1-02/A) if the control signal differs
from the switching state of the relay contacts, or if no monitoring current flows.
1 Fuse
The connections of both changeover contacts are routed out on relay K4. Switching state and cable damage
monitoring (not on BOB 1-02/A) is only realized at changeover contact K4.1 (terminals n13, n12 and n11).
E531439/06E 05-09 © MTU

Relationship between BOB 1 and the terminals of the PIM.
n10 Not used
n11 Relay K4: NC contact 1
n12 Relay K4: NO contact 1
n13 Relay K4: Common connection 1
n14 Relay K4: Common connection 2
n15 Relay K4: NO contact 2 (unmonitored)
n16 Relay K4: NC contact 2 (unmonitored)
E531439/06E 05-09 © MTU

16.2 BOB 1 – Technical data

General
Term Unit Value
15
Weight kg 0.042

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

25

50

925
Binary outputs
Term Unit Value
Switching capacity per relay W Max. 50
Switching voltage (external) VDC Max. 36
Switching current A Max. 2 (at

24 VDC)
Current for monitoring mA Max. 1

(per relay)
Short-circuit protection A Fuse

(3.15)
Relay switching time ms Max. 10
Relay actuation cycle /s Max. 20
E531439/06E 05-09 © MTU


Design
1 Component side 9 LED (yellow) "Transistor output 15 LED (yellow) "Transistor output
2 Conductor side 6 activated" 12 activated"
3 Plan view 10 LED (yellow) "Transistor output 16 LED (yellow) "Transistor output
4 LED (yellow) "Transistor output 7 activated" 13 activated"
1 activated" 11 LED (yellow) "Transistor output 17 LED (yellow) "Transistor output
2 activated" 12 LED (yellow) "Transistor output 18 LED (green) "Power supply (+24 V)"
6 LED (yellow) "Transistor output 9 activated" 19 Fuses
3 activated" 13 LED (yellow) "Transistor output
7 LED (yellow) "Transistor output 10 activated"
5 activated"
Features
• Separate activation of 14 transistor output stages (positive switching) by MPU 23 or MPU 27
• Indication of transistor switching states by LEDs (yellow)
• Output current monitoring and limitation
• Electrical isolation of output stage circuit by optocoupler
• Operating voltage of output stages (+12 - +36 VDC) supplied separately.
E531439/06E 05-09 © MTU

Function
BOB 2 is equipped with 14 identical MOS transistor output stages (positive switching) to output binary information.
The external operating voltage of the output stages is connected to the PIM via terminals n15 (+UEXT) and n16
(GNDEXT). It ranges between +12 VDC and +36 VDC independently of the operating voltage of the PIMs.
The output stage circuit is protected by a fuse (3.15 A).
MOS power transistors are used as output stages. Electrical isolation between the output
stages and the control logic is realized by optocouplers.
1 Fuse 3.15 A
2 Module housing with BOB 2
The MOS power transistors feature the following guard circuits:
allowing direct connection of inductive loads (e.g. relays etc.).
Switching states of output stage transistors are indicated by LEDs (yellow).
E531439/06E 05-09 © MTU

n15 Positive external operating voltage (+UEXT)
n16 Negative external operating voltage (GNDEXT)
E531439/06E 05-09 © MTU


General
Term Unit Value
15
Weight kg 0.030

from
MPU 23
or MPU 27

10

50
Transistor outputs
Term Unit Value
External operating voltage (+UEXT) VDC +12 - +36
Short-circuit protection (+UEXT) A Fuse

(3.15)
Switching current mA Per

output:
Max. 250
Total:
Max. 3 A.
Short-circuit protection Electronic

monitor-
ing.

