waukesha 16V275GL ESM

® ESM ® 16V275GL Engine System Manager Operation & Maintenance First Edition This document contains proprietary and trade secret information and is given to the receiver in confidence. The receiver by reception and retention of the document accepts the document in confidence and agrees that, except as with the prior expressed written permission of Dresser Waukesha, Dresser, Inc., it will (1) not use the document or any copy thereof or the confidential or trade secret information therein; (2) not copy or reproduce the document in whole, or in part, without the prior written approval of Dresser Waukesha, Inc.; and (3) not disclose to others either the document or the confidential or trade secret information contained therein. All sales and information herein supplied subject to Standard Terms of Sale, including limitation of liability. ATGL®, CFR®, ESM®, EXTENDER SERIES®, DRESSER®, ENGINATOR®, SERIES FOUR®, VGF®, VHP®, WKI®, and WAUKESHA® are registered trademarks of Dresser, Inc. APG™ and DRESSER logo are trademarks of Dresser, Inc. All other trademarks, service marks, logos, slogans, and trade names (collectively “marks”) are the properties of their respective owners. Dresser, Inc., disclaims any proprietary interest in these marks owned by others. FORM 6331-1 Dresser Waukesha, Inc. Dresser, Inc. Waukesha, Wisconsin 53188 Printed in U.S.A. 04/09 © Copyright 2009, Dresser, Inc. All rights reserved. CONTENTS How to Use This Manual CHAPTER 1 – SAFETY AND GENERAL Section 1.00 – Safety Safety Introduction ................................................. 1.00-1 Safety Tags and Decals......................................... 1.00-1 Equipment Repair and Service .............................. 1.00-1 Electrical ................................................................ 1.00-2 Fire Protection........................................................ 1.00-3 Body Protection...................................................... 1.00-3 Exhaust .................................................................. 1.00-3 Batteries................................................................. 1.00-3 Chemicals .............................................................. 1.00-3 Cleaning Solvents .................................................. 1.00-3 Emergency Shutdown............................................ 1.00-4 Programming ......................................................... 1.00-4 Handling Components ........................................... 1.00-4 Tools ...................................................................... 1.00-4 Electrical ......................................................... 1.00-4 Pneumatic....................................................... 1.00-4 Intoxicants and Narcotics....................................... 1.00-4 Protective Guards .................................................. 1.00-4 CHAPTER 2 – ESM OPERATION Section 2.00 – System Power and Wiring Power Supply Requirements................................. 2.00-1 Battery Requirements............................................ 2.00-1 Power Supplied by Batteries .......................... 2.00-2 Power Supplied by 24VDC Power Supply ..... 2.00-3 Power Distribution Junction Box............................ 2.00-4 Recommended Wiring.................................... 2.00-4 Connecting Ground and Power to Power Distribution Junction Box.................. 2.00-5 Customer Interface Harness ................................. 2.00-6 Required Connections.................................... 2.00-8 Optional Connections................................... 2.00-10 Local Control Option Harness ...................... 2.00-11 Section 2.05 – Start-Stop Control Start-Stop Control Description............................... 2.05-1 Start Sequence .............................................. 2.05-1 Normal Shutdown Sequence ......................... 2.05-2 Emergency Shutdown Sequence................... 2.05-2 Prelubing the Engine Without Starting ........... 2.05-5 Cranking the Engine Over Without Starting and Without Fuel............................ 2.05-5 Air Starter .............................................................. 2.05-5 Fuel Valve ...................................................... 2.05-6 Section 1.05 – General Information Wiring Requirements ............................................. 1.05-1 ESP Programming Conventions ............................ 1.05-2 Definitions .............................................................. 1.05-3 Acronyms ............................................................... 1.05-8 English/Metric Conversions ................................... 1.05-9 Torque Values...................................................... 1.05-10 Section 2.10 – Ignition System Ignition Theory....................................................... 2.10-2 Ignition Diagnostics ............................................... 2.10-3 Monitoring Ignition Energy Field..................... 2.10-3 Monitoring Spark Reference Number............. 2.10-3 Section 1.10 – Engine System Manager (ESM) Overview ESM Components.................................................. 1.10-3 Engine Control Unit (ECU).............................. 1.10-3 Power Distribution Junction Box ..................... 1.10-4 Ignition Power Module with Diagnostics (IPM-D)..................................... 1.10-4 Air-Fuel Power Module (AFPM)...................... 1.10-4 Stepper (AGR – Actuator, Gas Regulator) ..... 1.10-4 Throttle Actuator ............................................. 1.10-5 Wastegate Actuator ........................................ 1.10-5 Bypass Actuator.............................................. 1.10-5 Engine System Manager Sensors ......................... 1.10-5 Electronic Service Program (ESP)......................... 1.10-9 E-Help............................................................. 1.10-9 User Interface Panels ................................... 1.10-10 ESM Diagnostics.................................................. 1.10-10 Safety Shutdowns ................................................ 1.10-10 Start-Stop Control ................................................ 1.10-11 Ignition System .................................................... 1.10-11 Knock Detection................................................... 1.10-11 Air-Fuel Ratio Control .......................................... 1.10-11 ESM Turbocharger Control .................................. 1.10-11 ESM Speed Governing ........................................ 1.10-11 Section 2.15 – Knock Detection Knock Theory ................................................. 2.15-1 Knock Detection and Timing Control.............. 2.15-2 Waukesha Knock Index (WKI) ....................... 2.15-3 Section 2.20 – Air-Fuel Control Description ............................................................ 2.20-1 Components .......................................................... 2.20-1 Operation............................................................... 2.20-1 Lean Burn Oxygen Sensor............................. 2.20-2 Heater Block Assembly .................................. 2.20-3 Stepper........................................................... 2.20-4 System Wiring ................................................ 2.20-4 Theory of Operation ....................................... 2.20-4 User Settings.................................................. 2.20-5 Section 2.25 – ESM Turbocharger Control ESM Turbocharger Control Description ................ 2.25-2 Bypass, Wastegate, and Throttle Reserve Maps.....2.25-2 Resetting Learning Tables .................................... 2.25-2 Turbocharger Surge .............................................. 2.25-3 Throttle Reserve.................................................... 2.25-4 Electronic vs. Mechanical Wastegate.................... 2.25-4 FORM 6331 First Edition i CONTENTS Section 2.30 – ESM Speed Governing ESM Speed Governing.......................................... 2.30-1 Governing Theory........................................... 2.30-1 Speed Governing Inputs and Calibrations...... 2.30-1 Speed Governing Modes................................ 2.30-2 Rotating Moment of Inertia/Adjusting Gain............ 2.30-6 Other ESP Windows ..............................................3.00-9 Fault Log.........................................................3.00-9 E-Help.............................................................3.00-9 Version Details................................................3.00-9 Navigating ESP Panels........................................3.00-10 Common Features ........................................3.00-10 Display Fields ...............................................3.00-11 Button Bar ............................................................3.00-12 Fault Log Description ...........................................3.00-13 Using a Modem For Remote Monitoring ..............3.00-15 Setting Up Modem to ECU ...........................3.00-15 Connecting Modem To ECU And PC ...........3.00-17 Starting ESP For Modem Access .................3.00-17 Section 2.35 – Emergency Safety Shutdowns Overview................................................................ 2.35-1 Individual Safety Shutdowns Descriptions ..... 2.35-1 Emergency Stop (E-Stop) Switches ............... 2.35-1 Low Oil Pressure ............................................ 2.35-1 Engine Overspeed.......................................... 2.35-2 Customer-Initiated Emergency Shutdown...... 2.35-2 Engine Overload............................................. 2.35-2 Uncontrollable Engine Knock ......................... 2.35-2 High HT Jacket Water Coolant Temperature... 2.35-2 Low HT Jacket Water Coolant Pressure ........ 2.35-2 High Intake Manifold Air Temperature............ 2.35-2 High Oil Temperature ..................................... 2.35-2 Failure of Magnetic Pickup ............................. 2.35-2 Overcrank....................................................... 2.35-2 Engine Stall .................................................... 2.35-2 ECU Internal Faults ........................................ 2.35-2 Security Violation............................................ 2.35-2 Alarms ................................................................... 2.35-3 Section 3.05 – ESP Panel and Field Descriptions [F2] Engine Panel ..................................................3.05-1 [F3] Start-Stop Panel .............................................3.05-2 [F4] Governing Operating Status Panel .................3.05-3 [F5] Ignition Operating Status panel ......................3.05-4 [F8] AFR Setup Panel ............................................3.05-5 [F10] System/Shutdown Status Panel ...................3.05-6 [F11] Advanced Functions Panel ...........................3.05-7 Field Descriptions ..................................................3.05-8 Section 3.10 – ESP Programming Initial Engine Startup..............................................3.10-1 Basic Programming in ESP....................................3.10-2 Saving to Permanent Memory ...............................3.10-3 Exiting ESP Without Saving............................3.10-3 Sending Calibrations to ECU .................................3.10-4 Actuator Calibration ...............................................3.10-5 Reset Status LEDs on ECU ...................................3.10-7 Logging System Parameters..................................3.10-7 Create Text File ..............................................3.10-8 Creating .TSV File ..........................................3.10-9 Changing Units – U.S. or Metric ..........................3.10-10 Programming Remote ECU for Off-Site Personnel ..............................................3.10-11 Introduction ...................................................3.10-11 Modem Setup ...............................................3.10-11 Programming Load Inertia ...................................3.10-14 Programming Alarm and Shutdown Setpoints .....3.10-16 IPM-D Programming ............................................3.10-17 Air-Fuel Ratio Programming ................................3.10-17 Programming Fuel Type ...............................3.10-17 AFR Setup ....................................................3.10-19 Programming NOx Level ..............................3.10-20 Section 2.40 – ESM Communications MODBUS® (RS-485) Communications ................. 2.40-1 Wiring ............................................................. 2.40-1 Protocol .......................................................... 2.40-2 MODBUS® for PLC ........................................ 2.40-2 Personal Computers....................................... 2.40-2 Fault Code Behavior....................................... 2.40-2 Function Codes ..................................................... 2.40-3 Reading MODBUS® Addresses..................... 2.40-3 MODBUS® Exception Responses.................. 2.40-3 Function Code Tables .................................... 2.40-4 Additional Information on MODBUS® Addresses 30038 – 30041 ....... 2.40-9 Local Control Panel ............................................. 2.40-10 User Digital Inputs ........................................ 2.40-11 CHAPTER 3 – ELECTRONIC SERVICE PROGRAM (ESP) Section 3.00 – Introduction to Electronic Service Program (ESP) Recommended System Requirements.................. 3.00-1 Installing ESP From Download.............................. 3.00-1 Installing ESP From CD......................................... 3.00-3 Connecting PC to ECU.......................................... 3.00-3 Starting ESP .......................................................... 3.00-4 Connection Status .......................................... 3.00-4 User Interface Panels ............................................ 3.00-4 ii FORM 6331 First Edition CONTENTS CHAPTER 4 – TROUBLESHOOTING & MAINTENANCE Section 4.00 – Troubleshooting Where to Begin ...................................................... 4.00-1 Additional Assistance............................................. 4.00-1 Determining Fault Code by Using ESP.................. 4.00-2 Determining Fault Code by Reading ECU Status LEDs ................................................. 4.00-2 E-Help .................................................................... 4.00-3 Using E-Help................................................... 4.00-3 E-Help Window Description ............................ 4.00-4 ESM Fault Codes................................................... 4.00-6 Non-Code ESM Troubleshooting ......................... 4.00-10 Power Distribution Junction Box .......................... 4.00-11 Section 4.05 – ESM Maintenance Actuator Linkage .................................................... 4.05-2 Knock Sensors....................................................... 4.05-2 Replacing Knock Sensors............................... 4.05-2 AGR (Stepper) Maintenance.................................. 4.05-2 ESM System Wiring ............................................... 4.05-3 Battery Maintenance .............................................. 4.05-4 External Inspection ......................................... 4.05-4 Battery Indicated State of Charge................... 4.05-4 APPENDIX A - INDEX Appendix A - Index..................................................... A-1 WARRANTY INFORMATION Express Limited Warranty Covering Products Used in Continuous Duty Applications...................... W-1 Express Limited Warranty for Genuine Waukesha Service Parts and Waukesha Factory Remanufactured Service Parts .................... W-2 Express Limited Warranty for Products Operated in Excess of Continuous Duty Ratings...... W-3 FORM 6331 First Edition iii CONTENTS iv FORM 6331 First Edition HOW TO USE THIS MANUAL Your purchase of a Dresser Waukesha engine with Engine System Manager (ESM) was a wise investment. In the industrial engine field, the name Dresser Waukesha, stands for quality and durability. With normal care and maintenance, this equipment will provide many years of reliable service. Before placing the ESM in service, read Chapter 1 very carefully. This chapter covers Safety and General Information. Section 1.00 – “Safety” – Provides a list of warnings and cautions to make you aware of the dangers present during operation and maintenance of the engine. READ THEM CAREFULLY AND FOLLOW THEM COMPLETELY. Section 1.05 – “General Information” – Provides wiring requirements, programming conventions, definitions, acronyms, conversion tables, and torque values of metric and standard capscrews. Section 1.10 – “Engine System Manager (ESM) Overview” – Provides an overview of the engine control system, component locations, sensor locations, and ESP operation. ALWAYS be alert for the special warnings within the manual text. These warnings precede information that is crucial to your safety as well as to the safety of other personnel working on or near the engine. Cautions or notes in the manual contain information that relates to possible damage to the product or its components during engine operation or maintenance procedures. This manual contains packager, operation, and maintenance instructions for the ESM. There are four chapters within the manual, and each chapter contains two or more sections. The title of each chapter or section appears at the top of each page. To locate information on a specific topic, refer to the Table of Contents at the front of the manual or the Index at the back of the manual. Recommendations and data contained in the manual are the latest information available at the time of this printing and are subject to change without notice. Since engine accessories may vary due to customer specifications, consult your local Dresser Waukesha Distributor or Dresser Waukesha Service Operations Department for any information on subjects beyond the scope of this manual. FORM 6331 First Edition v HOW TO USE THIS MANUAL vi FORM 6331 First Edition SAFETY AND GENERAL CONTENTS SECTION 1.00 – SAFETY SECTION 1.05 – GENERAL INFORMATION SECTION 1.10 – ENGINE SYSTEM MANAGER (ESM) OVERVIEW FORM 6331 First Edition SAFETY AND GENERAL FORM 6331 First Edition SECTION 1.00 SAFETY SAFETY INTRODUCTION The following safety precautions are published for your information. Dresser Waukesha, Inc., does not, by the publication of these precautions, imply or in any way represent that they are the sum of all dangers present near industrial engines or fuel rating test units. If you are installing, operating, or servicing a Dresser Waukesha product, it is your responsibility to ensure full compliance with all applicable safety codes and requirements. All requirements of the Federal Occupational Safety and Health Act must be met when Dresser Waukesha products are operated in areas that are under the jurisdiction of the United States of America. Dresser Waukesha products operated in other countries must be installed, operated, and serviced in compliance with any and all applicable safety requirements of that country. For details on safety rules and regulations in the United States, contact your local office of the Occupational Safety and Health Administration (OSHA). The words “danger,” “warning,” “caution,” and “note” are used throughout this manual to highlight important information. Be certain that the meanings of these alerts are known to all who work on or near the equipment. This symbol identifies information about hazards or unsafe practices. Disregarding this inform a t i o n c o ul d r e s u l t i n P RO D U C T DA M AG E AND/OR PERSONAL INJURY. CAUTION NOTE: This symbol identifies information that is NECESSARY TO THE PROPER OPERATION, MAINTENANCE, OR REPAIR OF THE EQUIPMENT. SAFETY TAGS AND DECALS WARNING To avoid severe personal injury or death, all warning tags and decals must be visible and legible to the operator while the equipment is operating. EQUIPMENT REPAIR AND SERVICE Proper maintenance, service, and repair are important to the safe, reliable operation of the unit and related equipment. Do not use any procedure not recommended in the Dresser Waukesha manuals for this equipment. WARNING To prevent severe personal injury or death, always stop the unit before cleaning, servicing, or repairing the unit or any driven equipment. Place all controls in the OFF position and disconnect or lock out starters to prevent accidental restarting. If possible, lock all controls in the OFF position and take the key. Put a sign on the control panel warning that the unit is being serviced. Close all manual control valves. Disconnect and lock out all energy sources to the unit, including all fuel, electric, hydraulic, and pneumatic connections. Disconnect or lock out driven equipment to prevent the possibility of the driven equipment rotating the disabled engine. DANGER This symbol identifies information about immediate hazards. Disregarding this information will result in SEVERE PERSONAL INJURY OR DEATH. WARNING This symbol identifies information about hazards or unsafe practices. Disregarding this information could result in SEVERE PERSONAL INJURY OR DEATH. FORM 6331 First Edition 1.00-1 SAFETY WARNING To avoid severe personal injury or death, ensure that all tools and other objects are removed from the unit and any driven equipment before restarting the unit. WARNING Allow the engine to cool to room temperature before cleaning, servicing, or repairing the unit. Hot components or fluids can cause severe personal injury or death. Wire the supplied fuel gas shutoff valve so it is controlled by the ESM. If the fuel valve is controlled independently of the ESM, fault codes will occur when the fuel valve is not actuated in sequence by the ESM. Disregarding this information could result in product damage and/or personal injury. CAUTION Do not drop or mishandle knock sensor. If knock sensor is dropped or mishandled, it must be replaced. Disregarding this information could result in product damage and/or personal injury. CAUTION WARNING Some engine components and fluids are extremely hot even after the engine has been shut down. Allow sufficient time for all engine components and fluids to cool to room temperature before attempting any service procedure. D o n o t ov e r t i g h t e n capscrew. Overtightening will cause damage to the knock sensor. Disregarding this information could result in product damage and/or personal injury. CAUTION ELECTRICAL All induct ive load s, such as a fuel valve must have a suppression diode installed across the valve coil as close to the valve as is practical. Disregarding this information could result in product damage and/or personal injury. WARNING Never set the high idle speed above the safe working limit of the driven equipment. If the GOVREMSP signal goes out of range or the GOVREMSEL signal is lost, then the engine will run at the speed determined by the status of GOVHL IDL and calibrated low or high idle speeds. Disregarding this information could cause severe personal injury and/or product damage. When using an electric starter motor and a start attempt fails, wait at least two minutes (or a time period per the starter manufacturer’s instructions) before attempting an engine restart. The starter motor must cool down before engine restart to prevent damage to the starter motor. Disregarding this information could result in product damage and/or personal injury. CAUTION WARNING Always label “HIGH VOLTAGE” on engine-mounted equipment over 24 volts nominal. Failure to adhere to this warning could result in severe personal injury or death. CAUTION WARNING Do not install, set up, maintain, or operate any electrical components unless you are a technically qualified individual who is familiar with the electrical elements involved. Electrical shock can cause severe personal injury or death. Always use “OXYGEN SENSOR SAFE/NEUTRAL CURE” RTV gasket materials on engines with oxygen sensors. Disregarding this information will result in reduced sensor life or sensor failure. CAUTION WARNING Disconnect all electrical power supplies before making any connections or servicing any part of the electrical system. Electrical shock can cause severe personal injury or death. Always purchase ESM AFR oxygen sensors (P/N 740107A or later) from Dresser Waukesha. Performance goals of the system cannot be met without Dresser Waukesha’s oxygen sensor specifications. Disregarding this information could result in product damage and/or personal injury. CAUTION 1.00-2 FORM 6331 First Edition SAFETY Never attempt to power the engine using the +24VFOR U wire in the Local Control Option Harness. The +24VFOR U wire is for customer use to provide 24 VDC power to other equipment. Incorrectly powering the engine using the +24VFOR U wire could result in product damage and/or personal injury. CAUTION EXHAUST WARNING Do not inhale engine exhaust gases. Exhaust gases are highly toxic and could cause severe personal injury or death. All inductive loads , such as the fuel valve, must have a suppression diode installed across the valve coil as close to the valve as is practical. Disregarding this information could result in product damage and/or personal injury. BATTERIES CAUTION WARNING Comply with the battery manufacturer’s recommendations for procedures concerning proper battery use and maintenance. Improper maintenance or misuse can cause severe personal injury or death. Disconnect all engine harnesses and electronically controlled devices before welding on or near an engine. Failure to comply will void warranty. Failure to disconnect the harnesses and electronically controlled devices could result in product damage and/or personal injury. CAUTION WARNING Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxygen gases. Keep any device that may cause sparks or flames away from the battery to prevent explosion. Batteries can explode, causing severe personal injury or death. The electrical interference from solenoids and other electrical switches will not be cyclic and can be as high as several hundred volts. This could cause