Mastering MTU DiaSys for Engine Management

In the complex world of modern diesel engines, particularly those manufactured by MTU, having the right diagnostic and maintenance tools is paramount. For technicians and engineers working with MTU power systems, MTU DiaSys stands out as a critical piece of software. This powerful, Windows-based application is the primary interface for communicating with a wide array of MTU engine controllers, enabling a comprehensive suite of maintenance and service operations. From reading vital operational data to performing intricate diagnostic procedures, DiaSys is indispensable for ensuring the optimal performance and longevity of MTU engines.

What is MTU DiaSys?

MTU DiaSys is a sophisticated diagnostic software tool designed specifically for MTU engines and their associated control systems. It acts as a bridge, allowing your computer to communicate effectively with the electronic control units (ECUs) and other control modules installed on MTU engines. This communication is typically facilitated through a CAN (Controller Area Network) bus interface, with the IXXAT USB-to-CAN V2 being a common hardware component for establishing this connection. The software's primary function is to enable users to access, monitor, and manipulate various parameters and data points within the engine's control system.

The core capabilities of MTU DiaSys include:

• Reading and Recording Metrics: Access real-time engine data, including operating hours, temperatures, pressures, fuel consumption, and many other process variables. This data can be recorded for later analysis, performance tracking, or troubleshooting.
• Diagnostic Fault Codes: Retrieve and interpret diagnostic trouble codes (DTCs) that the engine's ECU has logged. This is crucial for identifying and resolving engine issues.
• Parameter Adjustment: In some cases, and depending on user permissions and hardware key levels, DiaSys allows for the adjustment of certain engine parameters to optimise performance or adapt to specific operating conditions.
• System Configuration: Configure various settings and functions within the engine control system.
• Firmware Updates: Facilitate the updating of firmware on MTU controllers.

Supported Systems and Languages

MTU DiaSys is designed to run on standard Windows operating systems, ensuring accessibility for most users. It is compatible with:

• Windows 7
• Windows 8
• Windows 10

The software is available in multiple languages to cater to a global user base, with German and English being the primary supported languages. This multilingual support is vital for international service operations.

Key Features and Updates

MTU consistently updates DiaSys to enhance its functionality, improve compatibility, and address potential issues. Recent updates and key features include:

Communication Interfaces

DiaSys communicates with a variety of MTU systems, including:

• Various MTU Engine Controllers (ECUs)
• RCS-5 Remote Control Systems
• MCS-5 Monitoring and Control Systems

IXXAT USB-to-CAN V2 Considerations

For users employing the IXXAT USB-to-CAN V2 interface, it's important to be aware of potential issues with older firmware versions. Specifically, older firmware might lead to the loss of CAN messages. To mitigate this, MTU strongly recommends installing the current IXXAT firmware version 1.07. Detailed instructions for this firmware update can typically be found within the DiaSys installation directory, often located at `C:\Programs (x86)\DiaSys\Doku\IXXAT\usb-to-can V2 Firmwareupdate_howto.pdf`.

Excel Export Format Change

A significant change in recent versions of DiaSys pertains to the Excel export format. To address security concerns where virus scanners might flag Office files containing macros as unsafe, the export format has been changed from the older *.XLS to the more modern *.XLSX format. However, it is crucial to note that Excel import functionality within DiaSys still exclusively supports the *.XLS format. If you need to import data that was exported as *.XLSX, you must first convert it to an *.XLS file to prevent the error message: “External table does not have the expected format.”

Enhanced Controller Roles (ECU-9, SXU, EXU)

Several enhancements have been made to how data is handled for specific controller roles:

• Chronological Error Log: The "Chronological error log" has been expanded to include "More information" and "Details number" columns. These new columns provide additional, valuable alarm and error information, aiding in more precise diagnostics.
• Bag Learning Maps: For ECU-9 and SXU controllers, “bag learning maps” (which track the lifetime of NTE events) are now reported as operational data to the central database. This aligns them with other important operational data, such as load profiles and error memories, providing a more holistic view of engine operation.

Improved Data Transfer and Handling

Data transfer and handling have also seen improvements:

• Enhanced Message Texts: When retrieving data from the central database, the clarity and usefulness of the message texts have been improved.
• New Recording Templates: For ECU-9 and SXU controllers, new recording templates have been added to the template database (`TemplateKD.mdb`). These templates can streamline the process of capturing specific operational data.
• Data Transfer via File – Export: Files previously exported with the *.EXE extension, which contained self-extracting executable code, have been modified. Now, exported files use the *.EXE extension but no longer contain executable code. Instead, they are directly extracted when imported into DiaSys. This change helps to circumvent blocks imposed by virus scanners, making data sharing more reliable.
• Data Transfer via File – Import: Import operations are now more robust, with no import error occurring if the path to the data file contains spaces. This simplifies the process of importing data from various locations.

Crash Recorder and Timeout Adjustments

Specific functionalities related to crash recording and communication timeouts have been addressed:

• Crash Recorder Updates: The message text for detecting blocked crash recorder data has been updated. This data is critical and needs to be sent to MTU for analysis.
• Increased Timeout: The timeout period for communication with the EIM (Engine Interface Module) has been increased. This adjustment aims to reduce the occurrence of DiaSys error messages related to communication timeouts, leading to a smoother user experience.

Default Path Changes

The default storage location for load profile data has been updated. It has moved from the root of the A: drive to `C:\ProgramData\DiaSys\Loadprofile_data`. This new default path is more standard for application data on modern Windows systems. Users can still change this path within the DiaSys “Options” menu if needed.