between
output
stage
circuit and
control
logic.
E531439/06E 05-09 © MTU


Design
1 Component side 9 LED (yellow) "Transistor output 15 LED (yellow) "Transistor output
2 Conductor side 6 activated" 12 activated"
3 Plan view 10 LED (yellow) "Transistor output 16 LED (yellow) "Transistor output
1 activated" 11 LED (yellow) "Transistor output 17 LED (yellow) "Transistor output
2 activated" 12 LED (yellow) "Transistor output 18 LED (green) "Power supply (+24 V)"
6 LED (yellow) "Transistor output 9 activated" 19 Fuse
5 activated"
Features
• Separate activation of 14 transistor output stages (ground switching) by MPU 23 or MPU 27
• Indication of transistor switching states by LEDs (yellow)
• Electrical isolation of output stage circuit by optocoupler
• Operating voltage of output stages supplied separately.
• Monitoring of external operating voltage
E531439/06E 05-09 © MTU

Function
BOB 3 is equipped with 14 identical MOS transistor output stages (ground switching) to output binary information.
The external operating voltage of the output stages is connected to the PIM via terminals n15 (+UEXT) and n16
(GNDEXT). It ranges between +12 VDC and +36 VDC independently of the operating voltage of the PIMs.
The output stage circuit is protected by a fuse (3.15 A) on BOB 2.
MOS transistors are used as output stages. Electrical isolation between the output stages
and the control logic is realized by optocouplers.
1 Fuse (3.15 A)
2 Module housing with BOB 3
The MOS transistors feature the following guard circuits:
allowing direct connection of inductive loads (e.g. relays etc.).
Switch-off is saved and must be reset by the software.
Switching states of output stage transistors are indicated by LEDs (yellow).
E531439/06E 05-09 © MTU

n01 Transistor output 1: Ground switching
n15 Positive external operating voltage (+UEXT)
n16 Negative external operating voltage (GNDEXT)
E531439/06E 05-09 © MTU


General
Term Unit Value
15
Weight kg 0.030

from
MPU 23
or MPU 27

10

50
Transistor outputs
Term Unit Value
External operating voltage (+UEXT) VDC +12 - +36
Short-circuit protection (+UEXT) A Fuse

(3.15)
Switching current mA Per

output:
Max. 250
Total:
Max. 3 A.
Short-circuit protection Electronic

monitoring

between
output
stage
circuit and
control
logic.
E531439/06E 05-09 © MTU

EGB – Purpose and Structure 149
17 EGB – Purpose and Structure
17.1 Printed circuit board EGB 1

Design
1 Component side 6 LED (green) "Operation"

2 Conductor side 7 LED (red) "Printed circuit
3 Plan view board RESET"
4 LED (yellow) "Spare" 8 LED (green) "Power supply (+12 V)"
5 LED (yellow) "Spare" 9 LED (green) "Power supply (−12 V)"
Features
• 8 analog channels for the acquisition of voltage signals (0 mV - 40 mV)
• Automatic calibration of measuring amplifier and A/D converter
• Internal reference voltage sources
• Terminal compensation for NiCr-Ni temperature sensors (integrated on COB)
Function
EGB 1 acquires max. eight voltage signals ranging between 0 mV - 40 mV. The use of differential inputs
makes the analog channels suitable for measuring the signals from NiCr-Ni thermocouples.
E531439/06E 05-09 © MTU

Function is described for one analog channel. All other analog channels are identical in structure.
Each analog channel features a differential voltage input. A differential filter in the input circuit offers optimum
interference voltage suppression and offers EMC protection at the same time.
1 Analog channel 1
2 Module housing with EGB 1
3 NiCr-Ni sensor
The voltage signal is selected by a multiplexer and subsequently amplified. A 12-bit-A/D converter
digitalizes the voltage signal. Data are processed and evaluated by MPU 23 or MPU 27.
Temperature compensation is performed by the software.
E531439/06E 05-09 © MTU

EGB – Purpose and Structure 151
Relationship between EGB 1 and the terminals of the PIM.
n01 Analog channel 1: Differential voltage input (+)
n02 Analog channel 1: Differential voltage input (−)
E531439/06E 05-09 © MTU