faults within the ESM that may or may not be indicated with diagnostics. Dresser Waukesha requires a “freewheeling” diode be added across the coils of relays and solenoids to suppress high induced voltages that may occur when equipment is turned off. Failure to comply will void product warranty. Disregarding this information could result in personal injury and/or product damage. CAUTION WARNING Always wear protective glasses or goggles and protective clothing when working with batteries. You must follow the battery manufacturer’s instructions on safety, maintenance, and installation procedures. Failure to follow the battery manufacturer’s instructions can cause severe personal injury or death. FIRE PROTECTION CHEMICALS WARNING Refer to local and federal fire regulations for guidelines for proper site fire protection. Fires can cause severe personal injury or death. WARNING Always read and comply with safety labels on all containers. Do not remove or deface the container labels. Improper handling or misuse could result in severe personal injury or death. BODY PROTECTION WARNING Always wear OSHA approved body, sight, hearing, and respiratory system protection. Never wear loose clothing, jewelry, or long hair around an engine. The use of improper attire or failure to use protective equipment may result in severe personal injury or death. CLEANING SOLVENTS WARNING Comply with the solvent manufacturer’s recommendations for proper use and handling of solvents. Improper handling or misuse could result in severe personal injury or death. Do not use gasoline, paint thinners, or other highly volatile fluids for cleaning. FORM 6331 First Edition 1.00-3 SAFETY EMERGENCY SHUTDOWN D o n o t ov e r t i g h t e n capscrew. Overtightening will cause damage to the knock sensor. Disregarding this information could result in product damage and/or personal injury. CAUTION WARNING An Emergency Shutdown must never be used for a normal engine shutdown. Doing so may result in unburned fuel in the exhaust manifold. Failure to comply increases the risk of an exhaust explosion, which can result in severe personal injury or death. TOOLS ELECTRICAL WARNING Do not install, set up, maintain, or operate any electric tools unless you are a technically qualified individual who is familiar with them. Electrical tools use electricity and, if used improperly, could cause severe personal injury or death. PNEUMATIC PROGRAMMING WARNING Never set the high idle speed above the safe working limit of the driven equipment. If the GOVREMSP signal goes out of range or the GOVREMSEL signal is lost, then the engine will run at the speed determined by the status of GOVHL IDL and calibrated low or high idle speeds. Disregarding this information could cause severe personal injury and/or product damage. Ensure that the correct rotating moment of inertia (load inertia) is programmed in ESP for the engine’s driven equipment. Failure to program the moment of inertia for the driven equipment on the engine in ESP will lead to poor steady state and transient speed stability. Disregarding this information could result in product damage and/or personal injury. WARNING Do not install, set up, maintain, or operate any pneumatic tools unless you are a technically qualified individual who is familiar with them. Pneumatic tools use pressurized air and, if used improperly, could cause severe personal injury or death. CAUTION INTOXICANTS AND NARCOTICS WARNING Do not allow anyone under the influence of intoxicants and/or narcotics to work in or around industrial engines. Workers under the influence of intoxicants and/or narcotics are a hazard to both themselves and other employees and can cause severe personal injury or death to themselves or others. Wire the supplied fuel gas shutoff valve (ESM fuel valve) so it is controlled by the ESM. Disregarding this information could result in product damage and/or personal injury. CAUTION Failure to program the moment of inertia for the driven equipment on the engine in ESP will lead to poor steady state and transient speed stability. Disregarding this information could result in product damage and/or personal injury. CAUTION PROTECTIVE GUARDS WARNING Provide guarding to protect persons or structures from rotating or heated parts. Contact with rotating or heated parts can result in severe personal injury or death. HANDLING COMPONENTS Do not drop or mishandle knock sensor. If knock sensor is dropped or mishandled, it must be replaced. Disregarding this information could result in product damage and/or personal injury. CAUTION 1.00-4 FORM 6331 First Edition SECTION 1.05 GENERAL INFORMATION WIRING REQUIREMENTS All electrical equipment and wiring shall comply with applicable local codes. This standard defines additional requirements for Dresser Waukesha engines. • Each end of flexible metal conduit must have an insulating sleeve to protect wires from chafing. Do not use non electrical grade R T V. Non-electrical RTVs can emit corrosive gases that can damage electrical connectors. Disregarding this information could result in product damage and/or personal injury. WARNING Do not install, set up, maintain, or operate any electrical components unless you are a technically qualified individual who is familiar with the electrical elements involved. Electrical shock can cause severe personal injury or death. CAUTION • An electrical grade RTV should be applied around the wires entering all electrical devices and is to be applied immediately after wire installation. • A small “drip loop” should be formed in all wires before entering the electrical devices. This drip loop will reduce the amount of moisture entering an electrical device via the wires if an electrical grade RTV does not seal completely. • The following procedures should be followed for wires entering engine junction boxes: – Bottom entrance is best, and side entrance is second best. – Insert grommet in opening to protect wires. – Wires should contain “drip loop” before entering box, except where bottom entrance is used. – When installing flexible conduit, use straight connector for side entrance. If top entrance is required, use elbow connector. • If wire harness has a covering, clamp harness so openings of covering are downward. •• The routing of wires should be determined for reliability and appearance and not by shortest distance. •• Installation connection wire must be coiled and secured to provide protection during shipment. WARNING Disconnect all electrical power supplies before making any connections or servicing any part of the electrical system. Electrical shock can cause severe personal injury or death. • Whenever two or more wires run together, they should be fastened together at no more than 4 – 6 in. (10 – 15 cm) intervals, closer where necessary, with tie wraps or tape. • All wires should be mounted off hot areas of the engine with insulated clips, at intervals of no more than 12 in. (30 cm), closer where necessary. Wires must never be run closer than 6 in. (15 cm) to exhaust manifolds, turbochargers, or exhaust pipes. • In cases where wires do not run over the engine, they should be fastened to rigid, non-moving bodies with insulated clips when possible or tie wraps. Fasteners should be spaced at no more than 12 in. (30 cm) intervals. • When wires run through holes, rubber grommets should be installed in holes to protect the wires. Wires should never be run over rough surfaces or sharp edges without protection. FORM 6331 First Edition 1.05-1 GENERAL INFORMATION WARNING Always label “HIGH VOLTAGE” on engine-mounted equipment over 24 volts nominal. Failure to adhere to this warning could result in severe personal injury or death. • All engine-mounted electrical equipment over 24 volts nominal shall have “HIGH VOLTAGE” warning decal. Decal is to be attached to all the equipment and junction boxes on visible surface (vertical surface whenever possible). • Wiring that is routed in rigid or flexible conduit shall have all wire splices made only in junction boxes, outlet boxes, or equipment boxes. Wire splices shall not be located in the run of any conduit. ESP PROGRAMMING CONVENTIONS The following is a list of conventions used in the ESP software and documentation: • All commands enclosed in brackets, [ ], are found on the PC keyboard. • Menu names and menu options are in bold type. • Panel names and dialog box names begin with Uppercase Letters. • Field and button names begin with Uppercase Letters and are enclosed in “quotes”. • The [Return] key is the same as the [Enter] key (on some keyboards [Return] is used instead of [Enter]). • The fields on the ESP user interface screens are color-coded. See Table 1.05-1 for color key. Table 1.05-1 Color Key for ESP User Interface Panels COLOR Gray Dark Green White Light Green Pink Yellow Red Blue Off (No Alarm) Readings and Settings (General operating information such as temperature and pressure readings) Dials and Gauges On or Normal System Operation Low, Warmup, or Idle Signal Alarm or Sensor/Wiring Check Warning or Shutdown User-Programmable MEANING 1.05-2 FORM 6331 First Edition GENERAL INFORMATION DEFINITIONS NOTE: The terms defined in this manual are defined as they apply to Dresser Waukesha’s Engine System Manager ONLY. Definitions are not general definitions applicable to all situations. Actuator Gas Regulator (AGR): An actuator is installed onto the regulator to adjust the fuel flow to the engine. Within the actuator resides a stepper motor which adjusts the regulator setting by increasing or decreasing the spring pressure acting on the regulator diaphragm. In various documentation, the term “stepper” means the same as “actuator.” Air-Fuel Power Module (AFPM): The Air-Fuel Power Module is an extension of the ESM system that provides power to the O2 sensor block heaters, as well as signal conditioning for the O2 sensors themselves. Air-Fuel Ratio: Air-fuel ratio is a term used to define the amount of air (in either weight or mass) in relation to a single amount of fuel. • Rich Burn – Catalyst Setting (Typical) – Stoichiometric Setting • Lean Burn – 16V275GL (~11.2% O2) 32.00: 1 AFR 15.95: 1 AFR 16.09: 1 AFR Bypass: The bypass directs air from the outlet of the turbocharger compressor to the inlet of the turbocharger turbine. When at likely surge conditions (low speed or partial load) opening the bypass will increase the flow through the compressor, which helps move the compressor away from the surge line and towards the peak efficiency island. Calibration: The Engine System Manager is designed to work with various Dresser Waukesha engine families and configurations. Each ECU is factory-calibrated to work with a specific engine model. The ECU contains thousands of calibrations such as the number of cylinders, timing, sensor default values, high/low limitations, and necessary filters. CAN: Controller Area Network. A serial bus network of microcontrollers that connects devices, sensors, and actuators in a system for real-time control applications like the ESM. Since messages in a CAN are sent through the network with unique identifiers (no addressing scheme is used), it allows for uninterrupted transmission if one signal error is detected. CD-ROM: Compact Disk - Read Only Memory. A compact disk format used to hold text, graphics, and audio. It is like an audio CD but uses a different format for recording data. The ESM ESP software (including E-Help) is available in CD-ROM format. Closed-Loop Control: Closed-loop control is a method of controlling a process. It looks at the process’ output and adjusts the process’ inputs according to some preprogrammed instructions. With Lean Burn AFR control, the oxygen sensor provides “feedback” about the combustion process and “closes the loop.” This is an accurate form of process control. Combustion Stability Limit: As engine load is reduced from manufacturer’s rated load, combustion pressure within the engine diminishes. Below some power output, combustion is no longer stable, and exhaust oxygen is not a good indicator of air-fuel ratio. This is the combustion stability limit. The actuator travel limits (rich and lean limits) are employed at loads below this point to prevent driving the engine into either rich or lean misfire. DB Connector: A family of plugs and sockets widely used in communications and computer devices. DB connectors come in 9, 15, 25, 37, and 50-pin sizes. The DB connector defines the physical structure of the connector, not the purpose of each line. Alternate Dynamics: Setting used at low loads and speeds, which reduces the throttle gains to provide better speed stability. Analog Signals: A voltage or current signal proportional to a physical quantity. Baud Rate: The baud rate is the number of signaling elements that occur each second. The baud indicates the number of bits per second (bps) that are transmitted. Boost Pressure: Pressure of incoming air into throttle. Bus: A collection of wires through which data is transmitted from one part of a computerized system to another. A bus is a common pathway, or channel, between multiple devices. FORM 6331 First Edition 1.05-3 GENERAL INFORMATION Dead Band: This is the oxygen sensor target (setpoint) “tolerance” or control window within which the actuator position remains constant. The dead band prevents excessive stepper travel under minor variations in conditions. Detonation: See definition for “Knock”. Digital Signals: Signals representing data in binary form that a computer can understand. The signal is 0 or 1 (off or on). Droop: When a governor operates in droop mode, it means that the governor will allow the engine to slow down slightly under load. Droop is used to simulate the situation with mechanical governors where the engine will run at a slightly higher rpm than the setpoint when no load is placed on the engine. E-Help: ESP-Help (E-Help) is the name of the electronic help file included with the ESP software. E-Help provides fault code troubleshooting information. Electronic Service Program (ESP): ESP is the service program (software) that is the primary means of obtaining information on ESM status. ESP provides a graphical (visual) interface and is the means by which the information that the ECU logs can be read. ESP can be installed on a PC with Microsoft® Windows® XP operating system. A PC used to run the ESP software connects to the ECU via an RS-232 serial cable. Engine Control Unit (ECU): The Engine Control Unit (ECU) is the central module, or “hub,” of the ESM. The entire ESM interfaces with the ECU. All ESM components, the PC with Electronic Service Program software, and customer-supplied data acquisition devices, connect to the ECU. Fault: A fault is any condition detected by the ESM that is out-of-range, unusual, or outside normal operating conditions. Included are the following: • Scale High: A scale high fault indicates the value of the sensor is higher than its normal operating range. • Scale Low: A scale low fault indicates the value of the sensor is lower than its normal operating range. • Short or Open Circuit: A short or open circuit indicates sensor value is outside valid operating range and is most likely due to a damaged sensor or wiring. Fault Log: The ECU records faults into the fault log as they occur. The fault log is viewed using the ESM ESP software. Feedforward Control: Feedforward control, also referred to as load coming control, is a governing feature that allows the engine to accept larger load additions than would normally be possible. Freewheeling Diode: A freewheeling diode is added across the coils of a relay or solenoid to suppress the high induced voltages that may occur when equipment is turned off. Function Keys: A set of keys on a computer keyboard that are numbered F1 – F12 which perform special functions, depending on the application program in use. Graphical User Interface (GUI): An interface that is considered user-friendly because pictures (or icons) accompany the words on the screen. The use of icons, pull-down menus, and the mouse make software with a graphical user interface easier to work with and learn. Hard Drive: The primary computer storage medium normally internally sealed inside a PC. Typically, software programs and files are installed on a PC’s hard drive for storage. Also referred to as the hard disk. High Signal: A digital signal sent to the ECU that is between 8.6 and 36 volts. Home Position: Home position is where the stepper nut is in the fully retracted position. Icon: A small picture on a PC screen that represents a file or program. Files and programs open when the user double-clicks the icon. Ignition Power Module with Diagnostic Capability (IPM-D): The IPM-D is a high energy, capacitor discharge, solid state ignition module. The ECU directs the IPM-D when to fire each spark plug. See Section 2.10 Ignition System for more information on the IPM-D or the ignition system. IMAP: Intake Manifold Absolute Pressure. IMAP is the pressure of the downstream air from the throttle and is used to gauge the load on the engine. 1.05-4 FORM 6331 First Edition GENERAL INFORMATION Isochronous: When the governor control is isochronous, it means that the governor will control at a constant engine speed, regardless of load (steady state). Knock: Knock is the autoignition of the unconsumed end gas after the spark plug has fired during an engine’s combustion cycle. When this happens, the pressure in the chamber will spike, causing the structure of the engine to resonate, and an audible “ping” or “knock” is heard. Knock Frequency: The unique vibration or frequency that an engine exhibits while in knock. Knock Sensor: Converts engine vibration to an electrical signal to be used by the ECU to isolate the “knock” frequency. Knock Threshold: The knock threshold is a self-calibrating limit to determine if a cylinder is detonating. Once a cylinder exceeds the knock threshold, the ESM retards ignition timing for the cylinder in knock. Lambda: Lambda is defined as the excess air-fuel ratio and is calculated as: lambda = actual air-fuel ratio / stoichiometric air-fuel ratio. The ESM air-fuel ratio routine controls engine air-fuel ratio by maintaining a lambda over various speed, load, fuel, and environmental conditions. Lean Burn Air-Fuel Ratio: A control routine that uses feedback from the heated lean burn O2 sensor in the exhaust stream to control the air-fuel ratio of the engine by adjusting fuel pressure via the stepper motor. LED: Light Emitting Diode. Semiconductor that emits light. LEDs are used as power, alarm, and shutdown indicators located on the front of the ECU. Load Coming: See definition for feedforward control. Load Control: The ESM load control mode is used when an engine is synchronized to a grid and/or other units. In this case the grid controls speed. Load Inertia: Programming the load inertia or rotating mass moment of inertia of the driven equipment will set the governor gain correctly, aiding rapid setup of the engine. If this field is programmed correctly, there should be no need to program any of the gain adjustment fields. The rotating mass moment of inertia must be known for each piece of driven equipment and then added together. Log File Processor: A processing program that is loaded with the installation of ESP to convert binary log files saved by the ECU (extension .ACLOG) into either a Tab Separated Value file ( .TSV) or a text file ( .TXT). Low Signal: A digital signal sent to the ECU that is less than 3.3 volts. Magnetic Pickup: A two-wire electrical device that produces a voltage and current flow as steel teeth or holes move by the face of the pickup. Master-Slave Communications: Communications in which one side, called the “master,” initiates and controls the session. The “slave” is the other side that responds to the master’s commands. MODBUS®: MODBUS® is a protocol, or a set of rules governing the format of messages that are exchanged between computers, which is widely used to establish communication between devices. MODBUS® defines the message structure that the ESM and customer controllers will recognize and use, regardless of the type of networks over which they communicate. The protocol describes the process a controller uses to request access to another device, how it will respond to requests from the other devices, and how errors will be detected and reported. MODBUS® establishes a common format for the layout and content of messages. Modem: Modulator Demodulator. A device that converts data from digital computer signals to analog signals that can be sent over a telephone line. This is called modulation. The analog signals are then converted back into digital data by the receiving modem. This is called demodulation. NVRAM: Non-Volatile Random Access Memory. This is a type of RAM memory that retains its contents when power is turned off. When new values are saved in ESP, they are permanently saved to NVRAM within the ECU. When values are saved to NVRAM, the information is not lost when power to the ECU is removed. The user can save unlimited times to ECU NVRAM (permanent memory). O2 Heater Block: The O2 sensor is packaged as an assembly consisting of a steel block with heater cartridges and a temperature sensor. This block is threaded into the exhaust outlet using a pipe nipple that allows some exhaust gas to flow across the sensor. FORM 6331 First Edition 1.05-5 GENERAL INFORMATION Open Circuit: An open circuit indicates that the signal being received by the ECU is outside the valid operating range and is most likely due to a damaged sensor or wiring. Panel: ESP displays engine status and information on several panels: Engine, Start-Stop, Governor, Ignition, AFR Setup, Status, and Advanced. These panels display system and component status, current pressure and temperature readings, alarms, ignition status, governor status, air-fuel control status, and programmable adjustments. PC: Personal Computer. A PC used to run the ESP software connects to the ECU via an RS-232 serial cable. PLC: Programmable Logic Controller. A microprocessor used in process control applications. PLC microprocessors are designed for high-speed, real-time, and rugged industrial environments. PWM: Pulse Width Modulation. A technique employed to regulate power by turning a signal ON and OFF (see square wave below). In the AFPM it is used to regulate the voltage to the heater(s). Sample Window: A predetermined start and end time in which each cylinder will be looked at for knock. The window is used so that knock is looked for only during the combustion event. Scale High: A scale high fault indicates the value of the sensor is higher than its normal operating range. Scale Low: A scale low fault indicates the value of the sensor is lower than its normal operating range. Short Circuit: A short circuit indicates that the value of the sensor is outside the valid operating range and is most likely due to a damaged sensor or wiring. Slave Communications: A computer or peripheral device controlled by another computer. For example, since the ESM has MODBUS® slave communications capability, one “master” computer or PLC could communicate with multiple ESM MODBUS® slaves over the two-wire RS-485 network. Speed Control: The ESM speed control mode allows the engine operator to chose a setpoint speed, and the governor will control the engine at that speed. The control can be either fixed or variable. Start Position: This is a programmable stepper (actuator) position used to set gas/air at a value that is favorable for starting. Requires remote or manual initiation prior to starting. Start position is programmed on the [F8] AFR Setup Panel. Step: One “step” of the stepper motor inside the actuator equals 1/400 of 1 revolution of the stepper motor. This small change in position results in 0.00025 inch of linear travel of the adjusting nut within the actuator. This increases or decreases the fuel regulator spring pressure and correspondingly changes the gas/air pressure to the carburetor. Stepper Gain: Stepper gain influences how large a change is made to the actuator position when the oxygen sensor signal is not within the specified tolerance of the sensor target (setpoint). A larger gain will result in a larger change. RAM: Random Access Memory. When a programmable value is edited in ESP, it is stored in the ECU’s temporary memory, RAM. This allows the user to evaluate changes made to the ECU before saving the values to the ECU’s permanent memory, NVRAM. The contents of RAM will be lost if ECU loses power, but are unaffected if the PC loses power or is disconnected from the ECU. RS-232: Recommended Standard-232. One of a set of standards from the Electronics Industries Association for hardware devices and their interfaces. RS-232 is a well-known standard for transmitting serial data between computers and peripheral devices (modem, mouse, etc.). In the case of the ESM, an RS-232 cable transmits data from the ECU to the PC and vice versa. RS-485: Recommended Standard-485. One of a set of standards from the Electronics Industries Association for hardware devices and their interfaces. RS-485 is used for multi-point communications lines and is a specialized interface. The typical use for RS-485 is a single PC connected to several addressable devices that share the same cable. 