New Features in Recent Versions

MTU DiaSys continues to evolve, with new features being introduced to support the latest MTU engine technologies:

• Plant Project Identification (ECU-7, ECU-9): This feature allows DiaSys to read and display PU (Power Unit) running information directly from the ECU, providing valuable context about the engine's project setup.
• Light Status (PV Recorder, ECU-9, SXU): For ECU-9 and SXU controllers, DiaSys can now read and display the “Light Status” information related to the PV (Process Value) Recorder.
• Configurable PV Recorder (PV Recorder General): The software gains the ability to read and display a configurable PV recorder directly from the ECU, offering greater flexibility in monitoring critical process values.
• Injector Wear Upload and Export (EXU-ESD): For EXU-ESD controllers, DiaSys can now read injector wear information and export it into a CSV file. This is crucial for predictive maintenance and understanding injector health.
• Crash Recorder Support (SXU): The SXU controller now has crash recorder functionality similar to that found in ECU-7, ECU-8, and ECU-9 controllers, enhancing its diagnostic capabilities.
• Specific Reset Functions (SXU): For SXU controllers, new functionalities include:
• “Hot Shutdown Counter Reset Function.”
• “NH3 HC Counter Reset Function.”
• “HC1 and HC2 Load Reset Function.”
• Emergency Start Information (ECU-7, ECU-9): DiaSys can now read and display recorded emergency start information from ECU-7 and ECU-9 controllers.
• Spray Oil Calibration (EXU-EMU9): A new “Spray Oil Calibration” feature is available for EXU-EMU9 controllers, allowing for precise calibration of the spray oil system.

Configuring an MTU Electronic Engine Controller with DiaSys

Configuring an MTU electronic engine controller using DiaSys involves a structured process. The setup typically requires:

Required Hardware and Software:

• A laptop equipped with the MTU DiaSys software installed.
• A compatible CAN controller, such as the IXXAT USB-to-CAN v2.
• A suitable connection cable to link the engine controller to your system, usually connecting to the SAM (Service Access Module) diagnostic plug on the engine.

Step-by-Step Configuration Process:

1. Select Activity Type:

Upon launching DiaSys, you'll often be prompted to select an “Activity Type” or user group. The available options and the features you can access are determined by the level of your hardware key. This ensures that users only access functions appropriate to their role and permissions.

2. Select Device Type:

If the “No device type preset” option is selected in the settings, you will need to choose the appropriate device type for the engine you are working with. To assist in identification, a button with a camera icon is usually provided. Clicking this will display an image of the device, which typically hides automatically after a short period or when the mouse cursor moves away.

3. Edit or Create an Assembly Description:

Assembly descriptions are fundamental for organising and saving data within DiaSys. They essentially define the engine and its associated order information.

• Creating a New Assembly Description: To create a new description, click the “New” button. This will open a window where you can input the engine number. Associating engine numbers with an order number allows DiaSys to automatically create specific directories for saving data related to that engine.
• Editing Existing Descriptions: You can also open and edit existing assembly descriptions, for example, to delete outdated entries.
• Language Settings: The “Options” button within DiaSys allows you to switch the software's display language between German and English.

4. Working in Online Mode (Establishing a Data Link):

Once the software is set up and your hardware is connected, you can establish a data link to the engine controller:

1. Initiate Connection: Select the option “Establish data link to controller…” to begin the communication process.
2. CAN Bus Connection: The controller is typically accessed via CAN bus 1 and linked to the engine number specified in your assembly description. Select “Connect online” and confirm by clicking “OK.”
3. Device Information: Upon a successful connection, a device information message will appear, displaying details such as the engine number, hardware serial number, and the controller's internal structure (CCS tree). Click “Next” to proceed.
4. Engine Number Mismatch: If there's a discrepancy between the engine number stored in the controller and the one in your assembly description, a general warning message will be displayed. Confirm by selecting “OK.”
5. Enter Engine Serial Number: You may be prompted to enter the engine serial number. After entering it, click “Next.”
6. Retrieve Data: When asked if you wish to retrieve data from the controller, select “Yes.”
7. Online Mode Ready: After these steps, if the connection is successful, the controller data will be loaded, and you will be ready to operate in online mode, accessing real-time engine information and diagnostic functions.

Troubleshooting Common Issues

While DiaSys is a robust tool, users might occasionally encounter issues. Here are a few common points:

• Communication Errors: Ensure your IXXAT interface is updated with the latest firmware. Check that all cables are securely connected and that the correct COM port or CAN interface is selected in DiaSys. Verify that the engine’s CAN bus is powered and active.
• Excel Import Errors: Remember the requirement to import only *.XLS files. Convert *.XLSX files to the older format if you encounter the “External table does not have the expected format” error.
• Access Denied / Limited Features: This is usually due to the hardware key level. Ensure you have the correct key for the operations you intend to perform. Contact your MTU service partner if you believe your key level is incorrect.

Conclusion

MTU DiaSys is an indispensable software suite for anyone involved in the maintenance, diagnostics, and service of MTU engines. Its comprehensive features, combined with ongoing updates and improvements, ensure that technicians have the tools necessary to keep these powerful engines running efficiently and reliably. Understanding its capabilities, proper configuration, and potential pitfalls, such as the Excel file format, is key to maximizing its utility. By leveraging MTU DiaSys effectively, you can significantly enhance your ability to diagnose problems, optimise performance, and maintain the overall health of MTU power systems.