17.2 EGB 1 – Technical data

General
Term Unit Value
15
Weight kg 0.030

from
MPU 23
or MPU 27

80

420
Analog channel
Term Unit Value
Measuring range mV 0 - +40
(RC
low-pass)
with
6 dB/decade
Resolution Bit 12

than 0.5
absolute
(without
sensor)
Terminal temperature compensation Yes, by

software
(absolute
tempera-
ture acqui-
sition on
printed cir-
cuit board
COB)

than 50
E531439/06E 05-09 © MTU

IIB – Purpose and Structure 153
18 IIB – Purpose and Structure
18.1 Printed circuit board IIB 1

Design
1 Component side 6 LED (yellow) "Binary channel 9 LED (yellow) "Binary channel
2 Conductor side 4 active" 1 active"
3 Plan view 7 LED (yellow) "Binary channel
4 LED (green) "Ready" 3 active"
5 LED (red) "Printed circuit 8 LED (yellow) "Binary channel
board RESET" 2 active"
Features
• Instrument outputs
• 4 analog voltage outputs for instrument control
• Output voltage ranging between 0 VDC - +10 VDC
• Voltage decoupling by isolation amplifier
• Binary inputs
• 4 electrically isolated binary channels in two-wire technology
• Constant input current (approx. 4 mA) in the input voltage range 8 VDC - 36 VDC
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Function
Instrument outputs
Control of analog display instruments, all instrument outputs are identical in structure.
The output voltage (0 VDC - +10 VDC) is generated from a data word by 8-bit-D/A converters and
routed to the terminals of the PIM via an isolation amplifier (buffer).
Binary inputs
Acquisition of binary signals (state), all binary channels are identical, function described for one binary channel.
Each binary channel is equipped with two inputs (two-wire technology) which are activated by an external voltage.
The current which then flows is limited to approx. 4 mA regardless of the external switching voltage used.
Input voltage range of the binary channel 36 VDC.
The following applies to the input voltage (Ui) of the binary channel:
• 4 VDC v Ui ≤ 8 VDC should be avoided (inadmissible range).
channels are sampled cyclically by MPU 23 or MPU 27.
Each binary channel is assigned an LED (yellow). The relevant LED lights up when a
binary channel is activated (logic "1").
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Relationship between IIB 1 and the terminals of the PIM.
n09 Positive output voltage for instrument 1
n10 Ground (GND) for instrument 1
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18.2 IIB 1 – Technical data

General
Term Unit Value
15
Weight kg 0.024

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

15

50

440
Instrument outputs
Term Unit Value
Output voltage range VDC +0 - +10

(±5 %)
Output current mA Max. 5
Isolation amplifier Yes
Electrical isolation No
Binary inputs
Term Unit Value

36
E531439/06E 05-09 © MTU

Term Unit Value

between
inputs and
between
inputs and
electron-
ics.

(RC) with
6 dB/decade

50

(unshielded)
twisted.
Max. 50
(shielded)
twisted.
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INB – Purpose and Structure 159
19 INB – Purpose and Structure
19.1 Printed circuit board INB 1

Design
1 Component side 4 LED (yellow) "Spare" 6 LED (green) "Spare"

2 Conductor side 5 LED (red) "Printed circuit
3 Plan view board RESET"
Use
INB 1 is only used in a PIM 1 (with printed circuit board COB 1 and processor printed circuit board MPU 23)
or in a PIM 2 (with printed circuit board COB 3 and processor printed circuit board MPU 23).
Features
• 4 outputs to control display instruments
• Instrument output as voltage or current output
• 2 outputs supply positive output signals
• 2 outputs supply positive and negative output signals
• Short-circuit-proof instrument outputs
• High resolution with 12-bit D/A converter
• Dimmer
• Wide dimming range (0 % - 100 %) by PWM
E531439/06E 05-09 © MTU


Function
Instrument outputs
Control of display instruments.
The output signals are generated by a 12-bit-D/A converter and routed to the terminals
of the PIM via isolation amplifier (buffer).
Two outputs to output positive output signals.