1.05-6 FORM 6331 First Edition GENERAL INFORMATION Stepper Lean Limit: The most “retracted” actuator position or lowest gas/air that is programmed at which the engine can be safely operated. A more retracted actuator position allows less fuel to pass to the engine. Thus, the “minimum fuel” position is called the “lean limit.” It is used to prevent under-fueling of the engine. Actuator operation is only permitted between the rich and lean limits. Stepper Rich Limit: The most “advanced” actuator position or highest gas/air that is programmed at which the engine can be safely operated. Since a more extended actuator position results in more fuel being delivered to the engine, this is the “maximum fuel” position or “rich limit.” The rich limit is programmable with a PC and is used to prevent rich misfire and detonation in the engine. Actuator operation is permitted only between the rich and lean limits. Stepper Motor: This specially designed electric motor that resides in the actuator produces a precise “step-wise” rotation of the motor shaft instead of the “traditional” continuous rotation of most electric motors. Synchronizer Control: Synchronizer control is governor dynamics used to rapidly synchronize an engine generator to the electric power grid. Temperature Compensation: A setting which adjusts the wastegate and bypass valve positions to compensate for changes in ambient temperature. A compressor inlet temperature of 77° F (25° C) is the baseline point. At 77° F (25° C) there will be no change in valve position regardless of what the temperature compensation is. The change in desired valve positions increases as temperature increases or decreases as temperature decreases. Throttle Reserve: The static pressure drop across the main throttle valve and carburetor. The upstream pressure (Boost) is higher than the downstream pressure (IMAP). Throttle reserve = Boost – IMAP. Also referred to as “differential pressure” or as “delta P.” Training Tool: A software program, separate from ESP, that is loaded on a PC during ESP installation and is for training use only. An ECU cannot be programmed using the Training Tool but allows the user to open ESP without an ECU connected. Turbocharger: An air charging device that uses exhaust gas energy to compress intake air. A turbocharger consists of a compressor wheel and a turbine wheel that are in individual housings, but are mounted on a common shaft. A center housing cools, lubricates, and supports the shaft. The turbocharger rotates when exhaust gases flow through one side of the turbocharger (turbine housing and wheel). Since the exhaust (turbine) wheel and intake (compressor) wheel are mounted on a common shaft, the exhaust gases turn the exhaust wheel, which in turn, drives the compressor wheel, forcing air into the intake manifold. Turbocharger Surge: Turbocharger surge is the “banging” or “swishing” heard occasionally in engine turbochargers. Turbocharger surge typically occurs at partial load, when the volume of air required by the engine is substantially less than what is required by the turbocharger to prevent flow reversal (surge). Frequent changes in temperature and pressure ratio requirements can also trigger turbocharger surge. User Interface: The means by which a user interacts with a computer. The interface includes input devices such as a keyboard or mouse, the computer screen and what appears on it, and program/file icons. Windowing: A technique that allows the ESM to look for knock only during the combustion time when knock could be present. Wastegate Valve: The wastegate valve proportions exhaust flow from the engine around the turbocharger turbine and directs excess exhaust directly into the exhaust stack. The wastegate valve is used to control throttle reserve in closed-loop control. WKI: Waukesha Knock Index. An analytical tool, developed by Dresser Waukesha, as a method for calculating the knock resistance of gaseous fuels. It is a calculated numeric value used to determine the optimum engine settings based on a specific site’s fuel gas composition. Workspace: The file containing ESP panels is called the workspace. The workspace file is saved to the hard drive upon installation of the software. When ESP is opened, the correct workspace for the engine is automatically opened. FORM 6331 First Edition 1.05-7 GENERAL INFORMATION ACRONYMS AC: Alternating Current AFPM: Air-Fuel Power Module AFR: Air-Fuel Ratio ATDC: After Top Dead Center bps: bits per second CAN: Controller Area Network CD-ROM: Compact Disk - Read Only Memory CSA: Canadian Standards Association E-Help: ESP-Help ECU: Engine Control Unit ECP: Electronic Control Panel ESM: Engine System Manager ESP: Electronic Service Program GUI: Graphical User Interface HSD: High Side Driver IMAP: Intake Manifold Air Pressure IMAT: Intake Manifold Air Temperature IPM-D: Ignition Power Module with Diagnostic capability LED: Light Emitting Diode MB: Megabyte MHz: Megahertz NVRAM: Non-Volatile Random Access Memory OC: Open Circuit PC: Personal Computer PWM: Pulse Width Modulation PLC: Programmable Logic Controller RAM: Random Access Memory rpm: revolutions per minute RS: Recommended Standard SC: Short Circuit SH: Scale High SL: Scale Low TSV: Tab Separated Value WKI: Waukesha Knock Index 1.05-8 FORM 6331 First Edition GENERAL INFORMATION ENGLISH/METRIC CONVERSIONS Table 1.05-2. English to Metric Formula Conversion CONVERSION Inches to Millimeters Cubic Inches to Litres Ounces to Grams Pounds to Kilograms Inch Pounds to Newton-meters Foot Pounds to Newton-meters Pounds per Square Inch to Bars Pounds per Square Inch to Kilograms per Square Centimeter Pounds per Square Inch to Kilopascals Fluid Ounces to Cubic Centimeters U.S. Gallons to Litres Degrees Fahrenheit to Degrees Centigrade FORMULA Inches and any fraction in decimal equivalent multiplied by 25.4 equals millimeters. Cubic inches multiplied by 0.01639 equals litres. Ounces multiplied by 28.35 equals grams. Inch pounds multiplied by 0.113 equals Newton-meters. Foot pounds multiplied by 1.3558 equals Newton-meters. Pounds per square inch multiplied by 0.0690 equals bars. Pounds per square inch multiplied by 0.0703 equals kilograms per square centimeter. Pounds per square inch multiplied by 6.8947 equals kilopascals. Fluid ounces multiplied by 29.57 equals cubic centimeters. Degrees Fahrenheit minus 32 divided by 1.8 equals degrees Centigrade. EXAMPLE 2-5/8 in. = 2.625 x 25.4 = 66.7 mm 9388 cu. in. = 9388 x 0.01639 = 153.9 L 21 oz. = 21 x 28.35 = 595 g Pounds multiplied by 0.4536 equals kilograms. 22,550 lb. = 22,550 x 0.4536 = 10,229 kg 360 in-lb = 360 x 0.113 = 40.7 N·m 145 ft-lb = 145 x 1.3558 = 197 N·m 9933 psi = 9933 x 0.0690 = 685 bar 45 psi = 45 x 0.0703 = 3.2 kg/cm2 45 psi = 45 x 6.8947 = 310 kPa 8 oz. = 8 x 29.57 = 237 cc U.S. Gallons multiplied by 3.7853 equals litres. 148 gal. = 148 x 3.7853 = 560 L 212° F – 32 ÷ 1.8 = 100° C Table 1.05-3. Metric to English Formula Conversion CONVERSION Millimeters to Inches Litres to Cubic Inches Grams to Ounces Kilograms to Pounds Newton-meters to Inch Pounds Newton-meters to Foot Pounds Bars to Pounds per Square Inch Kilograms per Square Centimeter to Pounds per Square Inch (psi) Kilopascals to Pounds per Square Inch (psi) Cubic Centimeters to Fluid Ounces Litres to U.S. Gallons Degrees Centigrade to Degrees Fahrenheit FORMULA Millimeters multiplied by 0.03937 equals inches. Litres multiplied by 61.02 equals cubic inches. Grams multiplied by 0.03527 equals ounces. Kilograms multiplied by 2.205 equals pounds. Newton-meters multiplied by 8.85 equals inch pounds. Newton-meters multiplied by 0.7375 equals foot pounds. Bars multiplied by 14.5 equals pounds per square inch. Kilograms per square centimeter multiplied by 14.22 equals pounds per square inch. Kilopascals multiplied by 0.145 equals pounds per square inch. Cubic centimeters multiplied by 0.0338 equals fluid ounces. Litres multiplied by 0.264 equals U.S. gallons. Degrees Centigrade multiplied by 1.8 plus 32 equals degrees Fahrenheit. EXAMPLE 67 mm = 67 x 0.03937 = 2.6 in. 153.8 L = 153.8 x 61.02 = 9385 cu. in. 595 g = 595 x 0.03527 = 21.0 oz. 10,228 kg = 10,228 x 2.205 = 22,553 lb. 40.7 N·m = 40.7 x 8.85 = 360 in-lb 197 N·m = 197 x 0.7375 = 145 ft-lb 685 bar = 685 x 14.5 = 9933 psi 3.2 kg/cm2 = 3.2 x 14.22 = 46 psi 310 kPa = 310 x 0.145 = 45.0 psi 236 cc = 236 x 0.0338 = 7.98 oz. 560 L = 560 x 0.264 = 148 gal. 100° C = 100 x 1.8 + 32 = 212° F FORM 6331 First Edition 1.05-9 GENERAL INFORMATION TORQUE VALUES NOTE: Refer to the tables below only when a torque value is not explicitly stated in a given procedure. Table 1.05-4 U.S. Standard Capscrew Torque Values SAE GRADE NUMBER GRADE 1 OR 2 TORQUE in-lb (N·m) DRY 62 (7) 71 (8) 133 (15) 159 (18) 212 (24) GRADE 5 TORQUE in-lb (N·m) GRADE 8 TORQUE in-lb (N·m) PLATED 159 (18) 97 (11) 168 (19) 177 (20) 301 (34) THREADS 1/4–20 1/4–28 5/16–18 5/16–24 3/8–16 OILED 53 (6) 62 (7) 124 (14) 142 (16) 195 (22) PLATED 44 (5) 53 (6) 106 (12) 124 (14) 168 (19) DRY 97 (11) 124 (14) 203 (23) 230 (26) 372 (42) OILED 80 (9) 106 (12) 177 (20) 203 (23) 336 (38) DRY 142 (16) 168 (19) 292 (33) 327 (37) 531 (60) OILED 133 (15) 159 (18) 265 (30) 292 (33) 478 (54) PLATED 124 (14) 133 (15) 230 (26) 265 (30) 416 (47) ft-lb (N·m) 3/8–24 7/16–14 7/16–20 1/2–13 1/2–20 9/16–12 9/16–18 5/8–11 5/8–18 3/4–10 3/4–16 7/8–9 7/8–14 1.0–8 1.0–14 20 (27) 28 (38) 30 (41) 39 (53) 41 (56) 51 (69) 55 (75) 83 (113) 95 (129) 105 (142) 115 (156) 160 (217) 175 (237) 235 (319) 250 (339) 18 (24) 25 (34) 27 (37) 35 (47) 37 (50) 46 (62) 50 (68) 75 (102) 86 (117) 95 (130) 104 (141) 144 (195) 158 (214) 212 (287) 225 (305) 16 (22) 22 (30) 24 (33) 31 (42) 33 (45) 41 (56) 44 (60) 66 (89) 76 (103) 84 (114) 92 (125) 128 (174) 140 (190) 188 (255) 200 (271) 35 (47) 49 (56) 55 (75) 75 (102) 85 (115) 110 (149) 120 (163) 150 (203) 170 (230) 270 (366) 295 (400) 395 (535) 435 (590) 590 (800) 660 (895) ft-lb (N·m) 32 (43) 44 (60) 50 (68) 68 (92) 77 (104) 99 (134) 108 (146) 135 (183) 153 (207) 243 (329) 266 (361) 356 (483) 392 (531) 531 (720) 594 (805) 28 (38) 39 (53) 44 (60) 60 (81) 68 (92) 88 (119) 96 (130) 120 (163) 136 (184) 216 (293) 236 (320) 316 (428) 348 (472) 472 (640) 528 (716) 49 (66) 70 (95) 78 (106) 105 (142) 120 (163) 155 (210) 170 (230) 210 (285) 240 (325) 375 (508) 420 (569) 605 (820) 675 (915) 910 (1234) 990 (1342) ft-lb (N·m) 44 (60) 63 (85) 70 (95) 95 (129) 108 (146) 140 (190) 153 (207) 189 (256) 216 (293) 338 (458) 378 (513) 545 (739) 608 (824) 819 (1110) 891 (1208) 39 (53) 56 (76) 62 (84) 84 (114) 96 (130) 124 (168) 136 (184) 168 (228) 192 (260) 300 (407) 336 (456) 484 (656) 540 (732) 728 (987) 792 (1074) NOTE: Dry torque values are based on the use of clean, dry threads. Oiled torque values have been reduced by 10% when engine oil is used as a lubricant. Plated torque values have been reduced by 20% for new plated capscrews. Capscrews that are threaded into aluminum may require a torque reduction of 30% or more. The conversion factor from ft-lb to in-lb is ft-lb x 12 equals in-lb. Oiled torque values should be reduced by 10% from dry when nickel-based anti-seize compound is used as a lubricant. Oiled torque values should be reduced by 16% from dry when copper-based anti-seize compound is used as a lubricant. 1.05-10 FORM 6331 First Edition GENERAL INFORMATION Table 1.05-5. Metric Standard Capscrew Torque Values (Untreated Black Finish) COARSE THREAD CAPSCREWS (UNTREATED BLACK FINISH) ISO PROPERTY CLASS SIZE M3 M4 M5 M6 M7 M8 M10 5.6 8.8 10.9 12.9 TORQUE N·m 0.6 1.37 2.7 4.6 7.6 11 22 TORQUE N·m 1.37 3.1 10.5 10.5 17.5 26 51 TORQUE N·m 1.92 4.4 15 15 25 36 72 TORQUE N·m 2.3 10.4 18 10.4 29 43 87 in-lb 5 12 24 41 67 97 195 in-lb 12 27 93 93 155 230 451 in-lb 17 39 133 133 221 319 637 in-lb 20 92 159 92 257 380 770 N·m M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 39 62 95 130 184 250 315 470 635 865 1111 1440 ft-lb 28 45 70 95 135 184 232 346 468 637 819 1062 N·m 89 141 215 295 420 570 725 1070 1450 1970 2530 3290 ft-lb 65 103 158 217 309 420 534 789 1069 1452 1865 2426 N·m 125 198 305 420 590 800 1020 1519 2050 2770 3560 4620 ft-lb 92 146 224 309 435 590 752 1113 1511 2042 2625 3407 N·m 150 240 365 500 710 960 1220 1810 2450 3330 4280 5550 ft-lb 110 177 269 368 523 708 899 1334 1806 2455 3156 4093 FINE THREAD CAPSCREWS (UNTREATED BLACK FINISH) ISO PROPERTY CLASS SIZE M8 x 1 M10 x 1.25 M12 x 1.25 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 8.8 10.9 12.9 TORQUE N·m 27 52 95 150 225 325 460 610 780 TORQUE ft-lb 19 38 70 110 165 239 339 449 575 TORQUE ft-lb 28 53 99 154 232 339 472 634 811 N·m 38 73 135 210 315 460 640 860 1100 N·m 45 88 160 250 380 550 770 1050 1300 ft-lb 33 64 118 184 280 405 567 774 958 NOTE: The conversion factors used in these tables are as follows: One N·m equals 0.7375 ft-lb, and one ft-lb equals 1.355818 N·m. FORM 6331 First Edition 1.05-11 GENERAL INFORMATION Table 1.05-6. Metric Standard Capscrew Torque Values (Electrically Zinc Plated) COARSE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED) ISO PROPERTY CLASS SIZE M3 M4 M5 M6 M7 M8 M10 5.6 8.8 10.9 12.9 TORQUE N·m 0.56 1.28 2.5 4.3 7.1 10.5 21 TORQUE N·m 1.28 2.9 5.75 9.9 16.5 24 48 TORQUE N·m 1.8 4.1 8.1 14 23 34 67 TORQUE N·m 2.15 4.95 9.7 16.5 27 40 81 in-lb 5 11 22 38 63 93 186 in-lb 11 26 51 88 146 212 425 in-lb 16 36 72 124 203 301 593 in-lb 19 44 86 146 239 354 717 N·m M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 36 58 88 121 171 230 295 435 590 800 1030 1340 ft-lb 26 42 64 89 126 169 217 320 435 590 759 988 N·m 83 132 200 275 390 530 675 995 1350 1830 2360 3050 ft-lb 61 97 147 202 287 390 497 733 995 1349 1740 2249 N·m 117 185 285 390 550 745 960 1400 1900 2580 3310 4290 ft-lb 86 136 210 287 405 549 708 1032 1401 1902 2441 3163 N·m 140 220 340 470 660 890 1140 1680 2280 3090 3980 5150 ft-lb 103 162 250 346 486 656 840 1239 1681 2278 2935 3798 FINE THREAD CAPSCREWS (ELECTRICALLY ZINC PLATED) ISO PROPERTY CLASS SIZE M8 x 1 M10 x 1.25 M12 x 1.25 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 8.8 10.9 12.9 TORQUE N·m 25 49 88 140 210 305 425 570 720 TORQUE ft-lb 18 36 64 103 154 224 313 420 531 TORQUE ft-lb 25 50 92 143 217 313 442 590 737 N·m 35 68 125 195 295 425 600 800 1000 N·m 42 82 150 235 350 510 720 960 1200 ft-lb 30 60 110 173 258 376 531 708 885 NOTE: The conversion factors used in these tables are as follows: One N·m equals 0.7375 ft-lb, and one ft-lb equals 1.355818 N·m. 1.05-12 FORM 6331 First Edition SECTION 1.10 ENGINE SYSTEM MANAGER (ESM) OVERVIEW The Dresser Waukesha Engine System Manager (ESM) is a system designed to optimize engine performance and maximize uptime. The ESM integrates spark timing control, speed governing, knock detection, start-stop control, air-fuel control, diagnostic tools, fault logging, and engine safeties. In addition, the ESM has safety shutdowns such as low oil pressure, engine overspeed, high intake manifold air temperature, high coolant outlet temperature, and uncontrolled knock. See Figure 1.10-1 for a general overview of the ESM inputs and outputs. It will be necessary as you go through this manual to familiarize yourself with the location of all the individual components that comprise the ESM. See Table 1.10-1 for component locations. Ignition Coils 24 VDC Personal Computer AIR / FUEL POWER MODULE Ignition Power Module w/ Diagnostics Power Distribution Junction Box Electronic Service Program O2 Sensor/ Heater Block Wastegate Control AGR Stepper Integrated Throttle Control • Throttle Actuator • Throttle Position • Power Electronics Intake Manifold Pressure (2) Oil Pressure • Pre-Filter • Post-Filter Barometric Pressure Modem Camshaft & Crankshaft Magnetic Pickup Fuel Pressure HT Coolant Pressure Knock Sensors HT Water Temperature Oil Temperature Intake Manifold Temperature Ambient Air Temperature Bypass Control Modem Remote Control Data Acquisition (SCADA or MMI) Figure 1.10-1. 16V275GL System Block Diagram FORM 6331 First Edition 1.10-1 ENGINE SYSTEM MANAGER (ESM) OVERVIEW Table 1.10-1. Location of Components – Right Bank 1 2 3 4 Location 1 2 Stepper Motor Component Emergency Stop Button (E-Stop) Location 3 4 Component Air-Fuel Power Module (AFPM) Ignition Power Module-Diagnostic (IPM-D) Table 1.10-2. Location of Components – Left Bank 1 2 3 4 Location 1 2 Component Emergency Stop Button (E-Stop) Customer Harness Connection Location 3 4 Component Power Distribution Junction Box Engine Control Unit (ECU) 1.10-2 FORM 6331 First Edition ENGINE SYSTEM MANAGER (ESM) OVERVIEW Table 1.10-3. Location of Components – Top View 1 2 Location 1 2 Throttle Actuator Wastegate Actuator Component Location 3 Bypass Actuator 3 Component ESM COMPONENTS ENGINE CONTROL UNIT (ECU) All ESM components, the customer-supplied PC with Electronic Service Program software, and customer-supplied data acquisition devices connect to the ECU. Communication is available through: • Status LEDs (light emitting diodes) that flash alarm/ shutdown codes on the front of the ECU • Analog and digital signals in/out to local panel or customer PLC • RS-485 (MODBUS® secondary) communication to local panel or customer PLC (MODBUS® master) • PC-based ESM Electronic Service Program via an RS-232 connection O Figure 1.10-2. ESM Installed on 16V275GL Engine 1 The Engine Control Unit (ECU) is the central module or “hub” of the ESM. The ECU is the single entry point of system control for easy interface and usability. The entire ESM interfaces with the ECU. Based on system inputs, the ECU logic and circuitry drive all the individual subsystems. The ECU is a sealed module with five connection points. The ECU is CSA approved for Class I, Division 2, Groups A, B, C, and D (T4 temperature rating), hazardous location requirements. 1) ESM Engine Control Unit (ECU) Figure 1.10-3. FORM 6331 First Edition 1.10-3 ENGINE SYSTEM MANAGER (ESM) OVERVIEW POWER DISTRIBUTION JUNCTION BOX The Power Distribution Junction Box is used to protect and distribute 24 VDC power to all the components on the engine that require power, such as the ECU, IPM-D, and actuators; no other power connections are necessary. It also triggers controlled devices such as the prelube motor and fuel valve. The Power Distribution Junction Box contains circuitry to clamp input voltage spikes to a safe level before distribution. It will disable individual output circuits from high current events such as a wire short. Also, LEDs inside the Power Distribution Junction Box aid in troubleshooting of the individual output circuits. AIR-FUEL POWER MODULE (AFPM) The Air-Fuel Power Module (AFPM) conditions the exhaust oxygen sensor signals, as well as controls the sensor heating elements, ensuring the temperatures are high enough for correct operation of the oxygen sensor. A programmed minimum temperature must be achieved before “closed-loop” control is enabled. 1 1) Air-Fuel Power Module (AFPM) Figure 1.10-6. STEPPER (AGR – ACTUATOR, GAS REGULATOR) Figure 1.10-4. Power Distribution Junction Box IGNITION POWER MODULE WITH DIAGNOSTICS (IPM-D) The Ignition Power Module with Diagnostic capability (IPM-D) is used to fire the spark plug at the required voltage (see Figure 1.10-5). A stepper motor is mounted on the gas regulator and is used to adjust the gas/air at the direction of the ESM (see Figure 1.10-7). The top cover has electronics built in to communicate with ESM. The stepper motor assembly is also referred to as the “AGR” (actuator, gas regulator). The stepper is controlled using signals transmitted over the ESM CAN (Controller Area Network) communication bus, which minimizes control wiring while maintaining a communication scheme. Stepper diagnostic information is relayed back to the ECU over the CAN bus. 1 1) Ignition Power Module With Diagnostics (IPM-D) 1 1) Stepper Actuator Figure 1.10-5. Figure 1.10-7. 1.10-4 FORM 6331 First Edition ENGINE SYSTEM MANAGER (ESM) OVERVIEW THROTTLE ACTUATOR An electronic throttle actuator is used to adjust the amount of air-fuel delivered to the engine through the throttle (see Figure 1.10-8). WASTEGATE ACTUATOR The wastegate actuator controls exhaust flow through the turbine side of the turbocharger. Its main function is to maintain the pressure ratio across the compressor, by directing a portion of the exhaust flow around the turbocharger (see Figure 1.10-8). BYPASS ACTUATOR The bypass valve controls air flow through the compressor side of the turbocharger. The bypass valve’s main function is to prevent turbocharger surge by increasing the flow through the compressor, which redirects air from the compressor outlet to the turbine inlet, which “bypasses” the engine (see Figure 1.10-8). Excess air is directed upstream of the turbine to maintain turbocharger speed and air flow through the compressor without increasing air flow to the engine. 2 1 3 ENGINE SYSTEM MANAGER SENSORS A wide variety of sensors are used to provide critical operating information to the ECU. If a sensor provides a signal outside the normal range long enough, the ECU will flag either an alarm or a shutdown, depending on how great the value deviates from normal or if the values exceed the setpoints programmed in ESP. Sensors normally do not require maintenance or adjustments. See Table 1.10-4 and Table 1.10-5 for sensor locations, and Figure 1.10-9. through Figure 1.10-18. for pictures of each. Table 1.10-4. Location of Sensors – Top View 1 2 3 4 5 1) Throttle Actuator 2) Bypass Actuator 3) Wastegate Actuator Figure 1.10-8. 6 Location 1 2 3 4 Component Intake Manifold Temperature Sensor (IMAT) Back Intake Manifold Pressure Sensor (IMAP) Front Intake Manifold Pressure Sensor (IMAP) Knock Sensors (One Per Cylinder) Location 5 6 7 Component Boost Pressure Sensor Coolant Pressure Sensor Coolant Temperature Sensor 7 FORM 6331 First Edition 1.10-5 ENGINE SYSTEM MANAGER (ESM) OVERVIEW Table 1.10-5. Location of Components – Front/Rear FRONT VIEW REAR VIEW 8 9 13 14 10 15 16 11 12 Location 8 9 10 11 12 O2 Sensor Component Ambient Air Temperature Sensor Fuel Pressure Sensor Barometric Pressure Sensor Crankshaft Magnetic Pickup Sensor Location 13 14 15 16 Component Oil Temperature Sensor Post-Filter Oil Pressure sensor Pre-Filter Oil Pressure Sensor Camshaft Magnetic Pickup 1 2 3 1) Intake Manifold Temperature Sensor (IMAT) 2) Back Intake Manifold Pressure Sensor (IMAP) 3) Front Intake Manifold Pressure Sensor (IMAP) Figure 1.10-10. Figure 1.10-9. 1.10-6 FORM 6331 First Edition ENGINE SYSTEM MANAGER (ESM) OVERVIEW 8 4 4) Knock Sensor 8) O2 Sensor Figure 1.10-11. Figure 1.10-14. 9 5 5) Boost Pressure Sensor 9) Ambient Air Temperature Sensor Figure 1.10-12. Figure 1.10-15. 7 6 10 6) Coolant Pressure Sensor 7) Coolant Temperature Sensor 10) Fuel Pressure Sensor Figure 1.10-13. Figure 1.10-16. FORM 6331 First Edition 1.10-7 ENGINE SYSTEM MANAGER (ESM) OVERVIEW 11 16 11) Barometric Pressure Sensor 16)Camshaft Magnetic Pickup Figure 1.10-17. Figure 1.10-20. 12 12) Crankshaft Magnetic Pickup Figure 1.10-18. 13 14 15 13) Pre-Filter Pressure 14) Oil Temperature 15) Post-Filter Pressure Figure 1.10-19. 1.10-8 FORM 6331 First Edition ENGINE SYSTEM MANAGER (ESM) OVERVIEW ELECTRONIC SERVICE PROGRAM (ESP) Figure 1.10-21. Electronic Service Program’s (ESP’s) Graphical User Interface The PC-based Electronic Service Program (ESP) is the primary means of obtaining information on system status. ESP provides a user-friendly, graphical interface in a Microsoft® Windows® XP operating system environment (see Figure 1.10-21). ESP also includes E-Help that provides fault code troubleshooting information. ESP is a diagnostic tool and the means by which the information recorded to the ECU fault logs can be read. Minimal site-specific programming is required. This is the ESP shortcut that appears on your desktop after loading the software on your PC. To open the ESP software, double-click on the shortcut. E-HELP ESP contains a help file named E-Help, which provides fault code troubleshooting information when a PC with the ESP software is used (see Figure 1.10-22 for a sample screen). The user can quickly and easily move around in E-Help through hypertext links from subject to subject. E-Help is automatically installed when the ESP software is installed. To access the help file anytime while using the ESP software, press the [F1] function key on the keyboard or select “Help” from the menu bar and choose “Help Contents...”. See Section 4.00 Troubleshooting “E-Help” for more information. FORM 6331 First Edition 1.10-9 ENGINE SYSTEM MANAGER (ESM) OVERVIEW • Yellow status LED on the front of the ECU lights and begins to flash a fault code. • Shutdown occurs and the red status LED on the front of the ECU lights and flashes a code. • Sensors and actuator switch into a “default state” where the actuator/sensors operate at expected normal values or at values that place the engine in a safe state. When the default state takes control, an alarm is signaled and the fault is logged but the engine keeps running (unless, as a result of the fault, a shutdown fault occurs). • Alarm or shutdown signal is transmitted over the customer interface (RS-485 MODBUS® and digital output). SAFETY SHUTDOWNS Figure 1.10-22. Sample E-Help Screen USER INTERFACE PANELS The ESM ESP software displays engine status and information on seven panels: [F2] Engine Panel [F8] AFR Setup Panel The ESM provides numerous engine safety shutdowns to protect the engine. These engine safety shutdowns include: • Emergency Stop (E-Stop) switches on each side of the engine • Low oil pressure • Engine overspeed [F3] Start-Stop Panel [F10] Status Panel [F4] Governor Panel [F5] Ignition Panel These panels display system and component status, current pressure and temperature readings, alarms, ignition status, governor status, air-fuel control status, and programmable adjustments. Each of the panels is viewed by clicking the corresponding tab or by pressing the corresponding function key ([F#]) on the keyboard. [F11] Advanced Panel •• 10% overspeed instantaneous •• Factory-calibrated to run no more than rated speed •• User-calibrated driven equipment overspeed • Customer-initiated emergency shutdown • Engine overload (based on percentage of engine torque) • Uncontrollable knock • HT water coolant temperature • HT water coolant pressure • High intake manifold air temperature • Overcrank • Engine stall • Security violation • High oil temperature • Failure of magnetic pickup • Internal ECU ESM DIAGNOSTICS The ESM performs self-diagnostics using the input and output values from the ECU, the sensors, and engine performance. The ECU detects faulty sensors and wires by checking for sensor readings that are out of programmed limits. When a fault occurs, several actions may take place as a result. A fault can have both internal actions and external visible effects. Each fault detected will cause one or more of the following actions to occur: • Alarm is logged by the ECU and appears in the ESP Fault Log. See Section 3.00 Introduction to Electronic Service Program (ESP) for more information. 