• Available voltage ranges:
• 0 VDC - +2.5 VDC
• 0 VDC - +5.0 VDC
• 0 VDC - +10.0 VDC
• Available current range:
• 0 mA - +1.0 mA
Two outputs to output positive and negative output signals.
Available voltage ranges:
• −2.5 VDC - 0 VDC - +2.5 VDC
• −5.0 VDC - 0 VDC - +5.0 VDC
• −10.0 VDC - 0 VDC - +10.0 VDC
Available current range:
• −1.0 mA - 0 mA - +1.0 mA
Dimmer
Regulation of instrument illumination.
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The operating voltage for the dimmable instrument illumination is provided by an external voltage source.
This voltage is smoothed on INB 1 and protected by an RF and reverse-battery protection circuit.
The dimming voltage is generated by a PWM circuit and features a current monitoring circuit. Max. 0.4 A may
flow for a dimming voltage of 24 VDC. The dimming voltage range lies between 0 % - 100 %.
E531439/06E 05-09 © MTU

Relationship between INB 1 and the terminals of the PIM.
n01 Output 1: Current output (0 mA - +1 mA)
n02 Output 1: Ground (GND)
n03 Output 1: Voltage output

(0 VDC - +2.5 VDC,
0 VDC - +5 VDC or
0 VDC - +10 VDC)

(0 VDC - +2.5 VDC,
0 VDC - +5 VDC or
0 VDC - +10 VDC)
n07 Output 3: Current output (−1 mA - 0 mA - +1 mA)

(−2.5 VDC - 0 VDC - +2.5 VDC,
−5 VDC - 0 VDC - +5 VDC or
−10 VDC - 0 VDC - +10 VDC)

(−2.5 VDC - 0 VDC - +2.5 VDC,
−10 VDC - 0 VDC - +10 VDC)
n13 Output: +UDIMM
n14 Output GNDDIMM
n15 Input: +UEXT
n16 Input GNDEXT
E531439/06E 05-09 © MTU

19.2 INB 1 – Technical data

General
Term Unit Value
15
Weight kg 0.030

from
MPU 23
+24
(−50 % to
+30 %) via
COB

10

25

650
Instrument outputs
Term Unit Value
Isolation amplifier Yes
Positive output voltages
Voltage ranges VDC 0 - +2.5

(±0.5 %)
0 - +5.0
(±0.5 %)
0 - +10.0
(±0.5 %)
Positive and negative output voltages
Voltage ranges VDC −2.5 -

0 - +2.5
(±0.5 %)
−5.0 -
0 - +5.0
(±0.5 %)
−10.0 -
0 - +10.0
(±0.5 %)
E531439/06E 05-09 © MTU

Term Unit Value
Positive output current
Output current range mA 0 - +1.0

(±1 %)
Compliance voltage VDC Max. 5
Positive and negative output current
Output current range mA −1.0 -

0 - +1.0
(±1 %)
Dimmer
Term Unit Value

36
Input filter Yes
Input fuse A Self-

restoring
fuse (1.1)
Output voltage Veff 0 – 30

(±2 %)
Output current A Less than

0.4
Short-circuit protection Yes,

electronic
Clock frequency for PWM kHz 1.84
E531439/06E 05-09 © MTU


Design
1 Component side 5 LED (yellow) "Instrument

2 Conductor side outputs active"
3 Plan view 6 LED (yellow) "Dimming voltage
4 LED (green) "Power supply (+15 V)" output active"
Features
• 4 outputs to control display instruments
• Instrument output as voltage or current output
• Bipolar or unipolar output signals
• Short-circuit-proof instrument outputs
• Dimmer
• Wide dimming range (0 % - 100 %) by PWM
Function
Instrument outputs
Control of display instruments.
E531439/06E 05-09 © MTU

The output signals are generated by a 12-bit-D/A converter and routed to the terminals
of the PIM via isolation amplifier (buffer).
Each instrument output can be used as a voltage or current output. The output signal type
and level can be configured by the software.
Unipolar output signals:
• Voltage ranges:
• 0 VDC - +2.5 VDC
• 0 VDC - +5.0 VDC
• 0 VDC - +10.0 VDC
• Current range:
• 0 mA - +1.0 mA
Bipolar output signals:
Voltage ranges:
• −2.5 VDC - 0 VDC - +2.5 VDC
• −5.0 VDC - 0 VDC - +5.0 VDC
• −10.0 VDC - 0 VDC - +10.0 VDC
Current range:
• −1.0 mA - 0 mA - +1.0 mA
Dimmer
Regulation of instrument illumination.
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The internal PIM supply voltage is used as an operating voltage for the dimmable instrument illumination.
This voltage is protected by a self-restoring fuse on the COB.
The dimming voltage is generated by a PWM circuit and features a current monitoring circuit. Max. 0.15 A
may flow for a dimming voltage of 24 VDC. The dimming voltage range lies between 0 % - 100 %.