1.10-10 FORM 6331 First Edition ENGINE SYSTEM MANAGER (ESM) OVERVIEW START-STOP CONTROL The ESM controls the start, normal stop, and emergency stop sequences of the engine, including prelube, postlube, exhaust vent, water heating/circulation, and gas train testing. The user is informed of any shutdowns or alarms via a series of flashing LEDs on the ECU or by monitoring the ESM with ESP. See Section 2.05 Start-Stop Control for more information. ESM TURBOCHARGER CONTROL The ESM Turbocharger Control is designed to control flow rates through the compressor-side and turbine-side of the turbochargers to prevent surge and overspeed, while maintaining proper throttle reserve. Flow through the compressor is controlled via the bypass, whereas flow through the turbine is controlled via the wastegate. The ESM Turbocharger Control consists of the ECU and two turbocharger control actuators that control the exhaust wastegate and bypass valves. The turbocharger control monitors four areas on the engine to determine wastegate and bypass valve position. For more information on speed governing see Section 2.25 ESM Turbocharger Control. IGNITION SYSTEM The ESM controls spark plug timing with a digital capacitive discharge ignition system. Together the ECU and the IPM-D provide accurate and reliable ignition timing resulting in optimum engine operation. For more information on the ignition system, see Section 2.10 Ignition System. KNOCK DETECTION The ESM protects Dresser Waukesha spark-ignited gas engines from damage using knock (detonation) detection. This is accomplished by monitoring vibrations at each cylinder with engine-mounted knock sensors. For more information on knock detection, see Section 2.15 Knock Detection and Timing Control. ESM SPEED GOVERNING Speed governing is completely integrated into the ESM; the ECU contains the governor electronics and software that control the actuator. The ESM speed governing system allows the customer to make all control adjustments in one place and at one panel. The ECU sends information to the bypass actuator and stepper motor to adjust the amount of air-fuel being delivered into the cylinders. This governing system provides the following benefits: • Ability to respond to larger load transients • Better engine stability • Easier setup • Integrated operation diagnostics For more information on speed governing see Section 2.30 ESM Speed Governing. AIR-FUEL RATIO CONTROL The ESM Lean Burn AFR Control builds upon the basic ESM configuration by adding the following: • Exhaust oxygen sensor/heater block assembly • Air/Fuel Power Module (AFPM) • Heater block temperature sensor (RTD) • Barometric pressure sensor • Ambient temperature sensor • AGR (Actuator, Gas Regulator) stepper for the gas regulator In addition, other sensor inputs already available to the ESM, such as the intake manifold pressure, are used. FORM 6331 First Edition 1.10-11 ENGINE SYSTEM MANAGER (ESM) OVERVIEW 1.10-12 FORM 6331 First Edition ESM OPERATION CONTENTS SECTION 2.00 – SYSTEM POWER AND WIRING SECTION 2.05 – START-STOP CONTROL SECTION 2.10 – IGNITION SYSTEM SECTION 2.15 – KNOCK DETECTION SECTION 2.20 – AIR-FUEL CONTROL SECTION 2.25 – ESM TURBOCHARGER CONTROL SECTION 2.30 – ESM SPEED GOVERNING SECTION 2.35 – EMERGENCY SAFETY SHUTDOWNS SECTION 2.40 – ESM COMMUNICATIONS FORM 6331 First Edition ESM OPERATION FORM 6331 First Edition SECTION 2.00 SYSTEM POWER AND WIRING POWER SUPPLY REQUIREMENTS WARNING Do not install, set up, maintain, or operate any electrical components unless you are a technically qualified individual who is familiar with the electrical elements involved. Electrical shock can cause severe personal injury or death. Power can also be supplied to the ESM by connecting a DC power supply directly to the Power Distribution Junction Box. The disadvantage of a DC power supply is that if the power is lost, the engine shuts down immediately. In addition, power supplies do not provide the noise filtering capabilities of batteries. To remedy this, a more expensive power supply may be needed, or optional batteries can be used to provide noise filtering. See “Connecting Ground and Power to Power Distribution Junction Box” on page 2.00-5 for information on wiring power inside the Power Distribution Junction Box. WARNING Disconnect all electrical power supplies before making any connections or servicing any part of the electrical system. Electrical shock can cause severe personal injury or death. Disconnect all engine harnesses and electronically controlled devices before welding on or near an engine. Failure to comply will void warranty. Failure to disconnect the harnesses and electronically controlled devices could result in product damage and/or personal injury. BATTERY REQUIREMENTS CAUTION WARNING Comply with the battery manufacturer’s recommendations for procedures concerning proper battery use and maintenance. Improper maintenance or misuse can cause severe personal injury or death. The ESM requires 20 – 30 VDC. The peak-to-peak voltage ripple must be less than 2 volts. The maximum, or high end, voltage is 32 volts. NOTE: The label on the ECU lists a voltage requirement of 12 – 36 VDC. That range is the power requirement for the ECU only. For proper operation, the ESM requires 20 – 30 VDC. The ESM will run on 20 – 30 VDC, but if the voltage drops below 21 VDC, the ESM will trigger alarm “ALM454”. ALM454 is triggered when the battery voltage is out of specification. ALM454 is a warning to the operator that some action must be taken to prevent power loss and engine shutdown. Batteries are the preferred method of supplying the ESM with clean, stable power. In addition, batteries have the advantage of continued engine operation if there is a disruption in the source of electric power. WARNING Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxygen gases. Keep any device that may cause sparks or flames away from the battery to prevent explosion. Batteries can explode, causing severe personal injury or death. WARNING Always wear protective glasses or goggles and protective clothing when working with batteries. You must follow the battery manufacturer’s instructions on safety, maintenance and installation procedures. Failure to follow the battery manufacturer’s instructions can cause severe personal injury or death. FORM 6331 First Edition 2.00-1 SYSTEM POWER AND WIRING The batteries must be maintained properly, in good operating condition, and at full charge. System voltage must remain above 20 VDC even during cranking to ensure proper operation. Failure to properly maintain the charge of the batteries causes sulfation of the battery plates, reducing and eventually destroying the ability of the battery to generate power or dampen ripples. Failure to adequately dampen ripples may lead to malfunction of battery POWER SUPPLIED BY BATTERIES powered devices. See Section 4.05 ESM Maintenance “Battery Maintenance”. Always turn the battery charger off first, before disconnecting the batteries. Then disconnect the battery negative (-) cable before beginning any repair work. Failure to disconnect the battery charger first could result in product damage and/or personal injury and voids product warranty. CAUTION CHARGING EQUIPMENT Size per Table 2.05-3 on page 2.05-2 Using Maximum ESM Current Draw + - POWER DISTRIBUTION JUNCTION BOX + 1/2 INCH GROUND STUD - + - ENGINE CRANKCASE EARTH GROUND 2/0 AWG MIN. POWER (+) NOT WIRED AT DRESSER WAUKESHA GROUND (-) WIRED AT DRESSER WAUKESHA GROUND (-) NOT WIRED AT DRESSER WAUKESHA EARTH GROUND (-) NOT WIRED AT DRESSER WAUKESHA ANY CHARGING EQUIPMENT MUST BE CONNECTED DIRECTLY TO THE BATTERIES Figure 2.00-1. Power Supplied by Batteries 2.00-2 FORM 6331 First Edition SYSTEM POWER AND WIRING POWER SUPPLIED BY 24VDC POWER SUPPLY + Size per Table 2.05-3 on page 2.05-2 Using Maximum ESM Current Draw 24VDC POWER SUPPLY POWER DISTRIBUTION JUNCTION BOX + 1/2 INCH GROUND STUD - + - Optional Batteries for Filtering ENGINE CRANKCASE EARTH GROUND 2/0 AWG MIN. POWER (+) NOT WIRED AT DRESSER WAUKESHA GROUND (-) WIRED AT DRESSER WAUKESHA GROUND (-) NOT WIRED AT DRESSER WAUKESHA EARTH GROUND (-) NOT WIRED AT DRESSER WAUKESHA ANY CHARGING EQUIPMENT MUST BE CONNECTED DIRECTLY TO THE BATTERIES Figure 2.00-2. Power Supply by 24VDC Power Supply FORM 6331 First Edition 2.00-3 SYSTEM POWER AND WIRING POWER DISTRIBUTION JUNCTION BOX RECOMMENDED WIRING Depending on the distance from the batteries or power supply, choose appropriate cable diameters for ground and power using Table 2.00-2 and Table 2.00-3. Table 2.00-2. AWG, mm2, and Circular mils AWG 0000 000 00 0 1 2 3 4 6 8 10 12 14 16 WARNING Do not install, set up, maintain, or operate any electrical components unless you are a technically qualified individual who is familiar with the electrical elements involved. Electrical shock could result in severe personal injury or death. NOTE: The batteries should be wired directly to the Power Distribution Junction Box (use the largest diameter cable that is practical; 00 AWG is the largest the Power Distribution Junction Box can accommodate). The installer needs to supply 24 VDC power to the Power Distribution Junction Box. Table 2.00-1 lists the current draw information for the ESM; always wire for maximum current draw. Table 2.00-1. ESM Current Draw ENGINE MODEL 16V275GL mm2 107.2 85.0 67.5 53.4 42.4 33.6 26.7 21.2 13.3 8.35 5.27 3.31 2.08 1.31 CIRCULAR MILS 211592 167800 133072 105531 83690 66369 52633 41740 26251 16509 10383 6529.8 4106.6 2582.7 AVERAGE MAXIMUM CURRENT DRAW CURRENT DRAW (AMPS) (AMPS) 20 nominal 40 These values do not include USER POWER 24V for U (5 Amps max) NOTE: The current draw is variable depending on if the O2 block heaters are on or off. The heaters are controlled using pulse width modulation, so the current will vary. Table 2.00-3. Recommended Wire Sizes (AWG) vs. Round Trip Length Between Battery and Power Distribution Junction Box ROUND TRIP LENGTH OF CONDUCTOR FT 10 15 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 MAXIMUM CURRENT (AMPS) 5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 M 3.0 4.6 6.1 7.6 9.1 12.2 15.2 18.3 21.3 24.4 27.4 30.5 33.5 36.6 39.6 42.7 45.7 48.8 10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 25 12 12 10 10 8 6 6 6 4 4 4 4 2 2 2 2 2 2 30 12 10 10 8 8 6 6 4 4 4 2 2 2 2 2 1 1 1 40 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 50 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 60 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 70 8 6 6 4 4 2 2 1 1 0 0 2/0 2/0 3/0 3/0 3/0 3/0 4/0 80 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 90 8 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 4/0 100 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0 – – – 2.00-4 FORM 6331 First Edition SYSTEM POWER AND WIRING CONNECTING GROUND AND POWER TO POWER DISTRIBUTION JUNCTION BOX 1 WARNING Disconnect all electrical power supplies and batteries before making any connections or servicing any part of the electrical system. Electrical shock can cause severe personal injury or death. 2 WARNING Do not install, set up, maintain, or operate any electrical components unless you are a technically qualified individual who is familiar with the electrical elements involved. Electrical shock can cause severe personal injury or death. Disconnect all engine harnesses and electronically controlled devices before welding on or near an engine. Failure to comply will void warranty. Failure to disconnect the harnesses and electronically controlled devices could result in product damage and/or personal injury. 1) Positive Battery Connection 2) Negative Battery Connection Figure 2.00-3. CAUTION 1. Locate M12 ground stud on right bank of crankcase. The right rear ground stud has two ground cables attached to it from the Power Distribution Junction Box. (see Figure 2.00-3). 2. Remove outer nut from stud. Do not loosen or remove the factory-installed ground cables located inside the Power Distribution Junction Box. 3. Attach ground cable to the ground stud using hardware as required. 4. Replace outer nut to ground stud. 5. Apply corrosion protection material such as Krylon® 1307 or K1308 Battery Protector (or equivalent) to ground connection. 6. Choose an appropriately sized sealing gland for the +24 VDC power cable. 7. Feed the power cable through the POWER cord grip. 8. Install an appropriately sized ring terminal on the power cable. 9. Attach the power ring terminal to the positive 3/8 inch stud located in the Power Distribution Junction Box (see Figure 2.00-3). 10. Attach prelube motor solenoid contacts to correctly labeled terminals (if customer supplied). 11. Attach fuel valve solenoid contact to correctly labeled terminals. FORM 6331 First Edition 2.00-5 SYSTEM POWER AND WIRING CUSTOMER INTERFACE HARNESS The electrical interference from solenoids and other electrical switches will not be cyclic and can be as high as several hundred volts. This could cause faults within the ESM that may or may not be indicated with diagnostics. Dresser Waukesha requires a “freewheeling” diode be added across the coils of relays and solenoids to suppress high induced voltages that may occur when equipment is turned off. Failure to comply will void product warranty. Disregarding this information could result in personal injury and/or product damage. Customer electrical connections to the ECU are made through the Customer Interface Harness. The harness is shipped loose with the engine and has a standard length of 25 ft. (8 m). Optional harness lengths of 50 ft. (15 m) and 100 ft. (30 m) are available. The terminated end of the harness connects to a bulkhead connector behind the Power Distribution Junction Box on the Power Distribution Junction Box bracket. The unterminated end of the harness connects to customer connections. Table 2.00-4 provides information on each of the unterminated wires in the Customer Interface Harness. Some connections of the Customer Interface Harness are required for ESM operation (see Table 2.00-5). For more information on optional connections, see Table 2.00-6. SIGNAL TYPE Ground Ground (See Note) Shield — Comms Comms 4 – 20 mA O/P+ (See Note) 4 – 20 mA O/P+ (See Note) 4 – 20 mA O/P+ (See Note) 4 – 20 mA O/P+ (See Note) Digital HSD O/P CAUTION NOTE: The Customer Interface Harness must be properly grounded to maintain CE compliance. Table 2.00-4. Customer Interface Harness Loose Wire Identification (Part 1 of 3) Circuit # 1110 1111 1137 1145 1305 1306 1600 WIRE LABEL DESCRIPTION SIGNAL NAME Aux. Input Ground Customer Reference Ground Harness Shield RS-485 Shield RS485 ARS485 B+ Average rpm WIRE FROM WIRE SOCKET COLOR PIN SIZE SIZE Black Black Silver Silver Green Yellow Dark Green Dark Green Dark Orange Dark Green White 29 4 44 13 2 23 9 20 16 20 20 20 20 20 20-24 16-20 20-24 20-24 20-24 20-24 20-24 Used for compatible load sharing GOVAUXGND input. Used for power generation applications only. LOGIC GND Used as the negative connection point for 4 – 20 mA signals. GOVAUXSHD Used as shield for compatible load sharing input. RS 485SHD RS 485ARS 485B+ PROG OP1 Customer shield ground for RS485 twisted shielded pair wire. RS485 MODBUS® RS485 MODBUS ® A 4 – 20 mA output from the ECU that represents an engine operating parameter. A 4 – 20 mA output from the ECU that represents an engine operating parameter. A 4 – 20 mA output from the ECU that represents an engine operating parameter. A 4 – 20 mA output from the ECU that represents an engine operating parameter. A digital output from the ECU that indicates the ECU is in either alarm or shutdown mode. A digital input to the ECU from the local control that must be high for the engine to run. If ESD goes low, the engine performs an emergency shutdown. A digital output from the ECU that indicates the ECU is in shutdown mode. Output is NOT latched. 1601 PROG OP2 Oil Pressure Coolant Temperature Intake Manifold Absolute Pressure Engine Alarm 21 20 20-24 1602 PROG OP3 3 20 20-24 1603 PROG OP4 11 20 20-24 1604 ENG ALM 14 20 20-24 1606 ESD Emergency Engine Shutdown Digital I/P Yellow 15 20 20-24 1607 ENG ESD Emergency Shutdown Digital HSD O/P White 42 20 20-24 1608 Digital input to the ECU that switches between remote speed setting input and high/low idle GOVREMSEL input. Must be used to enable remote speed input. Not typically used for power generation. Remote Speed Select Digital I/P Yellow 22 20 20-24 2.00-6 FORM 6331 First Edition SYSTEM POWER AND WIRING Table 2.00-4. Customer Interface Harness Loose Wire Identification (Continued), (Part 2 of 3) Circuit # 1609 WIRE LABEL START DESCRIPTION Momentary digital input to the ECU that is used to begin the engine start cycle. SIGNAL NAME Start Engine SIGNAL TYPE Digital I/P WIRE FROM WIRE SOCKET COLOR PIN SIZE SIZE Yellow 24 20 20-24 1611 RUN/STOP A digital input to the ECU from the local control that must be High = OK to Run high for the engine to run. If Low = Normal RUN/STOP goes low, the engine Shutdown performs a normal shutdown. Remote Speed Setting 4 – 20 mA Signal Remote Speed Setting 4 – 20 mA Signal + Aux. Input Signal Digital I/P Yellow 25 20 20-24 1613 Input to the ECU that is used for GOVREMSP- remote speed setting using 4 – 20 mA signal. Input to the ECU that is used for GOVREMSP+ remote speed setting using 4 – 20 mA signal. Used for compatible load sharing GOVAUXSIG input. Used for power generation applications only. Digital input to the ECU that changes the operating rpm of the engine. Used for power generation applications only. When using GOVREMSEL, the input status of GOVHL IDL must be checked. See information on setting this input to a “safe mode” in Table 2.00-5. A digital output from the ECU that indicates the engine is knocking and will shut down immediately unless some action is taken to bring the engine out of knock. Used for remote speed voltage input setting. Fit “jumper” between GOV 40 and GOV 41 to use 4 – 20 mA remote speed input. Used for remote speed voltage input setting. Fit “jumper” between GOV 40 and GOV 41 to use 4 – 20 mA remote speed input. 4 – 20 mA I/POpen circuit for 0.875 – 4.0 V operation 4 – 20 mA I/P+ Open circuit for 0.875 – 4.0 V operation ±2.5 V I/P Light Blue 27 20 20-24 1614 Light Green 39 20 20-24 1615 Red 28 20 20-24 1616 GOVHL IDL Rated Speed/Idle Speed Select Digital I/P Yellow 37 20 20-24 1617 KNK ALM Engine Knocking Digital HSD O/P White 47 20 20-24 1618 GOV 40 Remote Speed Setting Mode Select 0.875 – 4.0 V I/P+ Fit “jumper” between 40 and 41 for 4 – 20 mA operation 0.875 – 4.0 V I/PFit “jumper” between 40 and 41 for 4 – 20 mA operation Tan 40 20 20-24 1619 GOV 41 Remote Speed Setting Mode Select Tan 41 20 20-24 1620 Alternate governor dynamics. GOVALTSYN Used for power generation appli- Alternate Governor cations only to obtain a smooth Dynamics idle for fast paralleling to the grid. A 4 – 20 mA output from the ECU that represents the availAVL LOAD% able percentage of rated torque the engine is capable of producing. A 4 – 20 mA analog input to the ECU that represents the real-time WKI rating of the fuel. Use not necessary for most applications. A 4 – 20 mA analog input to the ECU that represents the real-time WKI rating of the fuel. Use not necessary for most applications. Digital I/P Yellow 10 20 20-24 1621 Available Load + 4 – 20 mA O/P+ Dark Green 33 20 20-24 1622 WKI- Fuel Quality (WKI) Signal - 4 – 20 mA I/P- Light Blue 31 20 20-24 1623 WKI+ Fuel Quality (WKI) Signal + 4 – 20 mA I/P+ Light Green 30 20 20-24 1624 A 4 – 20 mA output from the ACT LOAD% ECU that represents the actual percentage of rated torque the engine is currently producing. Engine Load + 4 – 20 mA O/P+ (See Note) Dark Green 32 20 20-24 FORM 6331 First Edition 2.00-7 SYSTEM POWER AND WIRING Table 2.00-4. Customer Interface Harness Loose Wire Identification (Continued), (Part 3 of 3) Circuit # 1627 WIRE LABEL USER DIP1 DESCRIPTION A digital input to the ECU that can be used to indicate a customer alarm. A digital input to the ECU that can be used to indicate a customer alarm. A digital input to the ECU that can be used to indicate a customer alarm. A digital input to the ECU that can be used to indicate a customer alarm. Digital input to the ECU that “kicks” the governor to help the engine accept large load additions. Mainly useful for stand-alone power generation applications. SIGNAL NAME User Defined Digital Input 1 User Defined Digital Input 2 User Defined Digital Input 3 User Defined Digital Input 4 SIGNAL TYPE Digital I/P WIRE FROM WIRE SOCKET COLOR PIN SIZE SIZE Yellow 16 20 20-24 1628 USER DIP2 Digital I/P Yellow 17 20 20-24 1629 USER DIP3 Digital I/P Yellow 18 20 20-24 1630 USER DIP4 Digital I/P Yellow 19 20 20-24 1631 LRG LOAD Load Coming Digital I/P Yellow 20 20 20-24 1636 A 4 – 20 mA input to the ECU KW TRANS+ that represents the generator power output. A 4 – 20 mA output to the ECU KW TRANS– that represents the generator power output. kW Transducer + 4 – 20 mA I/P+ Red 7 20 20-24 1637 kW Transducer – 4 – 20 mA I/P– Black 8 20 20-24 NOTE: Use LOGIC GND “Customer Reference Ground” as the negative connection point for these 4 – 20 mA signals. Self-regulating solid state logic can become high impedance during an overcurrent event. The overcurrent logic is rated for 1.1 A. REQUIRED CONNECTIONS Table 2.00-5 lists required connections of the unterminated wires of the Customer Interface Harness that are necessary for the ESM to enable the ignition and fuel. All digital inputs and outputs are referenced to battery negative. Digital High Side Driver (HSD) outputs can drive a maximum of 1 amp. All 4 – 20 milliamp inputs to the ECU are across an internal 200 Ω resistance. The input source common must be connected to Customer Reference Ground for proper operation. This also applies when a 0.875 – 4.0 volt input is used. All 4 – 20 milliamp outputs from the ECU are internally powered with a maximum drive voltage of 8 volts. NOTE: A high signal is a digital signal sent to the ECU that is between 8.6 and 36 volts. A low signal is a digital signal sent to the ECU that is less than 3.3 volts. All the 4 – 20 milliamp inputs have the ability to disable under fault conditions. If the input current exceeds 22 milliamps (or the output voltage exceeds 4.4 volts), the input is disabled to protect the ECU. When a current source becomes an open circuit, it typically outputs a high voltage to try to keep the current flowing. This can lead to the situation where the ECU protection circuit remains disabled because it is sensing a high voltage (greater than 4.4 volts). In practice, this should occur only when a genuine fault develops, in which case the solution is to cycle the ECU power after repairing the fault. The input is also disabled when the ECU is not powered. Therefore, if the current source is powered before the ECU, it will initially output a high voltage to try to make the current flow. The 4 – 20 milliamp inputs are all enabled briefly when the ECU is powered. If the input source continues to supply a high voltage (greater than 4.4 volts) for longer than 500 microseconds, the ECU input will be disabled again. The fault can be cleared by removing power to both the ECU and the current source, then powering the ECU before the current source. NOTE: It is recommended that the ECU remain powered at all times if possible. If not, always restore power to the ECU before powering the current source. A Zener diode is required to prevent the ECU from becoming disabled when a current source is powered before the ECU. The Zener diode should be a 6.2 volt., 1.0 watt Zener diode from (+) to (-) across all 4 – 20 mA input signals (see Figure 2.00-4). This diode may be applied at the signal source, such as an output card of a PLC, or at an intermediate junction box commonly used where the Customer Interface Harness terminates. 2.00-8 FORM 6331 First Edition SYSTEM POWER AND WIRING CUSTOMER INTERFACE HARNESS TYPICAL PLC ISOLATED CURRENT OUTPUT CARD 4 – 20 mA SIGNAL + POSITIVE ZENER DIODE 4 – 20 mA SIGNAL MAIN GOVREMSP+ 39 GOVREMSP- 27 NEGATIVE LOGIC GND 4 COMMON Figure 2.00-4. Zener Diode (4 – 20 mA Analog Inputs) Table 2.00-5. Required Connection Descriptions DESCRIPTION Start Engine Normal Shutdown (Run / Stop) WIRE LABEL START PHYSICAL CONNECTION Momentary (>1/2 second and 8.6V FOR LONGER THAN 1/2 SECOND YES IS CRANK TIME > ESP PURGE TIME AS PROGRAMMED ON [F3] START-STOP PANEL IN ESP? YES IGNITION ENABLED IS ESD > 8.6V? NO YES NO IS CRANK TIME > 20 SECONDS? YES NO IS RUN / STOP > 8.6V? YES NO IS RPM > 40 + ESP FUEL ON RMP ADJ? NO IS CRANK TIME > 20 SECONDS? YES NO IS AN ESD ACTIVE? NO YES YES FUEL V = 24 VDC (FUEL VALVE TURNED ON) IS RED MANUAL SHUTDOWN SWITCH(ES) ON SIDE OF ENGINE PRESSED? YES YES IS RPM > 200 RPM + ESP STARTER OFF RPM PROGRAMMED ON [F3] START-STOP PANEL IN ESP? NO PMR = 24 VDC (PRELUBE MOTOR TURNED ON) NO IS CRANK TIME > 20 SECONDS? NO YES ASV = 0 VDC (STARTER DISENGAGED) IS PMR “ON” TIME > ESP PRELUBE TIME AS PROGRAMMED ON [F3] START-STOP PANEL IN ESP? YES NO RPM > 300 RPM + ESP PRECHAMBER (PRECHAMBER FUEL TURNED ON) PROCESS EMERGENCY SHUTDOWN DUE TO ESD231 (OVERCRANK) PMR = 0 VDC (PRELUBE OFF) IS ENGINE RUNNING? YES NO PROCESS EMERGENCY SHUTDOWN DUE TO ESD232 (ENGINE STALL) ASV = 24 VDC (STARTER ENGAGED) SEQUENCE COMPLETE SEE FIGURE 2.05-4 WIRE LABEL SHOWN IN BOLD Figure 2.05-2. Start Flow Diagram FORM 6331 First Edition 2.05-3 START-STOP CONTROL RUN/STOP GOES LOWER THAN 3.3V HAS COOLDOWN TIMER EXPIRED AS PROGRAMMED ON [F3] START-STOP PANEL IN ESP? NO YES PMR = 24 VDC (POSTLUBE MOTOR TURNED ON) PREGASSOL AND FUELV = 0 VDC (PRECHAMBER AND MAIN FUEL VALVE TURNED OFF) NO IS ENGINE SPEED = 0 RPM? YES NO HAS 30 SECOND TIMER EXPIRED? YES IS PMR “ON” TIME > ESP POSTLUBE TIME AS PROGRAMMED ON [F3] START-STOP PANEL IN ESP? NO ENG ALM GOES FROM OPEN CIRCUIT TO 24 VDC PMR = 0 VDC (POSTLUBE MOTOR TURNED OFF) ECU RECORDS ALM222 (MAIN FUEL VALVE) SEQUENCE COMPLETE IGNITION OFF WIRE LABEL SHOWN IN BOLD Figure 2.05-3. Stop Flow Diagram 2.05-4 FORM 6331 First Edition START-STOP CONTROL PRELUBING THE ENGINE WITHOUT STARTING ESD FAULT NOTE: The engine can be prelubed without starting using the local control harness. See Section 2.00 System Power and Wiring for more information. The following describes how to prelube the engine without starting the engine. Refer to Section 3.10 ESP Programming “Basic Programming in ESP” for programming instructions. 1. Using ESP, program the “Pre Lube Time” field on the [F3] Start-Stop Panel to the maximum time of 10,800 seconds (180 minutes). 2. Begin the start sequence. ECU PERFORMS IMMEDIATE SHUTDOWN IGNITION TURNED OFF PREGASSOL AND FUELV GO FROM 24 VDC TO 0 3. After the engine prelubes for a sufficient time and before the end of 180 minutes, perform a normal shutdown sequence to cancel the start attempt. 4. Reprogram the prelube time to the previous value and save value to permanent memory. CRANKING THE ENGINE OVER WITHOUT STARTING AND WITHOUT FUEL ENG ESD GOES FROM OPEN CIRCUIT TO 24 VDC The following describes how to crank the engine over without starting the engine and without fuel. Refer to Section 3.10 ESP Programming for programming instructions. 1. Using ESP, program the “Purge Time” field on the [F3] Start-Stop Panel to the maximum time of 1800 seconds (30 minutes). ENG ALM GOES FROM OPEN CIRCUIT TO 24 VDC 2. Begin the start sequence. 3. The engine will crank until ESD231 Overcrank shutdown fault activates, at which time the engine will stop cranking. 4. Repeat steps 1 – 3 if necessary. 5. Reprogram the purge time to the previous value and save to permanent memory. FAULT RECORDED IN ECU AIR STARTER When the ESM receives an engine start signal from the user’s panel, the ESM controls the entire start process, including the sequence of events shown in Figure 2.05-2. Part of the start process includes engaging the starter. When the solenoid on the air-start valve receives the electronic voltage signal from the ECU, the air-start valve allows air to flow to the starter. The air-start valve uses a 1.5 NPT 150# flange inlet. The system must be vented to meet applicable codes. Failure to interface through the air-start valve provided will result in ESM fault codes. SEQUENCE COMPLETE Postlube will not run if the following critical ESDs Occur: ESD222 CUST ESD ESD223 LOW OIL PRESS ESD313 LOCKOUT/IGNITION ESD532 COOLANT PRESS LOW WIRE LABEL SHOWN IN BOLD Figure 2.05-4. Emergency Stop Flow Diagram FORM 6331 First Edition 2.05-5 START-STOP CONTROL FUEL VALVE Wire the supplied fuel gas shutoff valve so it is controlled by the ESM. If the fuel valve is controlled independently of the ESM, fault codes will occur when the fuel valve is not actuated in sequence by the ESM. Disregarding this information could result in product damage and/or personal injury. Refer to S-6656-23 (or current revision) “Natural Gas Pressure Limits to Engine-Mounted Regulator” in the Waukesha Technical Data Manual (General Volume) for minimum fuel pressure required for your application. CAUTION The customer must install the fuel gas shutoff valve (see Section 2.00 System Power and Wiring for wiring diagram). If the fuel valve is controlled independently of the ESM, fault codes will occur when the fuel valve is not actuated in sequence by the ESM. The Power Distribution Junction Box supplies up to 15 amps to the valve using solid state circuitry with built-in short circuit protection. All inductive loads such as a fuel valve must have a suppression diode installed across the valve coil as close to the valve as is practical. Disregarding this information could result in product damage and/or personal injury. CAUTION The fuel control valve is to be wired directly into the Power Distribution Junction Box, with the wires terminated at the terminal block shown in Figure 2.05-5. The position FUEL V SW is the (+) connection, and FUEL V GND is the (-) connection. Conduit, liquid tight flexible conduit, or other industry standard should be used along with the correct fittings as appropriate to maintain resistance to liquid intrusion. Figure 2.05-5. Power Distribution Junction Box 2.05-6 FORM 6331 First Edition SECTION 2.10 IGNITION SYSTEM The ESM controls spark plug timing with a high energy, digital capacitive discharge ignition system. The ignition system uses the capacitor discharge principle that provides a high variable energy, precisiontimed spark, for maximum engine performance. The ESM ignition system uses the ECU as its central processor. Two magnetic pickups are used to input information to the ECU. One pickup reads a magnet on the camshaft, and the other pickup senses 36 reference holes in the flywheel. See Figure 2.10-2 for the ESM Ignition System Diagram. The Ignition Power Module with Diagnostic capability (IPM-D) is needed to fire the spark plug at the required voltage (see Figure 2.10-2). The IPM-D is CSA approved for Class I, Division 2, Group D (T4 temperature rating), hazardous location requirements. 1 1) Ignition Power Module (IPM-D) Figure 2.10-1. Ignition Power Module (IPM-D) Location CAMSHAFT MAGNETIC PICKUP • POSITION OF CAMSHAFT ECU IPM-D IGNITION COILS SPARK PLUGS CRANKSHAFT MAGNETIC PICKUP • ANGULAR POSITION OF FLYWHEEL • ENGINE SPEED Figure 2.10-2. ESM Ignition System Diagram FORM 6331 First Edition 2.10-1 IGNITION SYSTEM IGNITION THEORY The ECU is calibrated to control spark timing. Timing can vary with engine speed, intake manifold pressure, engine-mounted knock sensors, and several other variables that optimize engine performance. When a knock signal exceeds the knock threshold, the ECU retards timing on an individual cylinder basis to keep the engine out of knock. See Section 2.15 Knock Detection for more information. Based on the calibration and readings, the ECU sends an electronic signal to the IPM-D that energizes the ignition coils to “fire” the spark plug. The IPM-D provides automatically controlled dual voltage levels depending on the operating conditions. See “Ignition Diagnostics” on page 2.10-3 for more information. The IPM-D is a high energy, capacitor discharge solidstate ignition module. The power supply voltage is used to charge the energy storage capacitor. This voltage is then stepped up by the ignition coils. A signal from the ECU triggers the IPM-D to release the energy stored in the capacitor. When the IPM-D receives the signal, the energy in the ignition coil is used to fire the spark plug. ESM-equipped engines have an index disc mounted on the camshaft gear and a magnetic pickup mounted on the gear cover of the engine (see Figure 2.10-3). The index disc is always fixed at the same angular location for every engine with ESM. The index disc has one magnet: the index magnet. The camshaft magnetic pickup determines which part of the four-stroke cycle the engine is in. The crankshaft magnetic pickup is used to sense 36 reference holes in the flywheel (see Figure 2.10-4). This magnetic pickup signals to the ECU the angular position of the crankshaft and engine speed (rpm). Since the camshaft disc rotates at half the engine speed, the crankshaft must rotate twice for the engine cycle to end. 2) Crankshaft Magnetic Pickup 1 1)Camshaft Magnetic Pickup Figure 2.10-3. Camshaft Pickup Location 2 Figure 2.10-4. Crankshaft Magnetic Pickup Location 2.10-2 FORM 6331 First Edition IGNITION SYSTEM IGNITION DIAGNOSTICS The IPM-D provides diagnostic information for both the primary and secondary sides of the ignition coil. The IPM-D detects shorted spark plugs and ignition leads, as well as spark plugs which require a boosted energy level to fire or do not fire at all. The diagnostic information is provided through a Controller Area Network (CAN) between the ECU and IPM-D, and then to the customer’s local control panel via MODBUS®. Four thresholds calibrated by Dresser Waukesha have been programmed into the ECU to trigger four different levels of alarm: • Primary: Indicates a failed ignition coil or faulty ignition wiring. NOTE: Another possible cause of a primary alarm would be the activation of the red lockout or E-Stop (emergency stop) switch on the side of the engine while the engine is running. • Low Voltage: Indicates a low voltage demand condition that may have resulted from a shorted coil or secondary lead, deposit buildup, or a failed spark plug (failure related to “balling” or shorting.) • High Voltage: Indicates that a spark plug is becoming worn and will need to be replaced. When this limit is exceeded, the “Ignition Energy” is raised to a level 2. See “Monitoring Ignition Energy Field” on page 2.10-3. • No Spark: Indicates that a spark plug is worn and must be replaced. When the spark reference number reaches one of the four programmed thresholds, an alarm is triggered. Three of these four thresholds (low voltage, high voltage, and no spark) were designed to be adjustable so the user can customize IPM-D predictive diagnostics to fit the specific needs of each engine. Using the [F5] Ignition Panel in ESP, the user can adjust the fault’s alarm and shutdown points to compensate for site conditions and minor variations in spark reference numbers between individual coils. See Section 3.10 ESP Programming IPM-D Programming for programming information. NOTE: The IPM-D default values are appropriate for all engine applications. NOTE: Improper use of these adjustments may limit the effectiveness of IPM-D diagnostics. MONITORING IGNITION ENERGY FIELD The “Ignition Energy” field on the [F5] Ignition Panel indicates at what level of energy the IPM-D is firing the spark plugs: Level 1 (low) or Level 2 (high). The pink “Ignition Energy” field will signal the user whether the ignition level is LEVEL 1 or LEVEL 2. During normal engine operation, the IPM-D fires at a Level 1 (normal) ignition energy. The IPM-D fires at a Level 2 (high) ignition energy on engine startup or as a result of spark plug wear. When sufficient spark plug wear is monitored, IPM-D raises the power level of the ignition coil. If the ignition energy is raised to Level 2 (except on startup), an alarm is triggered to alert the operator. Once Level 2 energy is applied, the spark reference number will decrease initially but the Fault Log will indicate the cylinder number of the spark plug that is wearing out. MONITORING SPARK REFERENCE NUMBER Predictive diagnostics based on a spark reference number for each cylinder is used to monitor each spark plug’s life. The spark reference number is an arbitrary number based on relative voltage demand at the spark plug and is calculated each time the cylinder fires. The spark reference number is displayed for each cylinder on the [F5] Ignition Panel in ESP. Spark reference numbers can be used to represent spark plug electrode wear (gap) and can be monitored (for example, with MODBUS®) and trended to predict the time of spark plug failure. The usefulness of the spark reference number lies in how much a number changes over time as a spark plug erodes. Based on a thorough trend analysis of the spark reference numbers, the user may want to adjust the high, low, or no spark voltage limits. It will take some testing and adjustment to obtain thresholds that optimize the use of these features. For maximum benefit, the spark reference number for each cylinder should be recorded at normal operating load with new spark plugs installed and then monitored over a period of time for changes. The “Left Bank Spark Reference #” and “Right Bank Spark Reference #” fields on the [F5] Ignition Panel display the spark reference number for each cylinder. As the secondary voltage increases, the spark reference number also increases. A gradual increase in the spark reference number is expected over time as the spark plug wears. The closer to end of spark plug life, the faster the spark reference number will increase. FORM 6331 First Edition 2.10-3 IGNITION SYSTEM 2.10-4 FORM 6331 First Edition SECTION 2.15 KNOCK DETECTION The ESM includes knock detection and protects Dresser Waukesha spark-ignited gas engines from damage due to knock. Knock is the ignition of the end gas after spark ignition has occurred during normal combustion. Knock is caused by site conditions and/or engine misadjustment, not the engine. See “Knock Theory” on page 2.15-1 for a definition of knock and examples of knock promoters and reducers. The ESM detects knock by monitoring vibrations at each cylinder with engine-mounted knock sensors (see Figure 2.15-1). When a signal exceeds a knock threshold, the ESM retards timing incrementally on an individual cylinder basis to keep the engine, and each cylinder, from “knocking.” • The ESM requires no calibration of the knock detection system by on-site personnel. The ESM knock detection system is self-calibrating. • If a knock is detected and the engine is shut down, the ECU records in the fault log that knocking occurred, even if a PC was not connected. • When a PC is connected to the ECU and the ESP software is active, the ESP software displays when knock is occurring. If the engine is shut down due to knock, the shutdown and number of the knocking cylinders are recorded in the fault log. KNOCK THEORY During normal combustion, the forward boundary of the burning fuel is called the “flame-front.” Combustion in a gaseous air-fuel homogeneous mixture ignited by a spark is characterized by the rapid development of a flame that starts from the ignition point and spreads continually outward. When this spread continues to the end of the chamber without abrupt change in its speed or shape, combustion is called “normal.” Knock is due to the ignition of the end gas after spark ignition has occurred. The end gas is the remaining air-fuel charge that has not yet been consumed in the normal flame-front. When the end gas mixture beyond the boundary of the flame-front is subjected to a combination of heat and pressure from normal combustion, knock will occur. If the knock has enough force, the pressure in the chamber will spike, causing the structure of the engine to resonate, and an audible “ping” or “knock” will be heard. Knock will depend on the humidity of intake air and the temperature and pressure of the end gas in the combustion chamber. Any change in engine operating characteristics that affects end gas temperature will determine whether knock will occur. The higher the end gas pressure and temperature rise and the time to which it is exposed to this severe stress, the greater the tendency for the fuel to detonate. Figure 2.15-1. Knock Sensor The following are the main features of the ESM knock detection: • The ESM monitors for knock during every combustion event. • A per-event measure of the knock level is compared to a reference level to determine if knock is present. • Action taken by the ESM when knock is detected is proportional to the knock intensity identified. FORM 6331 First Edition 2.15-1 KNOCK DETECTION Avoiding knock conditions is critical since knock is typically destructive to engine components. Severe knock often damages pistons, cylinder heads, valves, and piston rings. Damage from knock will eventually lead to complete failure of the affected part. Knock can be prevented; however, the conditions that promote knock are extremely complex and many variables can promote knock at any one time. Table 2.15-1. Knock Promoters and Reducers PROMOTERS Higher Cylinder Temperature Lower WKI Fuels More Advanced Spark Timing Higher Compression Ratios Higher Inlet Pressure Higher Coolant Temperatures Higher Intake Manifold Air Temperatures Lower Engine Speeds Lower Atmospheric Humidity Higher Engine Load Stoichiometric Air-Fuel Ratio (Rich Burn Engine) Rich Air-Fuel Ratio (Lean Burn Engine) Cylinder Misfire on Neighboring Cylinders PRESSURE, PSIA OPEN SAMPLE WINDOW KNOCK END OF SAMPLE WINDOW IGNITION SPARK REDUCERS Lower Cylinder Temperatures Higher WKI Fuels Less Advanced Spark Timing Lower Compression Ratios Lower Inlet Pressure Lower Coolant Temperatures Lower Intake Manifold Air Temperatures Higher Engine Speeds Higher Atmospheric Humidity Lower Engine Load Lean or Rich Air-Fuel Ratio (Without Engine Overload) Lean Air-Fuel Ratio TDC Figure 2.15-2. Windowing Chart The ESM controls timing between two limits: Maximum Advanced Timing and Most Retarded Timing. The maximum advanced timing is variable and depends on rpm, load, and the WKI value. The most retarded timing is a predetermined limit. The maximum advanced timing value is used in two different ways. First, under normal loads, the maximum advanced timing is the timing limit. Second, when the engine is under light load and cannot be knocking, it is used as the timing for all cylinders. In the event the ESM senses knock that exceeds the knock threshold, the ignition timing will be retarded at an amount proportional to the intensity of knock sensed. Ignition timing will then be retarded until either the signal from the knock sensor falls below the knock threshold or the most retarded timing position is reached. As soon as conditions permit, the ESM will advance spark timing to the maximum setpoint at a predetermined rate. If after a predetermined time, conditions do not permit timing to be advanced from the most retarded timing position, the ECU will perform the following actions: • ALM225 is logged, indicating the knocking cylinder(s). • The red status LED on the ECU will blink the knock fault code. • The engine will shut down after a predetermined time, and ESD224 is logged. KNOCK DETECTION AND TIMING CONTROL The ESM senses knock with a technique called “windowing.” This technique allows the ESM to look for knock only during the combustion time when knock could be present. The “window” opens shortly after the spark plug fires to eliminate the effects of ignition noise. This noise is caused from the firing of the spark plug and subsequent “ring-out” of coils. This “sample” window is closed near the end of the combustion event at a predetermined angle after top dead center (ATDC) in crankshaft degrees. See Figure 2.15-2. During knock, a unique vibration called knock frequency is produced. Knock frequency is just one of many frequencies created in a cylinder during engine operation. The knock sensors mounted at each cylinder convert engine vibrations to electrical signals that are routed to the ECU. The ECU removes the electrical signals that are not associated with knock using a built-in filter. When the filtered signal exceeds a predetermined limit (knock threshold), the ESM retards the ignition timing for the cylinder associated with that sensor by communicating internally with the ignition circuitry that controls the IPM-D. The amount the timing is retarded is directly proportional to the knock intensity. So when the intensity (loudness) is high, the ignition timing is retarded more than when the knock intensity is low. 2.15-2 FORM 6331 First Edition KNOCK DETECTION WAUKESHA KNOCK INDEX (WKI) The Waukesha Knock Index (WKI) is an analytical tool, developed by Dresser Waukesha, as a method for calculating the knock resistance of gaseous fuels. It is a calculated numeric value used to determine the optimum engine settings based on a specific site’s fuel gas composition. The WKI value can be determined using the WKI computer program for the Microsoft® Windows® operating system that is distributed to Waukesha Technical Data Book holders and is also available by contacting a Distributor, Dresser Waukesha Sales Engineering Department, or downloading from WEDlink. The WKI program will calculate the WKI value from a customer’s gas analysis breakdown. Once the WKI value is known, it can be entered into the ECU using the ESP software. This is important since spark timing and engine derate curves are adjusted based on the value of the WKI value stored in the ECU. For applications with changing fuel conditions, such as a wastewater treatment plant with natural gas backup, the ESM can be signaled about the fuel’s changing WKI value in real time using the two WKI analog input wires in the Customer Interface Harness. The calibration of the Customer Interface wires, WKI+ and WKI–, is shown in Table 2.15-2. An input less than 2 mA or greater than 22 mA indicates a wiring fault, and the default WKI value is used instead. Table 2.15-2. Calibration of Remote WKI Input ANALOG USER INPUT WKI Fuel Quality Signal 4 mA 20 WKI 20 mA 135 WKI FORM 6331 First Edition 2.15-3 KNOCK DETECTION 2.15-4 FORM 6331 First Edition SECTION 2.20 AIR-FUEL CONTROL DESCRIPTION The ESM Lean Burn Air-Fuel Ratio Control (AFR) system is designed to control the air-fuel ratio of Dresser Waukesha’s lean burn, gaseous fueled, industrial engines. An engine’s air-fuel ratio defines the amount of air in relation to a single amount of fuel supplied to an engine for combustion. By controlling an engine’s air-fuel ratio with ESM AFR Control, exhaust emissions are minimized while maintaining peak engine performance. The AFR Control regulates the engine’s air-fuel ratio even with changes in engine load, fuel pressure, fuel quality, and environmental conditions. The ESM Lean Burn AFR Control is completely integrated into the ESM, with all sensor inputs, control routines, and output actions handled by the ECU. The ECU works with the Air/Fuel Power Module (AFPM), which provides power and signal conditioning for the lean burn oxygen sensor assembly. • Air/Fuel Power Module (AFPM) • Heater block temperature sensor (RTD) • Barometric pressure sensor • Ambient temperature sensor • AGR (Actuator, Gas Regulator) stepper for the gas regulator In addition, other sensor inputs already available to the ESM, such as the intake manifold pressure, are used. OPERATION The oxygen sensor continually reports the concentration of oxygen in the exhaust to the Lean Burn AFR routine in the ECU. Based on this signal, the AFR Control determines if a correction to the air-fuel ratio is required. If a change is needed, a command is sent to the AGR actuator (installed on the fuel regulator), which adjusts the fuel flow to the engine. The heater block temperature sensor ensures that the temperature of the exhaust sample that is measured by the oxygen sensor is high enough to permit correct system operation (see Figure 2.20-1and Figure 2.20-2). COMPONENTS The ESM Lean Burn AFR Control builds upon the basic ESM configuration by adding the following: • Exhaust oxygen sensor/heater block assembly INPUTS OUTPUTS AIR / FUEL POWER MODULE Stepper Position Exhaust Oxygen Heater Block Temperature Ambient Temperature Barometric Pressure Intake Manifold Pressure User-Programmable Limits Stepper Home Position Figure 2.20-1. AFR Control Inputs and Outputs FORM 6331 First Edition 2.20-1 AIR-FUEL CONTROL Oxygen Sensor AIR / FUEL POWER MODULE RTD Sensor Heater Block Assembly Heater Cartridges Intake Manifold Pressure Transducer Barometric Pressure Sensor Ambient Temperature Sensor Pressure Snubber Actuator Figure 2.20-2. AFR Control Block Diagram LEAN BURN OXYGEN SENSOR All lean burn sensor applications are based on the linear output characteristics of the lean burn oxygen sensor (see Figure 2.20-3). AFM SENSOR DISPLAY 2.50 V RICH O2 SETPOINT The exhaust oxygen content of lean burn engines can be used as an indicator of the air-fuel mixture supplied to the engine for combustion. The signal from the lean burn oxygen sensor is fed into the AFPM module, which conditions it and forwards it to the ECU. Any mixture deviation is sensed and transmitted to the AFPM module in the form of an electrical signal. The ECU determines whether a correction is required and adjusts the actuator accordingly. Lean burn sensors have an extended service life, typically lasting over 10,000 hours. Oil additives, fuel contaminants, compounds released from certain RTV sealants, incorrectly applied anti-seize, and overtemperature can attribute to shortened sensor life. Always use “OXYGEN SENSOR SAFE/NEUTRAL CURE” RTV gasket materials on engines with oxygen sensors. Disregarding this information will result in reduced sensor life or sensor failure. INCREASING LEAN EXHAUST OXYGEN (DRY VOLUME PERCENT) CAUTION TYPICAL SETPOINT: 16V275GL @ 32:1 (11.2% O2) Figure 2.20-3. Oxygen Sensor Response vs. Exhaust Oxygen Concentrations for Various Air-Fuel Ratios Always purchase ESM AFR oxygen sensors (P/N 740107A or later) from Dresser Waukesha. Performance goals of the system cannot be met without Dresser Waukesha’s oxygen sensor specifications. Disregarding this information could result in product damage and/or personal injury. CAUTION 2.20-2 FORM 6331 First Edition AIR-FUEL CONTROL HEATER BLOCK ASSEMBLY The lean burn sensor is installed in the heater block assembly, which consists of the following: • O2 sensor • Gasket • Two heater cartridges • RTD temperature sensor • Sensor block • Special pipe nipple • Insulation 2 1 3 2 WARNING Always keep lean burn oxygen sensor assembly insulation installed over components. Lean burn sensing assembly components become extremely hot in use. Failure to keep insulation installed over assembly could cause severe personal injury. NOTE: Insulation MUST be installed around lean burn oxygen sensing assembly for correct sensor operation. 