(−2.5 VDC - 0 VDC - +2.5 VDC,
−10 VDC - 0 VDC - +10 VDC)

(−2.5 VDC - 0 VDC - +2.5 VDC,
−10 VDC - 0 VDC - +10 VDC)

(−2.5 VDC - 0 VDC - +2.5 VDC,
−10 VDC - 0 VDC - +10 VDC)

(−2.5 VDC - 0 VDC - +2.5 VDC,
−10 VDC - 0 VDC - +10 VDC)
n13 Output: +UDIMM
n14 Output GNDDIMM
n15 Input: +UEXT
n16 Input GNDEXT
E531439/06E 05-09 © MTU


General
Term Unit Value
15
Weight kg 0.030

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

10

200

1200
Instrument outputs
Term Unit Value
Output voltages
Voltage ranges VDC −2.5 -

0 - +2.5
(±0.5 %)
−5.0 -
0 - +5.0
(±0.5 %)
−10.0 -
0 - +10.0
(±0.5 %)
Positive and negative output current
E531439/06E 05-09 © MTU

Term Unit Value
Output current range mA −1.0 -

0 - +1.0
(±1 %)
Dimmer output
Term Unit Value
Output voltage Veff 0 - 24

(±2 %),
pulse-
width
modulated
Output current A Less than

0.15
Short-circuit protection Yes,

electronic
Clock frequency for PWM kHz 1.84
Dimming range % 0 - 100
E531439/06E 05-09 © MTU


Design
1 Component side 6 LED (yellow) "Current output 10 LED (yellow) "Current output
2 Conductor side 3 active" 7 active"
3 Plan view 7 LED (yellow) "Current output 11 LED (yellow) "Frequency
4 LED (yellow) "Current output 4 active" output active"
1 active" 8 LED (yellow) "Current output 12 LED (green) "Power supply
5 LED (yellow) "Current output 5 active" (+15 V) OK"
2 active" 9 LED (yellow) "Current output 13 LED (red) "Printed circuit
6 active" board RESET"
Use
INB 3 is only used in a PIM 5 (with COB 17 and MPU 27) or in a PIM 3 (with COB 5 and
MPU 27). Operation with MPU 23 is not possible.
Features
• 7 current outputs (4 mA - 20 mA) to control display instruments
• 1 frequency output (0 Hz - 1500 Hz) to control a display instrument
• Short-circuit-proof outputs
E531439/06E 05-09 © MTU

Function
Control of up to seven display instruments with current inputs (4 mA - 20 mA) and a display instrument
with a frequency input (0 Hz - 1500 Hz) at the same time.
Current outputs
Seven independent current sources.
Control of current sources by 10-bit-D/A converter on INB 3.
Yellow status LEDs are assigned to the current outputs. The LEDs signal current
flow at the corresponding current output.
Each current source features an overcurrent protection circuit and is short-circuit-proof
(current limited to max. 25 mA per output).
The max. load impedance of 300 Ω per channel must not be exceeded.
Frequency output
Control of a display instrument.
The frequency output supplies a binary output signal with a 1:1 pulse-duty factor.
The output voltage of the signal depends on the operating voltage and is normally +24 VDC
(20.5 VDC ≤ Uhigh ≤ +23.7 VDC and Ulow = 0 VDC).
The function of the frequency output is indicated by a yellow status LED.
The frequency output features an overcurrent protection circuit and is short-circuit-proof.
E531439/06E 05-09 © MTU