5 1 2 3 4 1) Heater Block Assembly 2) Insulation Figure 2.20-6. Heater Block Assembly Insulation 4) RTD Port 5) Sensor Port 1) Not Used 2) Sensor Mounting bolt 3) Heater Port The assembly is installed in the exhaust elbow per the latest edition of Form 6333, 16V275GL Operation and Maintenance manual. Exhaust supply tubing is also required (see Figure 2.20-7). Figure 2.20-4. Heater Block – Front View 2 1 3 4 5 2 1 1) Heater 2) Special Pipe Nipple 3) Gasket 4) Lean Burn Oxygen Sensor 5) RTD Temperature Sensor 1) Exhaust Elbow 2) Exhaust Supply Tubing Figure 2.20-5. Heater Block Assembly FORM 6331 First Edition Figure 2.20-7. Exhaust Supply Tubing 2.20-3 AIR-FUEL CONTROL STEPPER A stepper motor is used to bias the output pressure of the gas regulator (see Figure 2.20-8). All electronics are packaged with the stepper motor in an integral enclosure. The proximity switch is located inside the stepper housing to prevent accidental breakage, and no external wiring is added for the switch. The stepper is controlled using signals transmitted over the ESM CAN (Controller Area Network) communication bus. Stepper diagnostic information is relayed back to the ECU over the CAN bus. SYSTEM WIRING All wiring related to AFR Control and the AFPM is integrated into the ESM wiring harnesses. The RTD temperature sensor and lean burn oxygen sensor feature in-line connectors for ease of troubleshooting and replacement. The AFPM features connectors similar to that of the ECU. THEORY OF OPERATION The Lean Burn AFR system controls engine air-fuel ratio and consists of three basic components: an oxygen sensor, actuator, and AFR Control routine in the ESM. The AFR system is a closed-loop process that looks at system outputs and adjusts system inputs according to calibrated software routines. The AFR Control functions by monitoring oxygen levels in the exhaust gases with an oxygen sensor located in the engine’s exhaust stream. The oxygen level, detected by the sensor, is then fed to the AFPM module through an electrical signal, where it is conditioned and then forwarded to the ECU. If the oxygen level detected by the sensor is different from the programmed oxygen setpoint, the AFR Control directs the actuator to adjust the gas over air (gas/air) pressure of the fuel regulator. The actuator adjusts the fuel regulator setting, within programmed limits, by increasing or decreasing the spring pressure acting on the regulator diaphragm. The design gives very accurate positioning capability. The regulator adjustment richens or leans out the air-fuel ratio. The desired oxygen setpoint is based on the lambda setpoint of the engine, determined by the factory, to achieve the desired emissions output. Other factors such as environmental conditions, fuel type, fuel quality, and engine operating conditions are used in conjunction with the desired lambda setpoint to determine the corresponding exhaust oxygen setpoint to achieve emissions as conditions vary. An RTD temperature sensor is used to ensure that the sampled exhaust temperatures are high enough for correct operation of the O2 sensor. A programmed minimum temperature must be achieved before closed-loop control is enabled. A programmed maximum temperature is also incorporated as a safety to shut down operation on high heater block temperature conditions. Figure 2.20-8. Stepper 2.20-4 FORM 6331 First Edition AIR-FUEL CONTROL USER SETTINGS A minimum of user settings, done through the ESP interface, are required to successfully set up the system. While stepper movement is controlled by the ESM AFR Control routine, user-programmable limits must be programmed on the [F8] AFR Setup Panel in ESP (see Figure 2.20-9). This limits the stepper’s travel range and triggers alarms if the system attempts to work outside of the range. The stepper position is indicated on the ESP panels as “steps.” Another user setting required is that of the start position. This position is determined by an adjustment procedure for correct air-fuel ratio during engine start, and then is used to automatically set the stepper whenever the engine is being started. The stepper position will remain within the programmable limits after startup while the AFR Control is in automatic mode (see Figure 2.20-10). If a limit is reached, an alarm will be raised. When in manual mode, the user can adjust the stepper position outside the programmable limits. Figure 2.20-9. AFR Setup Panel Rich Limit – max. travel permitted STEPPER POSITION AIR-FUEL RATIO Typical Stepper Position Lean Limit – min. travel permitted Load (Air-Fuel Ratio can vary with load) Load or IMAP Stepper travel is trapped between two programmable limits while in automatic mode Figure 2.20-10. Air-Fuel Ratio and Stepper Limits vs. Load FORM 6331 First Edition 2.20-5 AIR-FUEL CONTROL 2.20-6 FORM 6331 First Edition SECTION 2.25 ESM TURBOCHARGER CONTROL The ESM Turbocharger Control is designed to control flow rates through the compressor-side and turbineside of the turbochargers to prevent surge and overspeed, while maintaining proper throttle reserve. Flow through the compressor is controlled via the bypass, whereas flow through the turbine is controlled via the wastegate. The bypass valve controls air flow through the compressor side of the turbocharger. Its main function is to prevent turbocharger surge, which refers to the reversal of flow through the compressor side of the turbocharger. This occurs if the compressor is supplying a relatively low flow of air to the engine while having a pressure ratio (boost pressure/inlet pressure) that is too high. To counteract this problem, the flow can be increased through the compressor by opening the bypass valve, which redirects air from the compressor outlet to the turbine inlet, which “bypasses” the engine (see Figure 2.25-1). Excess air is directed upstream of the turbine to maintain turbocharger speed and air flow through the compressor without increasing air flow to the engine. The wastegate valve controls exhaust flow through the turbine side of the turbocharger. Its main function is to maintain the pressure ratio across the compressor by directing a portion of the exhaust flow around the turbocharger (see Figure 2.25-1). ENGINE CYLINDER EXHAUST FLOW EXHAUST STACK AIR OUT AIR TO ENGINE WASTEGATE VALVE BYPASS VALVE THROTTLE INTERCOOLER AIR IN TURBINE COMPRESSOR TURBOCHARGER Figure 2.25-1. ESM Turbocharger Wastegate And Bypass Valving FORM 6331 First Edition 2.25-1 ESM TURBOCHARGER CONTROL ESM TURBOCHARGER CONTROL DESCRIPTION The ESM turbocharger control consists of the ECU and two turbocharger control actuators that control the exhaust wastegate and bypass valves. The turbocharger control monitors four areas on the engine to determine wastegate and bypass valve position. The first area that it monitors is the pressure differential, or throttle reserve, across the carburetor and throttle plate. Pressure differential is determined by the difference in pressure between two points. The first point is referred to as the Boost Pressure, which measures the pressure at the turbocharger’s compressor outlet. The boost pressure sensor is located before the carburetor, upstream of the throttle. The second area that the turbocharger control monitors is the intake manifold pressure, referred to as IMAP (Intake Manifold Absolute Pressure). The IMAP is calculated by taking the average of two sensors located in the intake manifold, downstream of the throttle. The third area that is monitored is the compressor inlet air temperature. The cooler the air is, the more dense it becomes; the warmer the air, the less dense it becomes. The bypass has a temperature compensation routine that adjusts position to compensate for changes in inlet temperature. The fourth area monitored is engine operating speed, which is used for the bypass, wastegate, and throttle reserve maps. Once the wastegate has learned the new position that provides proper throttle reserve for a given speed and boost pressure, that position is used as the new initial position in the wastegate position map. This “learned” wastegate position map is stored in the ECU and is preserved even if the engine is shut down and restarted. There is a 10% fixed limit that the wastegate position is allowed to deviate from its initial, unlearned position map, while the engine is running. There is also a limit of 5% that the stored learned position map can deviate from the initial, unlearned position map. There are certain conditions in which the learning functionality can learn an improper value. This can occur if the engine is starved for fuel or in some condition that causes the throttle to be wide open, which would cause the throttle reserve to drop. The wastegate control would begin to close in order to increase reserve, and that wastegate position could then become the learned value for that given speed and boost pressure. When the problem that caused the throttle to go wide open is fixed, the map would have a bad value in that particular spot. If the engine returns to that value, it would become unstable and it could be necessary to reset the BYC Boost learning table. See “Resetting Learning Tables” in this section for more information. RESETTING LEARNING TABLES 1. Shut engine down. 2. In ESP go to the [F11] Advanced Panel. BYPASS, WASTEGATE, AND THROTTLE RESERVE MAPS The bypass valve position is controlled by a bypass map. This bypass map represents the position the bypass valve should be at a given rpm and IMAP. At each different rpm value, a pressure and position is mapped. The wastegate valve is controlled through both a programmed wastegate position map and a programmed throttle reserve map. The wastegate position map is used to provide an initial wastegate position, based on speed and boost pressure. The throttle reserve map represents what the desired reserve pressure should be at a given rpm and IMAP. If the throttle reserve that results from that initial wastegate position does not match the desired reserve from the throttle reserve map, the wastegate position will change until the measured reserve matches the desired reserve. The wastegate will open to lower reserve and close to increase reserve. In order for the wastegate control to learn a new position, the engine speed and throttle must be stable. 2.25-2 Figure 2.25-2. Advanced Functions Panel 3. Click “Reset Wastegate Learning Table...” button to bring up the “Reset Learning Tables” pop-up window. FORM 6331 First Edition ESM TURBOCHARGER CONTROL (see Figure 1.10-2). The peak efficiency line runs through the center of the compressor efficiency islands. The turbocharger control maps are set up to keep the operating point near the center of the efficiency island through the entire operating range of the engine to afford optimal performance and discourage turbocharger surge. Frequent changes in inlet air temperature and pressure ratios can also trigger turbocharger surge. As the ambient temperature decreases, the engine requires less volumetric flow because the air is more dense. When this occurs, the engine operating point moves from the line of peak efficiency toward the surge line. As the engine operating point approaches the surge line, the classic “banging” or “swishing” can be heard. Although not normally detrimental to engine components, turbocharger surge results in poor engine performance. Pressure ratios can drastically spike when shedding engine load, due to the rapid closing of the throttle to prevent the engine from overspeeding. When the throttle closes quickly, volume of air upstream of the throttle can experience a sharp rise in pressure, which can cause turbocharger surge. The ESM turbocharger control is a flexible, electronic method of turbocharger control that is able to respond to these frequently changing conditions, resulting in improved turbocharger efficiency and engine performance. The ESM turbocharger control allows for the best match between the engine and the turbocharger under a wide range of altitudes and changing ambient conditions by electronically controlling bypass and wastegate settings. Figure 2.25-3. Reset Learning Tables Window 4. Click the “Reset BYC Boost Table” button to reset the learning table. 5. Restart the engine, and allow the control to relearn its positions. TURBOCHARGER SURGE The term turbocharger surge is used to describe the “banging” or “swishing” that can be heard from an engine's turbocharger. Turbocharger surge commonly occurs at partial load and low speed when the volume of air required by the engine is substantially less than that required by the turbocharger to prevent flow reversal, which is what happens when a turbocharger surges. The turbocharger compressor performs best when the engine operates along the line of peak efficiency SURGE LINE PEAK EFFICIENCY LINE PRESSURE RATIO PRESSURE RATIO A PEAK EFFICIENCY ISLAND A LOWER TEMPERATURES FLOW CFM FLOW CFM Figure 2.25-4. Turbocharger Peak Efficiency and Turbocharger Surge Graphs FORM 6331 First Edition 2.25-3 ESM TURBOCHARGER CONTROL THROTTLE RESERVE The turbocharger control strategy controls the wastegate position in a closed-loop control of throttle pressure drop (throttle reserve) as a function of engine speed and boost pressure. ESM turbocharger control does not require remapping of the wastegate as a function of changing environmental or operating conditions. It is responsive to changes in air-fuel ratio, barometric pressure, ambient temperature and humidity, altitude, air filter restriction, and engine mechanical health. There is a strong correlation between surge, engine power, and the difference in pressures as measured before and after the throttle. This pressure differential is called throttle reserve. It has been shown that if the throttle reserve is too low, the engine will not be able to sustain the desired power level. If the throttle reserve is too high, the engine can surge. The safe operating region lies between these two points (see Figure 2.25-5). AIR FLOW THROTTLE BOOST IMAP BOOST - IMAP = THROTTLE RESERVE Figure 2.25-6. Throttle Reserve Schematic ELECTRONIC VS. MECHANICAL WASTEGATE The electronic wastegate control has many advantages over a mechanical system of wastegates. First, the ESM turbocharger control is a flexible system since setpoint at various loads and speeds are precisely programmed. With a mechanical system, the wastegate is set at a single operation point (maximum load) that opens based on a spring rate as compressor discharge (boost) pressure increases. In addition, the differential pressure controller for the compressor is set at a single operating point. For the best turbocharger/engine match, a flexible system like the ESM turbocharger control is required. Second, on the ESM turbocharger control system, the bypass circuit routes air from the compressor discharge to the turbine inlet. On mechanical systems, it is common for the pressure differential valve to route air from the compressor discharge to the atmosphere. The ESM system arrangement is better on the turbocharger because mass flow is balanced between the compressor and turbine, allowing the turbocharger to operate within the design envelope on both sides. The electronic system design also allows more air flow increase with minimal turbocharger speed increase. Finally, ESM turbocharger control allows the wastegate to be closed at high load-low speed, unlike mechanical systems. This improves the turndown capability of the engine. The wastegate and bypass valves are managed to improve the throttle angle (controllability), reserve (throttle response), turbocharger performance, and engine economy trade-offs. TURBOCHARGER SURGE ZONE Max. RESERVE Safe Zone Throttle Reserve Min. Required LOW POWER ZONE ENGINE POWER Figure 2.25-5. Relationship Between Key Engine Parameters Throttle reserve is the pressure drop measured across the throttle valve and carburetor (see Figure 2.25-6). The upstream pressure (boost pressure) is higher than the downstream pressure (IMAP). The throttle reserve is calculated as the difference between the boost and IMAP (Throttle Reserve = Boost - IMAP). 2.25-4 FORM 6331 First Edition SECTION 2.30 ESM SPEED GOVERNING ESM SPEED GOVERNING The engine speed governing is completely integrated into the ESM. Information is sent from the ECU to the throttle actuator to adjust the amount of fuel and air being delivered into the cylinders. The ESM ECU contains the governor electronics and software that control the throttle actuator. The ECU controls engine speed (rpm) by controlling the amount of air-fuel mixture supplied to the engine. The ESM speed governing system allows the customer to make all control adjustments in one place and at one panel. Integral ESM speed governing provides the following benefits: • Better engine stability • Easier setup • Integrated operation diagnostics GOVERNING THEORY In order to control the engine speed, the ECU needs to know the following: • Current engine speed • Desired engine speed • Speed error To determine current engine speed, the ECU uses the crankshaft magnetic pickup that senses the 36 reference holes in the flywheel. As the holes pass the end of the magnetic sensor, a signal wave is generated. The frequency of the signal is proportional to engine speed. The desired engine speed is set by means of calibrations and/or external inputs to the ECU. The ECU calculates the difference between the current speed and the desired speed to determine the speed error. An electronic actuator is used to convert the electrical signal from the ECU into motion to change the amount of air and fuel delivered to the engine through the throttle (see Figure 2.30-1). 1) Throttle Actuator 1 Figure 2.30-1. SPEED GOVERNING INPUTS AND CALIBRATIONS Figure 2.30-2 illustrates the types of inputs to the ESM for speed governing control. The actual inputs required to the ECU depend on the governing control desired. Required external inputs are programmed to the ECU via the customer’s local control panel. These inputs include remote speed/load setting, remote speed setting enable, rated speed/idle speed, and an auxiliary rpm input for load control. Using these customer inputs, the ESM speed governing system is set to run in either speed control mode or load control mode. Governing control is further customized for location requirements through user-selectable parameters describing the driven load. Custom control adjustments to the ESM speed governing system are made with ESP. FORM 6331 First Edition 2.30-1 ESM SPEED GOVERNING The rotating moment of inertia of the driven equipment must be programmed in ESP. The correct governor gain depends on the rotating moment of inertia of the engine and driven equipment. Further gain calibrations may be made through ESP. By inputting the rotating moment of inertia of the driven equipment, the gain is preset correctly, saving time during setup of the engine. The rotating moment of inertia of the engine and the driven equipment are used in predicting governor sensitivity. See “Rotating Moment of Inertia/Adjusting Gain” on page 2.30-6 for more information. ESP CALIBRATED INPUTS • • • • • • LOAD INERTIA LOW/HIGH IDLE SPEEDS DROOP GAIN ADJUSTMENTS SYNCHRONIZATION SPEED FEEDFORWARD ADJUSTMENTS CUSTOMER INPUTS • • • • • REMOTE SPEED/LOAD SETTING REMOTE SPEED SETTING ENABLE IDLE/RATED SPEED SIGNAL LOAD COMING SIGNAL SYNCHRONIZER MODE SETTING ESM SPEED GOVERNING SYSTEM (INSIDE ECU) SENSOR INPUT • MAGNETIC PICKUP NOTE: The actual inputs required to the ECU depend on the governing control desired. ENGINE TORQUE MODIFICATION Figure 2.30-2. ESM Speed Governing System Inputs SPEED GOVERNING MODES Using inputs from the user’s panel or PLC, the ESM is set to run in one of two control modes: • Speed Control Mode – Fixed Speed – Variable Speed • Load Control Mode Speed Control Mode Speed control mode allows the engine operator to choose a setpoint speed, and the ECU will run the engine at that speed. The control can be either fixed speed or variable speed. Fixed Speed WARNING Never set the high idle speed above the safe working limit of the driven equipment. If the GOVREMSP signal goes out of range or the GOVREMSEL signal is lost, then the engine will run at the speed determined by the status of GOVHL IDL and calibrated low or high idle speeds. Disregarding this information could cause severe personal injury and/or product damage. When fixed speed control is selected with the ESP, the ECU will maintain a constant engine rpm regardless of load (within the capacity of the engine). 2.30-2 FORM 6331 First Edition ESM SPEED GOVERNING There are two fixed speeds available: low idle and high idle. Low idle speed is the default, and high idle is obtained by connecting a digital input to the ECU of +24 VDC nominal. Low idle speed is preset for each engine family, but by using ESP, the low idle speed can be offset lower or higher than the preset value. High idle speed is also adjustable using ESP, but is constrained to be higher than low idle speed and no higher than the maximum rated speed of the engine. The digital signal input to the ECU must be connected to +24 VDC (8.6 – 36 volts) for rated speed, open circuit for idle speed, and remote speed setting enable (GOVREMSEL) must be an open circuit. When using the Remote Speed/Load Setting, GOVHL IDL should be set to a safe mode. “Safe mode” means that if the wire that enables remote rpm operation (GOVREMSEL) fails, the speed setpoint will default to the GOVHL IDL idle value. Consider all process/driven equipment requirements when programming idle requirements. Variable Speed Variable speed is used to synchronize the output of multiple generator sets driving an isolated electrical grid. The ECU will allow the engine to slow down slightly under load. Variable speed is used to simulate the situation with mechanical governors where the engine will run at a slightly higher rpm than the setpoint when no load is placed on the engine. When operating an engine for variable speed applications, user connections determine the rpm setpoint. When the Remote Speed Select input signal is high (8.6 – 36 volts), the “Remote RPM” field on the [F4] Governor Panel is green and displays “ON.” Connecting the GOVREMSEL digital input to the ECU at +24 VDC enables variable speed mode. The speed setpoint can then be varied with either a 4 – 20 mA or a 0.875 – 4.0 volt input. The ESM checks for an out-of-range input that is less than 2 mA, greater than 22 mA, less than 0.45 volts, or greater than 4.3 volts. If an out-of-range speed setpoint is detected, the engine will then run at the speed indicated by the status of the high idle/low idle digital input. The engine speed setpoint range is already preadjusted to go from minimum to maximum engine speed using the 4 – 20 mA or 0.875–4.0 VDC input (see Table 2.30-1). Table 2.30-1. Engine Speed Range SPEED RANGE (4 – 20 mA RANGE) 750 – 1005 rpm 4 – 20 mA SIGNAL + 4 – 20 mA SIGNAL - 39 GOV REMSP + 27 GOV REMSP 40 GOV 40 CUSTOMER INTERFACE HARNESS JUMPERED 41 GOV 41 X NO CONNECTION X 0.875 – 4.0 V SIGNAL + 0.875 – 4.0 V SIGNAL - 39 GOV REMSP + 27 GOV REMSP CUSTOMER INTERFACE HARNESS 40 GOV 40 41 GOV 41 Figure 2.30-3 Connection Options for Variable Speed Setting Input FORM 6331 First Edition 2.30-3 ESM SPEED GOVERNING RPM DROOP REMOTE SPEED SELECTION DIGITAL INPUT GOV REMSP+ GOV REMSPOR GOV 40 GOV 41 GOVREMSEL REMOTE SPEED ANALOG INPUT INITIAL RPM + MODIFIED RPM + + SEE NOTE LIMIT THE RPM VALUE TYPICAL APPLICATIONS = GAS COMPRESSION AND MECHANICAL DRIVES LIMIT (RAMP) RPM CHANGE CALIBRATED RAMP TIME FINAL RPM VALUE TO BE USED IN GOVERNOR CALCULATION NOTE: If Remote Speed Selection Digital Input goes open circuit, then engine will run at Calibrated Low or High Idle rpm depending on status of Low/High Idle Digital Input. Figure 2.30-4. Logic Diagram Showing Variable Speed TYPICAL APPLICATIONS = ELECTRIC POWER GENERATION ISLAND OR GRID WOODWARD™ LOAD SHARING MODULE P/N 9907-173 GOVAUXSIG GOVAUXGND RPM DROOP + INITIAL RPM + + + MODIFIED RPM + + TARGET RPM LOW/HIGH IDLE DIGITAL INPUT GOVHL IDL RAMP FUNCTION + LIMIT THE RPM VALUE CALIBRATED LOW IDLE RPM CALIBRATED HIGH IDLE RPM AD LIMIT (RAMP) RPM CHANGE CALIBRATED RAMP TIME FINAL RPM VALUE TO BE USED IN GOVERNOR CALCULATION G LR LO ALTERNATE DYNAMICS DIGITAL INPUT SYNC RPM Figure 2.30-5. Logic Diagram Showing Fixed Speed 2.30-4 FORM 6331 First Edition ESM SPEED GOVERNING Load Control Mode Load control mode is used when a generator set is synchronized to a grid. In this case, the grid controls speed, and the ESM speed governing system controls the engine load using signals from an external device. The SYNC RPM is adjusted so that the actual engine speed setpoint is approximately 0.2% higher than synchronous speed. For example, if the grid frequency is 60 Hz (1200 rpm), the high idle is adjusted so that the engine speed setpoint is 1.002 times 1200 rpm, which is 1202.4 rpm. This ensures that the electric phasing of the grid and the engine are different so that the phases will “slide” past each other. When an external synchronizer determines that the voltage and phase of the generator match the grid, the breaker is closed. The load of the engine can now be controlled by an external load control such as the Woodward™ Load Sharing Module (Woodward™ P/N 9907-173) through the GOVAUXSIG and GOVAUXGND -2.5 to +2.5 volt input of the ESM (see Figure 2.30-6). The speed bias output of most load sharing devices can be configured to match the -2.5 to +2.5 volt input range of the ESM GOVAUXSIG and GOVAUXGND inputs. Refer to the load sharing device manual for information on how to configure the range and offset of the speed bias output of your load sharing device. Next, start the engine and adjust the Proportional and Integral gains of the load sharing device to obtain stable operation of the engine power output. Refer to the load sharing device manual for more information on how to set the gains of the device. Feedforward Control (Load Coming Control) Feedforward control (or load coming) is a proactive rather than a reactive feature that allows the engine to accept larger load additions than would normally be allowed. Feedforward works by immediately opening the throttle by a user-calibrated amount when a digital input goes high (8.6 – 36 volts). For example, when starting a large electric motor that is operating in island electric power generation mode, the moment the electric motor is started, or a second or two before, the feedforward digital input is raised high, and the ESM opens the throttle to produce more power. Unlike standard governing, the ESM does not have to wait for the engine speed to drop before opening the throttle. NOTE: Feedforward Control is not currently used on the 16V275GL engine. CUSTOMER INTERFACE HARNESS GOVAUXGND 29 28 46 USE SHIELDED TWISTED PAIR CABLE OUTPUT 19 20 WOODWARD™ LOAD SHARING MODULE Figure 2.30-6. External Load Control – Woodward™ Load Sharing Module Alternate Dynamics (Synchronizer Control) Alternate dynamics is a setting used at low loads and speeds, which reduces the throttle gains to provide better speed stability. Raising a high digital input (8.6 – 36 volts) to the ECU puts the ESM speed governing system in alternate dynamics. During the time the alternate dynamics input is high, the field is green and displays “ON”. During the time the alternate dynamics input is low, the field is gray and displays “OFF”. FORM 6331 First Edition GOVAUXSHD GOVAUXSIG 2.30-5 ESM SPEED GOVERNING ROTATING MOMENT OF INERTIA/ADJUSTING GAIN Ensure that the correct rotating moment of inertia (load inertia) is programmed in ESP for the engine’s driven equipment. Failure to program the moment of inertia for the driven equipment on the engine in ESP will lead to poor steady state and transient speed stability. Disregarding this information could result in product damage and/or personal injury. CAUTION The correct gains for an engine model are preloaded to the ECU. Having the gains preloaded greatly reduces startup time. To make this work, the ECU needs only one piece of information from the customer: the rotating moment of inertia or load inertia of the driven equipment. The rotating moment of inertia is the difference in how easy or difficult it will be to set any object in motion around a defined axis of rotation. The higher the moment of inertia of an object, the more force will have to be applied to set that object in a rotational motion. Conversely, the lower the moment of inertia, the less force needed to make the object rotate about an axis. NOTE: Rotating moment of inertia is not the weight or mass of the driven equipment. Once this information is available, the ECU calculates the actual load changes on the engine based on speed changes. Rotating moment of inertia is needed for all driven equipment. Setting the rotating moment of inertia (or load inertia) with ESP is the first task when setting up an engine and must be done with the engine not rotating. The rotating moment of inertia value is programmed on the [F4] Governor Panel in ESP. Refer to Section 3.10 ESP Programming “Programming Load Inertia” for programming steps. 2.30-6 FORM 6331 First Edition SECTION 2.35 EMERGENCY SAFETY SHUTDOWNS IMPORTANT! The following critical ESDs will prevent post-shutdown functionality from occurring: • ESD222 CUST ESD • ESD223 LOW OIL PRESS • ESD313 LOCKOUT/IGNITION • ESD532 COOLANT PRESS LOW To clear a critical ESD (to allow a restart or enable recirculation), you must cycle either of the E-Stop switches at the engine. • Failure of magnetic pickup • Internal ECU When a safety shutdown occurs, several internal actions and external visible effects take place. Each safety shutdown will cause the following actions to occur: • Ignition spark stops instantaneously. • Fuel delivery stops instantaneously. • The digital output from the ECU to the customer is changed to indicate to the customer’s driven equipment or PLC that the ESM has shut down the engine and something is not operating as expected. • Red status LED on the front of the ECU flashes the shutdown fault code. • Shutdown signal is transmitted over the customer interface (RS-485 MODBUS® and digital output). INDIVIDUAL SAFETY SHUTDOWNS DESCRIPTIONS EMERGENCY STOP (E-STOP) SWITCHES When an E-stop switch is pressed, the engine performs an emergency stop (see Section 2.05 Start-Stop Control “Emergency Shutdown Sequence”). LOW OIL PRESSURE The ESM is calibrated by Dresser Waukesha to both alarm and shut down on low oil pressure. The ESM uses several techniques to avoid falsely tripping on low oil pressure when either starting or stopping the engine. The low oil pressure alarm and shutdown setpoints are a function of engine speed. In addition, low oil pressure alarm and shutdowns are inhibited for a period of time after engine start. The low oil pressure alarm and shutdown setpoints can be offset in the [F11] Advanced Panel. Setpoints can only be offset in a safe direction and cannot exceed factory limits. OVERVIEW The ESM provides numerous engine safety shutdowns to protect the engine. These engine safety shutdowns include: • Emergency Stop (E-Stop) switches on each side of the engine • Low oil pressure • Engine overspeed •• 10% overspeed instantaneous •• Dresser Waukesha-calibrated to run no more than rated speed •• User-calibrated driven equipment overspeed • Customer-initiated emergency shutdown • Engine overload (based on percentage of engine torque) • Uncontrollable knock • High HT jacket water coolant temperature • Low HT jacket water coolant pressure • High intake manifold air temperature • Overcrank • Engine stall • Security violation • High oil temperature FORM 6331 First Edition 2.35-1 EMERGENCY SAFETY SHUTDOWNS ENGINE OVERSPEED The ESM is calibrated by Dresser Waukesha (not user programmable) to perform an immediate emergency shutdown upon detection of engine speed greater than 10% of rated rpm. For example, running a 1000 rpm engine at 1100 rpm or a 1200 rpm engine at 1320 rpm will cause a shutdown. In addition to the engine overspeed calibration, the user has the option to program an overspeed shutdown to protect driven equipment for situations where the driven equipment is rated at a lower speed than the engine. CUSTOMER-INITIATED EMERGENCY SHUTDOWN If the customer emergency shutdown circuit opens because of a driven equipment problem, wiring, or pushing the E-Stop button, the system will perform an emergency shutdown. ENGINE OVERLOAD If the engine is operated above rated power by a percent specified by Dresser Waukesha, it will be shut down after a period of time. The amount of time the engine is allowed to run at overload is determined by Dresser Waukesha. UNCONTROLLABLE ENGINE KNOCK Uncontrollable engine knock will shut down the engine after a period of time calibrated by Dresser Waukesha. A digital output from the ECU indicates that uncontrollable knock is occurring so that the customer can initiate some knock reduction strategy such as reducing engine load. HIGH HT JACKET WATER COOLANT TEMPERATURE The ESM is calibrated by Dresser Waukesha to both alarm and shut down upon high coolant temperature detection. The coolant temperature alarm and shutdown setpoints can be offset in the [F11] Advanced Panel. Setpoints can only be offset in a safe direction and cannot exceed factory limits. LOW HT JACKET WATER COOLANT PRESSURE The ESM is calibrated by Dresser Waukesha to both alarm and shut down upon low coolant pressure detection. HIGH INTAKE MANIFOLD AIR TEMPERATURE The ESM is calibrated by Dresser Waukesha to both alarm and shut down upon high intake manifold temperature detection. High intake manifold temperature alarm and shutdowns are inhibited for a period of time that is calibrated by Dresser Waukesha after engine start or stop. The high intake manifold temperature alarm and shutdown setpoints can be offset in the [F11] Advanced Panel. Setpoints can only be offset in a safe direction and cannot exceed factory limits. HIGH OIL TEMPERATURE The ESM is calibrated by Dresser Waukesha to both alarm and shut down on high oil temperature. The amount of time the engine is allowed to run at the high temperature is determined by Dresser Waukesha. The high oil temperature alarm and shutdown setpoints can be offset in the [F11] Advanced Panel. Setpoints can only be offset in a safe direction and cannot exceed factory limits. FAILURE OF MAGNETIC PICKUP Failure of the camshaft or crankshaft magnetic pickups or wiring will trigger an emergency engine shutdown. OVERCRANK If the engine is cranked longer than the time calibrated by Dresser Waukesha the starting attempt is terminated; the ignition and fuel are stopped; and the starter motor is de-energized. ENGINE STALL If the engine stops rotating without the ECU receiving a shutdown signal from the customer’s equipment, then the ESM will perform an emergency shutdown. One reason for an engine stall would be failure of an upstream fuel valve starving the engine of fuel and causing a shutdown. The ESM then shuts off the fuel valve and stops ignition. ECU INTERNAL FAULTS Certain ECU internal faults will trigger an engine emergency shutdown. SECURITY VIOLATION The ECU is protected from unauthorized reprogramming. In addition, the calibrations programmed to the ECU are engine specific. If the user attempts to calibrate the ESM with the wrong engine information, a security fault will occur. 2.35-2 FORM 6331 First Edition EMERGENCY SAFETY SHUTDOWNS ALARMS The ESM may also trigger a number of alarms, none of which will actively shut down the engine. A digital output on the ECU will go from open circuit to +24 VDC nominal. The cause of the alarm can be seen with the flashing LED code, with ESP, and through MODBUS® (see Section 4.00 Troubleshooting for a list of alarm and shutdown codes). If the customer desires to shut down the engine because of a sensor/wiring alarm from the oil pressure sensor (ALM211) or coolant temperature sensor (ALM333), use a 4 – 20 mA analog output or the values in MODBUS®. It is the customer’s responsibility to supply a third party device (such as a PLC) to read either the oil pressure and/or coolant temperature 4 – 20 mA signal or MODBUS® outputs and generate a shutdown signal. NOTE: Some faults have both an alarm and a shutdown associated with them. FORM 6331 First Edition 2.35-3 EMERGENCY SAFETY SHUTDOWNS 2.35-4 FORM 6331 First Edition SECTION 2.40 ESM COMMUNICATIONS MODBUS® (RS-485) COMMUNICATIONS MODBUS® is an industrial communications network that uses the master-slave topology. The standard allows for RS-485 (EIA/TIA-485 Standard) hardware and multidrop networking. RS-485 networks permits one MODBUS® master, such as a PC or PLC, on a network with up to 32 devices. The ECU is a slave device and will provide data to a MODBUS® master device at up to 19,200 baud over the RS-485 communications link of the ECU. The data that will be made available will include most filtered analog input values and some derived values. No control is done through MODBUS®. The master controls all communication on the network, while the ECU operates as a slave and simply responds to requests issued by the master. NOTE: The ECU will respond with exception responses wherever applicable and possible. See “MODBUS® Exception Responses” on page 2.40-3 for more information. The baud rate and the ECU identification number are user programmable through the [F11] Advanced Panel in ESP. No other programming is required in ESP for MODBUS®. Refer to Section 3.10 ESP Programming for more information. The user can assign an identification number (1 of 247 unique addresses) to a particular ECU, allowing other devices such as PLCs to share the network even if they use the same data fields. The baud rate can be changed to 1200, 2400, 9600, or 19,200 baud. The lower baud rates are to accommodate slower communications links such as radio or microwave modems. In order for communication to work properly between units, the communication parameters must be adjusted to match. MODBUS® The ESM is configured at the factory as: • 9600 baud • 8 data bits • parity none • stop bit = 1 WIRING The MODBUS® wiring consists of a two-wire, halfduplex RS-485 interface. Since half duplex mode does not allow simultaneous transmission and reception, it is required that the master controls the direction of data flow. NOTE: It is possible to use a master with a full duplex RS-485 interface; however, it is necessary to connect the two positive and negative signals together. So Txand Rx- become “A” and Tx+ and Rx+ become “B.” Two MODBUS® wires are available at the end of the Customer Interface Harness (loose wires). The two wires are gray and labeled RS 485A- and RS 485B+. See Section 2.00 System Power and Wiring for customer interface harness connections. RS-485 networking needs termination resistors if long wire runs are used. Termination resistors of 120Ω are placed across the RS-485 A- and B+ wires at the devices at both ends of the network. For short distances of 32 ft. (10 m) or less and with slower baud rates, termination resistors are not needed. NOTE: Typically, short distances of 32 ft. (10 m) will not require termination resistors. However, if you experience communication errors, first verify that the programmed baud rate on the [F11] Advanced Panel is the same as the MODBUS® master. If the baud rate is programmed correctly, termination resistors may be necessary to resolve communication errors. The communication network is susceptible to noise when no nodes are transmitting. Therefore, the network must be biased to ensure the receiver stays in a constant state when no data signal is present. This can be done by connecting one pair of resistors on the 2.40-1 FORM 6331 First Edition ESM COMMUNICATIONS RS-485 balanced pair: a pull-up resistor to a 5V voltage on the RS485A- circuit and a pull-down resistor to the common circuit on the RS485B+ circuit. The resistor must be between 450Ω and 650Ω. This must be implemented at one location for the whole serial bus. Alternatively, a Fail-Safe Bias Assembly is available (P/N P122048). PROTOCOL The MODBUS protocol can be used in two different modes: RTU (Remote Terminal Unit) and ASCII (American Standard Code of Information Interchange). The ESM works only in the RTU mode. In RTU mode, every element is represented by 8 bits (except data that can consist of a variable number of successive bytes). MODBUS® FOR PLC MODBUS® is typically a secondary protocol for many PLC manufacturers. Most PLC manufacturers use their own proprietary protocol, and MODBUS® is either not supported or an option. However, third party suppliers have made MODBUS® available for a wide range of PLCs. PERSONAL COMPUTERS RS-485 cards for PCs are available from many sources; however, not all RS-485 cards are the same. Two-wire RS-485 cannot transmit and receive at the same time. Microsoft® Windows® does not turn off the transmitter without special software or additional hardware on the RS-485 card. Before specifying PC software, make sure it has the ability to turn off the RS-485 transmitter or use a RS-485 card with special hardware to turn off the transmitter when not in use. National Instruments™ makes one example of an RS-485 card with special hardware. To make the National Instruments™ RS-485 card work with Lookout™ software, the serial port should be set for hardwired with a receive gap of 30 bytes. FAULT CODE BEHAVIOR The MODBUS® fault codes behave exactly like the flashing LED codes. As soon as a fault is validated, it is latched and remains that way until either the engine is shut down and then restarted, or the fault codes are cleared using ESP. NOTE: MODBUS® fault codes trigger when the LED codes cycle through the flashing code sequence. So when a new fault occurs, neither the MODBUS® nor the LEDs are updated until the current LED code flashing sequence is finished. Due to this behavior, you may notice up to a 30-second delay from when a fault occurs and when the fault is registered through MODBUS®. The length of delay will depend on the number of faults and the size of the digits in the fault code (for example, ALM211 will require less time to flash than ALM552). 2.40-2 ® The following example illustrates how MODBUS® values change during an alarm event: • An engine running for exactly 50 hours, with no prior alarm faults, would have the following MODBUS® address values: Address 00006 40007 40008 40009 40023 40024 40025 40026 Value 0 0 0 0 0 0 0 0 Definition Indicates a validated alarm is active Number of Alarm Faults Most recent fault code 2nd most recent fault code Engine Operating Hours (in seconds) of Most recent fault Engine Operating Hours (in seconds) of 2nd most recent fault • If a coolant overtemperature alarm (ALM333) triggered, the MODBUS® values would change to: Address 00006 40007 40008 40009 40023 40024 40025 40026 Value 1 1 333 0 2 48928 0 0 Definition Indicates a validated alarm is active Number of Alarm Faults Most recent fault code 2nd most recent fault code Engine Operating Hours (in seconds) of Most recent fault Engine Operating Hours (in seconds) of 2nd most recent fault • If the condition causing the alarm clears (in this scenario, the temperature decreases) the MODBUS® values would change to: Address 00006 40007 40008 40009 40023 40024 40025 40026 Value 0 1 333 0 2 48928 0 0 Definition Indicates a validated alarm is active Number of Alarm Faults Most recent fault code 2nd most recent fault code Engine Operating Hours (in seconds) of Most recent fault Engine Operating Hours (in seconds) of 2nd most recent fault NOTE: Only address 00006 has changed to indicate that no alarm is currently active. • If exactly 24 hours were to pass after ALM333, and the battery voltage dropped below 21 volts causing ALM454 to become active, the MODBUS® address values would change to: Address 00006 40007 40008 40009 40023 40024 40025 40026 Value 1 2 333 454 2 48928 4 4256 Definition Indicates a validated alarm is active Number of Alarm Faults Most recent fault code 2nd most recent fault code Engine Operating Hours (in seconds) of Most recent fault Engine Operating Hours (in seconds) of 2nd most recent fault FORM 6331 First Edition ESM COMMUNICATIONS FUNCTION CODES The MODBUS® function codes supported are codes 01 to 04. Table 2.40-1. lists the address IDs that are associated with each function code. Function code details are located in Table 2.40-3. through Table 2.40-6. Table 2.40-1. MODBUS® Function Codes FUNCTION CODE 01 02 03 04 READING MODBUS® ADDRESSES All 16-bit addresses specified in this document are in Motorola format (most significant byte first). Similarly, when two 16-bit addresses are joined to form a 32-bit double address, the most significant word comes first. The largest decimal value that a 16-bit address can contain is 65,535, and when a value larger than this is required, a 32-bit double address will be used. Example: The following is an example of two 16-bit addresses that are joined to form a 32-bit value: Current engine hours use MODBUS® address 40041 and 40042. If the value of address 40041 = 3 and register 40042 = 5474, then the total engine hours in seconds is: 3 x 65536 (Address 40041) + 5474 (Address 40042) = 202082 seconds (or 56.13389 hours) MODBUS® NAME Read Coil Status Read Input Status Read Holding Registers Read Input Registers ADDRESS ID 0XXXX 1XXXX 4XXXX 3XXXX NOTE: When performing the device addressing procedure, it is of great importance that there are not two devices with the same address. In such a case, the whole serial bus can behave in an abnormal way, with it being impossible for the master to communicate with all present slaves on the bus. ADDRESS 40041 ADDRESS 40042 Decimal 3 = Binary 0000000000000011 16-BIT ADDRESS Decimal 5474 = Binary 0001010101100001 16-BIT ADDRESS Decimal 202082 = Binary 0000000000000011 0001010101100001 32-BIT ADDRESS Figure 2.40-1. Example of Combining Two 16-Bit Addresses MODBUS® EXCEPTION RESPONSES When a master device sends a signal to a slave device, four possible situations can occur: • If the slave device receives the signal error-free and can handle the signal normally, a normal response is returned. • If the slave device does not receive an error-free signal, no response is returned. The master device will eventually process a time-out condition for the signal. • If the slave device receives the signal but detects an error, no response is returned. The master program will eventually process a time-out condition for the signal. • If the slave device receives the signal error-free but cannot handle it, the slave will return an exception response informing the master of the nature of the error. See Table 2.40-2. for exception responses. Table 2.40-2. MODBUS® Exception Responses CODE 01 NAME ILLEGAL FUNCTION ILLEGAL DATA ADDRESS MEANING The function code received in the signal is not an allowable action for the slave device. The data address received in the signal is not an allowable address for the slave device. 02 The ECU will respond with exception responses wherever applicable and possible. FORM 6331 First Edition 2.40-3 ESM COMMUNICATIONS FUNCTION CODE TABLES Table 2.40-3. Function Code 01 (0XXXX Messages) MODBUS® ADDRESS 00001 00002 00003 00004 00005 00006 00007 00008 00009 00010 00011 NAME Main Fuel Valve Pre-Chamber Fuel Valve Engine Running Starter Motor Pre/Post Lube Engine Alarm Engine Shutdown Engine Knocking No Spark Ignition Power Level Ignition Enabled DESCRIPTION Status of the main fuel valve Status of the prechamber fuel valve Whether the engine is running or not running Whether the starter motor is engaged or not Whether the pre/post lube pump is running Whether a validated alarm is active Whether the shutdown is active ENGINEERING UNITS 1 = ON 0 = OFF 1 = ON 0 = OFF 1 = RUNNING 0 = OFF 1 = ENGAGED 0 = OFF 1 = RUNNING 0 = OFF 1 = ON 0 = OFF 1 = OK 0 = SHUTDOWN Whether the engine is in uncontrollable knock 1 = ON 0 = OFF Whether the engine is experiencing a no-spark situation 1 = NO SPARK 0 = OK Whether the ignition power level is high or low 1 = HIGH 0 = LOW Whether the ignition is enabled or not 1 = ON 0 = OFF Table 2.40-4. Function Code 02 (1XXXX Messages) MODBUS® ADDRESS 10001 10002 10003 10004 10005 10006 10007 10008 10009 10010 10011 10012 10014 10015 10016 10017 NAME Start Engine Signal Normal Shutdown Emergency Shutdown Remote rpm Select Run High Idle Load Coming Alternate Dynamics/ Synchronizer Mode Lockout Button/Ignition Module User Digital Input 1 User Digital Input 2 User Digital Input 3 User Digital Input 4 AFR Manual/Automatic Status (Left Bank) DESCRIPTION Whether the start engine signal is active Whether the normal shutdown signal is active Whether the emergency shutdown signal is active Whether the remote rpm analog input is active or inactive Whether the run high-idle digital input is active Whether the load coming digital input is active Whether the alternate governor dynamics is active Whether either the lockout button has been depressed or the IPM-D has failed, or is not powered Whether user digital input 1 is high Whether user digital input 2 is high Whether user digital input 3 is high Whether user digital input 4 is high ENGINEERING UNITS 1 = Start Engine Signal High 0 = Start Engine Signal Low 1 = Normal Shutdown 0 = OK to Run 1 = Emergency Shutdown 0 = OK to Run 1 = Remote rpm Select Active 0 = Remote rpm Select Inactive 1 = Run Engine At High Idle 0 = Run Engine At Low Idle 1 = Load Coming Digital Input Active 0 = Load Coming Digital Input Inactive 1 = Alternate Gov Dynamics Is Active 0 = Alternate Gov Dynamics Is Inactive 1 = Lockout Active 0 = Lockout Inactive 1 = User DIP 1 High 0 = User DIP 1 Inactive 1 = User DIP 2 High 0 = User DIP 2 Inactive 1 = User DIP 3 High 0 = User DIP 3 Inactive 1 = User DIP 4 High 0 = User DIP 4 Inactive Whether the air-fuel ratio control is in man- 1 = Automatic Mode ual or automatic mode 0 = Manual Mode Reserved For Future Use Reserved For Future Use Reserved For Future Use 2.40-4 FORM 6331 First Edition ESM COMMUNICATIONS Table 2.40-5. Function Code 03 (4XXXX Messages) (Part 1 of 2) MODBUS® ADDRESS 40001 40002 NAME Number of ESD fault codes First ESD fault code to occur* ENGINEERING UNITS 16-bit unsigned integer that goes from 0 to 5 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-3 for ESD Fault Codes) 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-3 for ESD Fault Codes) 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-3 for ESD Fault Codes) 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-3 for ESD Fault Codes) 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-3 for ESD Fault Codes) 16-bit unsigned integer that goes from 0 to 5 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-2 for ALM Fault Codes) 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-2 for ALM Fault Codes) 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-2 for ALM Fault Codes) 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-2 for ALM Fault Codes) 16-bit unsigned integer that goes from 111 to 555, excluding any values that contain zeros (see Table 4.00-2 for ALM Fault Codes) 32-bit unsigned integer – full range 32-bit unsigned integer – full range 32-bit unsigned integer – full range 32-bit unsigned integer – full range 32-bit unsigned integer – full range 32-bit unsigned integer – full range 32-bit unsigned integer – full range 32-bit unsigned integer – full range 32-bit unsigned integer – full range 32-bit unsigned integer – full range 16-bit unsigned integer that goes from 0 to 2304 (0 to 112%) 16-bit unsigned integer that goes from 0 to 2560 (0 to 125%) 16-bit unsigned integer that goes from 0 to 20,000 Reserved For Future Use Reserved For Future Use Reserved For Future Use Reserved For Future Use 40003 Second ESD fault code to occur* 40004 Third ESD fault code to occur* 40005 Fourth ESD fault code to occur* 40006 40007 40008 Fifth ESD fault code to occur* Number of ALM fault codes First ALM fault code to occur* 40009 Second ALM fault code to occur* 40010 Third ALM fault code to occur* 40011 Fourth ALM fault code to occur* 40012 40013 40014 40015 40016 40017 40018 40019 40020 40021 40022 40023 40024 40025 40026 40027 40028 40029 40030 40031 40032 40033 40034 40035 40036 40037 40038 40039 Fifth ALM fault code to occur* Engine operating hours (in seconds) of most recent ESD fault code Engine operating hours (in seconds) of second most recent ESD fault code Engine operating hours (in seconds) of third most recent ESD fault code Engine operating hours (in seconds) of fourth most recent ESD fault code Engine operating hours (in seconds) of fifth most recent ESD fault code Engine operating hours (in seconds) of most recent ALM fault code Engine operating hours (in seconds) of second most recent ALM fault code Engine operating hours (in seconds) of third most recent ALM fault code Engine operating hours (in seconds) of fourth most recent ALM fault code Engine operating hours (in seconds) of fifth most recent ALM fault code Desired engine load Actual engine load Position of stepper motor 1 FORM 6331 First Edition 2.40-5 ESM COMMUNICATIONS Table 2.40-5. Function Code 03 (4XXXX Messages) (Continued), (Part 2 of 2) MODBUS® ADDRESS 40040 40041 40042 40043 40044 40045 40046 40047 40048 40049 40050 40051 NAME Reserved For Future Use Current engine operating hours (in seconds) Rich