The frequency output of INB 3 is specially designed for connection of a frequency-dependent

speed instrument ("VDO-Ocean-Line" series).
n01 Current output 1 (0 mA - 20 mA)
n02 Ground (GND)
n04 Ground (GND)
n06 Ground (GND)
n08 Ground (GND)
n10 Ground (GND)
n12 Ground (GND)
n14 Ground (GND)
n15 Frequency output (0 Hz - 1500 Hz)
n16 Ground (GND)
E531439/06E 05-09 © MTU


General
Term Unit Value
15
Weight kg 0.026

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

20
Power consumption (24 VDC) mA Less

than 10
(without
load).
Less
than 200
(loaded
with
7 x 25)

340 (with-
out load).
Less than
3.0 W
(loaded
with 7 x 25
mA)
Instrument outputs
Term Unit Value
Instrument outputs (current outputs)
Output current range mA 4 - 20

(±1 %)
Short-circuit-proof Yes
Resolution of D/A converter Bit 10
Max. load impedance Ω R <

300 per
channel
E531439/06E 05-09 © MTU

Term Unit Value
Frequency output
Frequency range Hz 0 - 1500
Pulse-duty factor 1:1
Power supply V 24 internal

(depend-
ing on
the supply
voltage of
the PIM).
Output voltage VDC At 24:

20.5 ≤
Uhigh ≤
+23.7
Ulow + 0
Paral-
lel con-
nection
of max.
3 instru-
ments
(VDO) pos-
sible.
Short-circuit-proof Yes
E531439/06E 05-09 © MTU

MFB – Purpose and Structure 175
20 MFB – Purpose and Structure
20.1 Printed circuit board MFB 1

Design
1 Component side 6 LED (yellow) "Analog speed 11 LED (green) "Ready"

2 Conductor side signal 2" 12 Fuses
3 Plan view 7 LED (yellow) "Binary speed
4 LED (yellow) "Analog speed signal 2"
signal 1" 8 LED (yellow) "Relay K2 activated"
5 LED (yellow) "Binary speed 9 LED (yellow) "Relay K1 activated"
signal 1" 10 LED (green) "+24 V output"
Use
MFB 1 is used in slot 2 or slot 3 in conjunction with MPU 23. Slot 4 is not possible in this case.
Slot 2, 3, or 4 is used in conjunction with processor printed circuit board MPU 27.
Features
• Electrically isolated power supply of the channels by DC/DC converter
• All inputs equipped with EMC protective filter
• Inputs for analog speed signals (input voltage up to 80 VAC)

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Technical Publication

Field Automation Level

General Provisions ......................................................... 05

Functional Description ...................................................... 15

E531439/06E 05-09 © MTU

7.2 CCB 1 – Technical data ................................................... 66

E531439/06E 05-09 © MTU

15 BIB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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22 SAB – Purpose and Structure .................................................... 205

Workshop Manual .......................................................... 219

Appendix .................................................................. 241

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E531439/06E 05-09 © MTU

E531439/06E 05-09 © MTU

1.1 General conditions

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1.2 Personnel and organizational requirements

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1.3 Safety precautions when working on the engine

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Working on electrical/electronic assemblies

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1.4 Auxiliary materials, fire prevention and environmental

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E531439/06E 05-09 © MTU

1.5 Standards for warning notices in the publication

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E531439/06E 05-09 © MTU

E531439/06E 05-09 © MTU

2 PIM – Purpose and Structure

2.1 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 23

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2.2 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 23

E531439/06E 05-09 © MTU

Slots and terminals

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2.3 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 27

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2.4 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 27

E531439/06E 05-09 © MTU

Slots and terminals

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2.5 Overview of PIM printed circuit boards

Printed circuit board Function

MPU 23 • Single-chip processor with main and data memory

MPU 27 • Single-chip processor with main and data memory

MPU 23 extension boards

Printed circuit board Function

CCB 1 • 1 additional CAN interface as per ISO 11 898

SCB 2 • 1 additional RS422 interface

SCB 4 • 1 additional RS232 interface

MPU 27 extension boards

Printed circuit board Function

FCB 2 • Display module

Connection printed circuit boards (motherboards)