stepper maximum motor limit of active fuel (left bank) Lean stepper minimum motor limit of active fuel (left bank) ENGINEERING UNITS 32-bit unsigned integer – full range 16-bit unsigned integer that goes from 0 to 20,000 16-bit unsigned integer that goes from 0 to 20,000 Reserved For Future Use Reserved For Future Use Reserved For Future Use Reserved For Future Use Reserved For Future Use Reserved For Future Use Countdown in seconds until engine starts once starter pressed 16-bit unsigned integer that goes from 0 to 20,000 Table 2.40-6. Function Code 04 (3XXXX Messages) (Part 1 of 4) MODBUS® ADDRESS 30001 30002 30003 30004 30005 30006 30007 30008 30009 30010 30011 30012 30013 30014 30015 30016 30017 30018 30019 30020 30021 NAME Average rpm Oil pressure Intake manifold absolute pressure Boost absolute pressure Throttle position Fuel control valve Bypass position Coolant outlet temperature Spark timing 1 Spark timing 2 Spark timing 3 Spark timing 4 Spark timing 5 Spark timing 6 Spark timing 7 Spark timing 8 Spark timing 9 Spark timing 10 Spark timing 11 Spark timing 12 Spark timing 13 SCALING Average engine rpm * 4 Oil pressure * 2 in units of kPa gauge Intake manifold pressure * 4 in units of kPa absolute Boost pressure * 4 in units of kPa absolute Throttle position in units of percent open * 20.48 ENGINEERING UNITS 16-bit unsigned integer that goes from 0 to 8800 (0 to 2200 rpm) 16-bit unsigned integer that goes from 0 to 2204 (0 to 1102 kPa) 16-bit unsigned integer that goes from 0 to 2304 (0 to 576 kPa) 16-bit unsigned integer that goes from 0 to 2304 (0 to 576 kPa) 16-bit unsigned integer that goes from 0 to 2048 (0 to 100%) Fuel Control Valve position * 20.48 in units of 16-bit unsigned integer that goes percent open. from 0 to 2048 (0 to 100%) Bypass position * 20.48 in units of percent open (Coolant outlet temperature in C + 40) * 8 16-bit unsigned integer that goes from 0 to 2048 (0 to 100%) 16-bit unsigned integer that goes from 0 to 1520 (-40 to 150° C) (Spark timing + 15) * 16 of 1st cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing +15) * 16 of 2nd cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing + 15) * 16 of 3rd cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing + 15) * 16 of 4th cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing + 15) * 16 of 5th cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing + 15) * 16 of 6th cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing + 15) * 16 of 7th cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing + 15) * 16 of 8th cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing + 15) * 16 of 9th cylinder in the 16-bit unsigned integer that goes firing order from 0 to 960 (-15 to 45° BTDC) (Spark timing + 15) * 16 of 10th cylinder in the firing order (Spark timing + 15) * 16 of 11th cylinder in the firing order (Spark timing + 15) * 16 of 12th cylinder in the firing order (Spark timing + 15) * 16 of 13th cylinder in the firing order 16-bit unsigned integer that goes from 0 to 960 (-15 to 45° BTDC) 16-bit unsigned integer that goes from 0 to 960 (-15 to 45° BTDC) 16-bit unsigned integer that goes from 0 to 960 (-15 to 45° BTDC) 16-bit unsigned integer that goes from 0 to 960 (-15 to 45° BTDC) 2.40-6 FORM 6331 First Edition ESM COMMUNICATIONS Table 2.40-6. Function Code 04 (3XXXX Messages) (Continued), (Part 2 of 4) MODBUS® ADDRESS 30022 30023 30024 30025 30026 30027 30028 30029 30030 30031 30032 30033 30034 30035 30036 30037 Setpoint rpm IMAP left bank/rear IMAP right bank/front Barometric pressure Ambient temperature NAME Spark timing 14 Spark timing 15 Spark timing 16 Desired spark timing Battery voltage Intake manifold air temperature (left bank) Oil temperature SCALING (Spark timing + 15) * 16 of 14th cylinder in the firing order (Spark timing + 15) * 16 of 15th cylinder in the firing order (Spark timing + 15) * 16 of 16th cylinder in the firing order (Spark timing + 15) * 16 Battery voltage * 16 (Intake manifold air temperature in C + 40) * 8 (Oil temperature in C + 40) * 8 Reserved For Future Use Reserved For Future Use Reserved For Future Use Reserved For Future Use Setpoint rpm * 4 Example: If register 30033 = 4000, then 4000/4 = 1000 rpm Intake manifold pressure * 4 in units of kPa absolute Intake manifold pressure * 4 in units of kPa absolute Barometric pressure * 16 in units of kPa (Ambient temp. in Centigrade + 40) * 8 ENGINEERING UNITS 16-bit unsigned integer that goes from 0 to 960 (-15 to 45° BTDC) 16-bit unsigned integer that goes from 0 to 960 (-15 to 45° BTDC) 16-bit unsigned integer that goes from 0 to 960 (-15 to 45° BTDC) 16-bit unsigned integer that goes from 0 to 960 (-15 to 45° BTDC) 16-bit unsigned integer that goes from 0 to 640 (0 to 40 VDC) 16-bit unsigned integer that goes from 0 to 1520 (-40 to 150° C) 16-bit unsigned integer that goes from 0 to 2048 (-40 to 216° C) 16-bit unsigned integer that goes from 0 to 8800 (0 to 2200 rpm) 16-bit unsigned integer that goes from 0 to 2304 (0 to 576 kPa) 16-bit unsigned integer that goes from 0 to 2304 (0 to 576 kPa) 16-bit unsigned integer that goes from 800 to1680 (50 to 105 kPa) 16-bit unsigned integer that goes from 0 to 1120 (-40 to 100° C) 30038 30039 Digital input values A 32-bit number representing the status of all of the 1XXXX messages NOTE: For more information on addresses 30038–30039, see “Additional Information on 32-bit unsigned integer – full range MODBUS® Addresses 30038 – 30041” on page 2.40-9. A 32-bit number representing the status of all of the 0XXXX messages NOTE: For more information on addresses 30040–30041, see “Additional Information on 32-bit unsigned integer – full range MODBUS® Addresses 30038 – 30041” on page 2.40-9. Reserved For Future Use Reserved For Future Use Reserved For Future Use Reserved For Future Use Reserved For Future Use 16-bit unsigned integer that goes from 0 to 23704 (0 to 11852 kW) 16-bit unsigned integer that goes from 0 to 2048 (16 to 144 WKI) Reserved For Future Use 16-bit unsigned integer that goes from 0 to 4200 (0 to 21% O2) Reserved For Future Use Reserved For Future Use 30040 30041 Digital output values 30042 30043 30044 30045 30046 30047 30048 30049 30050 30051 30052 30053 30054 30055 Desired O2 % %O2 * 200 O2 heater block temperature Actual O2 % %O2 * 200 Engine power output WKI value Power * 2 in kW (WKI -16) *16 (Temperature in C + 40) * 2 Reserved For Future Use 16-bit unsigned integer that goes from 0 to 1840 (-40 to 880° C) 16-bit unsigned integer that goes from 0 to 4200 (0 to 21% O2) FORM 6331 First Edition 2.40-7 ESM COMMUNICATIONS Table 2.40-6. Function Code 04 (3XXXX Messages) (Continued), (Part 3 of 4) MODBUS® ADDRESS 30056 30057 30058 30059 30060 30062 30063 30064 30065 30066 30067 30068 30069 30070 30071 30072 30073 30074 30075 30076 30077 30078 30079 30080 30081 30082 30083 30084 30085 30086 30087 30088 30089 30090 Oil temperature alarm limit Oil temperature shutdown limit IMAT alarm limit IMAT shutdown limit Coolant temperature alarm limit Coolant temperature shutdown limit Gauge oil pressure alarm limit Engine torque Rated torque Spark reference number cyl. #1 in firing order Spark reference number cyl. #2 in firing order Spark reference number cyl. #3 in firing order Spark reference number cyl. #4 in firing order Spark reference number cyl. #5 in firing order Spark reference number cyl. #6 in firing order Spark reference number cyl. #7 in firing order Spark reference number cyl. #8 in firing order Spark reference number cyl. #9 in firing order Spark reference number cyl. #10 in firing order Spark reference number cyl. #11 in firing order Spark reference number cyl. #12 in firing order Spark reference number cyl. #13 in firing order Spark reference number cyl. #14 in firing order Spark reference number cyl. #15 in firing order Spark reference number cyl. #16 in firing order % * 20.48 % * 20.48 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Value * 1 Reserved For Future Use Reserved For Future Use Reserved For Future Use Reserved For Future Use (Oil temperature in C + 40) * 8 (Oil temperature in C + 40) * 8 (Intake manifold air temperature in C + 40) * 8 (Intake manifold air temperature in C + 40) * 8 (Coolant temperature in C + 40) * 8 (Coolant temperature in C + 40) * 8 Oil pressure * 2 in units of kPa gauge 16-bit unsigned integer that goes from 0 to 2048 (-40 to 216 C) 16-bit unsigned integer that goes from 0 to 2048 (-40 to 216 C) 16-bit unsigned integer that goes from 0 to 1520 (-40 to 150 C) 16-bit unsigned integer that goes from 0 to 1520 (-40 to 150 C) 16-bit unsigned integer that goes from 0 to 1520 (-40 to 150 C) 16-bit unsigned integer that goes from 0 to 1520 (-40 to 150 C) 16-bit unsigned integer that goes from 0 to 2204 (0 to 1102 kPa) The ECU temperature NAME SCALING Reserved For Future Use Reserved For Future Use (Temperature in Centigrade + 40) * 8 Reserved For Future Use Reserved For Future Use ENGINEERING UNITS 16-bit unsigned integer that goes from 0 to 1120 (-40 to 100° C) 16-bit unsigned integer that goes from 0 to 2560 (0 to 125%) 16-bit unsigned integer that goes from 0 to 2560 (0 to 125%) 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 16-bit unsigned integer that goes from 0 to 255 2.40-8 FORM 6331 First Edition ESM COMMUNICATIONS Table 2.40-6. Function Code 04 (3XXXX Messages) (Continued), (Part 4 of 4) MODBUS® ADDRESS 30091 30092 30093 30094 30095 30096 30097 30098 30099 Oil filter differential pressure NAME Gauge oil pressure shutdown limit HT coolant Pressure Fuel pressure SCALING Oil pressure * 2 in units of kPa gauge HT coolant pressure range * 2 units of kPa gauge Fuel coolant pressure range * 2 units of kPa gauge Reserved For Future Use ENGINEERING UNITS 16-bit unsigned integer that goes from 0 to 2204 (0 to 1102 kPa) 16-bit unsigned integer that goes from 0 to 2304 (0 to 1152 kPa) 16-bit unsigned integer that goes from 0 to 2304 (0 to 1152 kPa) 16-bit unsigned integer that goes from 0 to 2204 (0 to 1102 kPa) 16-bit unsigned integer that goes from 0 to 2304 (0 to 1152 kPa) 16-bit unsigned integer that goes from 0 to 2304 (0 to 1152 kPa) 16-bit unsigned integer that goes from 0 to 2304 (0 to 1152 kPa) HT coolant pressure gauge * 2 units of kPa Gauge HT coolant Pressure gauge Gauge coolant pressure Gauge fuel pressure HT coolant pressure range * 2 units of kPa gauge Fuel coolant pressure range * 2 units of kPa gauge Reserved For Future Use Oil filter differential pressure range * 2 units of kPa gauge ADDITIONAL INFORMATION ON MODBUS® ADDRESSES 30038 – 30041 To save programming time, the value of MODBUS® address 30039 can be converted to binary to determine the state of MODBUS® addresses 10001 through 10016, and the value of MODBUS® address 30041 can be converted to binary to determine the state of MODBUS® addresses 00001 through 00011. Example 1 In this example, address 30039 has a value of 4105, and will be used to determine the status of MODBUS® addresses 10001 through 10016. • Convert 4105 to a binary number. In binary 4105 = 1000000001001. The left-most digit in the binary number is known as the most significant digit. The right-most digit is the least significant digit. MODBUS® ADDRESSES BINARY VALUE • Comparing the values with Table 2.40-4. on page 2.40-4 in this section shows the following: ADDRESS 10016 10015 10014 10013 10012 10011 10010 10009 10008 10007 10006 DECIMAL 4105 = BINARY 1 0 0 0 0 0 0 0 0 1 0 0 MOST SIGNIFICANT DIGIT LEAST SIGNIFICANT DIGIT 10005 10004 10003 • Each 0 or 1 corresponds to the current value of MODBUS® address 10001 through 10016 starting with the least significant digit being 10001. 10002 10001 FORM 6331 First Edition 10 0 10 16 0 10 15 0 10 14 0 10 13 0 10 12 01 10 1 01 10 0 0 10 09 00 10 8 0 10 07 0 10 06 0 10 05 0 10 04 0 10 03 00 10 2 00 1 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 1 LEAST SIGNIFICANT DIGIT VALUE 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 1 DEFINITION Reserved for future use Reserved for future use Manual Mode Alternator OK User DIP 4 Inactive User DIP 3 Inactive User DIP 2 Inactive User DIP 1 Inactive Lockout Inactive Alternate Gov Dynamics Inactive Load Coming Digital Input Inactive Run Engine at Low Idle Remote RPM Select Active OK to Run OK to Run Start Engine Signal Active 2.40-9 ESM COMMUNICATIONS Example 2 In this example, address 30041 has a value of 5, and will be used to determine the status of MODBUS® addresses 00001 through 00011. • Convert 5 to a binary number. In binary 5 = 101. The left-most digit in the binary number is known as the most significant digit. The right-most digit is the least significant digit. • Comparing the values with Table 2.40-3. on page 2.40-4 in this section shows the following: Address 00011 00010 00009 00008 00007 00006 00005 DECIMAL BINARY = 00004 00003 00002 00001 MOST SIGNIFICANT DIGIT LEAST SIGNIFICANT DIGIT Value 0 0 0 0 0 0 0 0 1 0 1 Definition Ignition Enabled Ignition Power Level = Low No Spark = OK Engine Uncontrollable Knock = Off Engine Is Not Shut down Engine Alarm Is Off Pre/Post Lube Pump Not Running Start Motor Is Disengaged Engine Is Running Prechamber Fuel Valve = Off Main Fuel Valve = On 5 0000000000101 LOCAL CONTROL PANEL With the ESM, the packager may choose any compatible control panel. The ESM has a number of 4 – 20 mA analog outputs that can be either read into a PLC or read with a local display (see Table 2.40-7). The displays can be used for locally mounted tachometer, oil pressure, coolant temperature, or intake manifold pressure displays. Displays are available in 24 VDC, AC, or loop powered, the latter requiring no external power source. • Each 0 or 1 corresponds to the current value of MODBUS® address 10001 through 10016 starting with the least significant digit being 10001. MODBUS® ADDRESSES Table 2.40-7 Calibration of Analog Outputs ANALOG OUTPUT Average rpm Oil pressure Coolant temperature Intake manifold absolute pressure Percentage of rated torque the engine is producing Available percentage of rated torque the engine is capable of producing 00 0 00 16 01 00 5 0 00 14 01 00 3 0 00 12 01 00 1 01 00 0 0 00 09 00 00 8 0 00 07 0 00 06 0 00 05 0 00 04 0 00 03 00 00 2 00 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 BINARY VALUE LEAST SIGNIFICANT DIGIT WIRE NAME PROG OP1 PROG OP2 PROG OP3 PROG OP4 ACT LOAD% AVL LOAD% 4 MA 0 rpm 0 psig (0 kPa) 32° F (0° C) 0 in-hg Abs. (0 kPa Abs.) 0% 0% 20 MA 2016 rpm 150 psig (1035 kPa) 320° F (160° C) 149 in-hg Abs. (504 kPa Abs.) 125% 125% 2.40-10 FORM 6331 First Edition ESM COMMUNICATIONS USER DIGITAL INPUTS The USER DIP inputs make it possible to wire external signals into the ESM to provide system diagnostic capability for customer-supplied equipment. There are four digital inputs: USER DIP 1, USER DIP 2, USER DIP 3, and USER DIP 4 in the Customer Interface Harness. When a +24 VDC signal is applied to one of these inputs, ALM541 is activated by the ESM. The alarm is recorded in the ESP Fault Log and the yellow status LED on the front of the ECU flashes the alarm code. NOTE: Only an alarm signal is activated – no other control action is taken by the ESM when one of the USER DIPs goes high! The following examples explain how the USER DIP inputs can be used in the field. Example 1 An oil level alarm can be wired into the ESM using one of the USER DIP inputs. This level sensor is of the Normally Open type, where the contacts are open when the oil is at proper level, and the contacts close to complete a signal path when the oil level falls too low (see Figure 2.40-2). When the oil level is low, the contacts complete a +24 VDC signal into the USER DIP and ALM541 for USER DIP 1 is activated. Also, the yellow status LED on the ECU flashes the alarm code. NOTE: The negative side of the 24 VDC supply must be connected to the customer reference ground wire labeled LOGIC GND. Figure 2.40-2. Example 1: User Digital Input Used with Oil Level Switch (Normally Open Type) Example 2 If a solid state level sensor is used, a relay is used to generate the correct signal. This example is shown in Figure 2.40-3. When the oil level is normal, the fuel level sensor does not supply a ground to the relay, the relay contact remains open, and the USER DIP is low. 24 VDC (+) RELAY When the oil level becomes too low, the sensor completes the circuit to ground, and the relay coil energizes. This causes the contacts to close and +24 VDC is applied to the USER DIP and ALM541 is activated. Also, the yellow status LED on the ECU flashes the alarm code. (–) ECU USER DIP 1 OIL LEVEL SWITCH Figure 2.40-3. Example 2: User Digital Input Used with Solid State Level Sensor (Open Collector) FORM 6331 First Edition 2.40-11 ESM COMMUNICATIONS Example 3 The oil level sensor can also be used to trigger an engine shutdown. Since the ESD digital input must remain at +24 VDC for the engine to run, and opening the circuit will cause a shutdown, a relay can be used to properly manipulate the signal. This example is shown in Figure 2.40-4. As in the previous example, when the oil level becomes low, the relay is energized, causing the USER DIP to go high. At the same time, the ESD signal goes low, resulting in an engine shutdown and ESD222 shutdown code being logged. Also, the red status LED on the ECU flashes the shutdown code. NOTE: The engine cannot be restarted until the fault condition is corrected. 24 VDC (+) RELAY (–) USER DIP 1 ECU ESD OIL LEVEL SWITCH Figure 2.40-4. Example 3: ESD Digital Input Used to Trigger an Engine Shutdown 2.40-12 FORM 6331 First Edition ELECTRONIC SERVICE PROGRAM (ESP) CONTENTS SECTION 3.00 – INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) SECTION 3.05 – ESP PANEL AND FIELD DESCRIPTIONS SECTION 3.10 – ESP PROGRAMMING FORM 6331 First Edition ELECTRONIC SERVICE PROGRAM (ESP) FORM 6331 First Edition SECTION 3.00 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) The PC-based Electronic Service Program (ESP) is the primary means of obtaining information on system status. ESP provides a user-friendly, graphical interface in a Microsoft® Windows® XP operating system environment. If the user needs troubleshooting information while using the ESP software, an electronic help file is included. ESP is also a diagnostic tool and is the means by which the information recorded to the ECU fault logs can be read. INSTALLING ESP FROM DOWNLOAD NOTE: Before downloading the ESP from WEDlink.net, verify you have administration rights on your computer or have the IT department download and install the program. 1. Log on to www.WEDlink.net and select “Products” located on the left sidebar. About Administration Directory Documents Media Center Products Training & Registration Training Information RECOMMENDED SYSTEM REQUIREMENTS ESP software with E-Help can be installed from a Dresser Waukesha-supplied CD-ROM or can be downloaded from WEDlink. The minimum PC requirements are: • 700 MHz processor • 128 MB RAM • 200 MB free hard disk space • Microsoft® Windows® XP operating system • Microsoft® Internet Explorer 5.0 • 1024 x 768 Color VGA Display • RS-232 Serial Port • CD-ROM Drive • Mouse or other pointing device recommended but not required An RS-232 serial cable (P/N 740269) supplied by Dresser Waukesha is used to connect the PC to the ECU. See “Connecting PC to ECU” on page 3.00-3 for more information. Figure 3.00-1. WEDlink Home Page 2. Select “Engine Controls” located on left sidebar. CFR Products Engine Controls Engine Families Product Applications Product Support Figure 3.00-2. WEDlink Products Page FORM 6331 First Edition 3.00-1 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) 3. Select “ESM” located on left sidebar. 5. Right-click on the link and choose “Save Target As.” 6. Save program to a folder that allows easy access. For example, save the file to your desktop. ESM AFM DSM IM 7. Save the file to your computer (download time may be extensive depending on Internet speed). 8. After download is complete, double-click the zipped file. 9. In the window that opens, click “Extract all files” to open the Extraction Wizard. Figure 3.00-3. WEDlink Engine Control Page NOTE: The ESM page contains the ESP download. 4. Scroll down until the “Current Version” of ESP available for download is located. SCROLL DOWN Figure 3.00-6. Extracting Files 10. Follow the procedures in the Extraction Wizard. 11. After file is unzipped, open the folder that was unzipped and run the setup.exe program and follow the Installation Wizard to install ESP. Figure 3.00-4. WEDlink ESM Page (Top) CURRENT VERSION OF ESP AVAILABLE FOR DOWNLOAD Figure 3.00-7. Setup.Exe File Figure 3.00-5. WEDlink ESM Page (Bottom) 3.00-2 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) INSTALLING ESP FROM CD The ESP CD contains an installation program to automatically load ESP on the hard drive of your PC. Complete the steps that follow to load the ESP software using the installation program. 1. Make sure your PC meets the system requirements listed at the beginning of this section. 2. Start Microsoft® Windows® XP operating system on your PC. 3. Close any other applications that may be open on your PC’s desktop. 4. Insert the ESP CD into the CD drive of your PC. • If Autorun is enabled on your PC system, installation starts automatically approximately 30 seconds after the CD is inserted. Continue with Step 7. • If installation doesn’t start automatically after 30 seconds, continue with Step 5. 5. From the Start menu, select Run.... 6. Type d:\setup.exe and click “OK” (if “d” is not the letter of your CD drive, type in the appropriate letter). 7. Complete installation by following the instructions provided by the Installation Wizard. NOTE: By default, the ESP software is installed in C:\Program Files\ESM. 8. When installation is complete, four ESP shortcuts will appear on your desktop. Table 3.00-1. ESP Desktop Shortcuts DESCRIPTION ESM ESP: Double-clicking this shortcut icon opens the standard ESP program. SERIAL CABLE (P/N 740269) 9-PIN CONNECTOR CONNECTING PC TO ECU An RS-232 serial cable (P/N 740269) supplied by Dresser Waukesha is used to connect the PC to the ECU. This cable has a 9-pin RS-232 connection that plugs into the PC and an 8-pin Deutsch® connector that plugs into the ECU (see Figure 3.00-8). 8-PIN DEUTSCH® CONNECTOR “SERVICE INTERFACE” CONNECTION Figure 3.00-8. Serial Cable Connection 1. Locate the RS-232 serial cable supplied by Dresser Waukesha. 2. Connect the 9-pin end of the RS-232 serial cable to the PC’s communication port. Typically, this is port 1 (also referred to as COM 1, serial a, or serial 1). 3. Connect the 8-pin connector of the serial cable to the “Service Interface” connection on the side of the ECU (see Figure 3.00-8). 4. Verify all connections are secure. NOTE: The PC can be connected to the ECU via a modem connection. See “Using a Modem For Remote Monitoring” on page 3.00-15 for more information on modem connections and ESP startup information. NOTE: If the ESP software and associated workspace files are not saved to your PC’s hard drive, complete the steps under the section “Installing ESP From CD” on page 3.00-3 or “Installing ESP From Download” on page 3.00-1. SHORTCUT ESM Training Tool: Double-clicking this shortcut icon opens a version of ESP that is used for training only. This program runs even without an ECU connected. ESP Modem Access: Double-clicking this shortcut icon opens a version of ESP that allows use of ESP with a modem and requires modem cables for use. (See “Using a Modem For Remote Monitoring” on page 3.00-15). Log File Processor: Double-clicking this shortcut icon opens a program that converts ESP log files into a usable file format. (See Section 3.10 ESP Programming “Logging System Parameters”). FORM 6331 First Edition 3.00-3 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) STARTING ESP Once the PC is connected to the ECU, ESP can be started on the PC. 1. Apply power to the ECU. 2. Start ESP by one of the following methods: • Double-click the ESM ESP icon on your desktop. CONNECTION STATUS Once ESP is open, you can always verify you have a good connection between the ECU and PC by looking at the “connection” icon on the top right corner of the ESP screen. Table 3.00-2. Connection Status Icons DESCRIPTION Searching: This icon indicates that ESP is currently searching for a connection between the ECU and ESP and your PC. ICON • From the Windows® taskbar (lower-left corner of your desktop), click Start → All Programs → Waukesha Engine Controls → Engine System Manager (ESM) → ESP. 3. If an ESP communication error occurs, check serial cable connections to the PC and ECU. Click “Retry.” Connection: This icon indicates that there is a good connection between the ECU and ESP on your PC. No Connection: This icon indicates that there is not a connection between the ECU and ESP on your PC. See Note below. NOTE: If the icon displayed indicates no connection, either there is no power to the ECU, the serial cable is not connected properly to the ECU or PC, or the cable is defective. USER INTERFACE PANELS NOTE: Complete ESP user interface panel descriptions are provided in Section 3.05 ESP Panel and Field Descriptions. The ESM ESP software displays engine status and information on seven panels: Figure 3.00-9. Communication Error Dialog Box [F2] Engine Panel [F8] AFR Setup Panel 4. If after checking serial cable and retrying connection an error still occurs, click “Select COM Port.” 5. From the Communications Settings dialog box, select the communication port that you are using for communication to the ECU and click “OK.” [F3] Start-Stop Panel [F10] Status Panel [F4] Governor Panel [F5] Ignition Panel These panels display system and component status, current pressure and temperature readings, alarms, ignition status, governor status, air-fuel control status, and programmable adjustments. Each of the panels is viewed by clicking the corresponding tab or by pressing the corresponding function key ([F#]) on the keyboard. NOTE: The [F1] function key displays ESP’s electronic help file called “E-Help.” E-Help provides fault code troubleshooting information. See Section 4.00 Troubleshooting “E-Help” for more information. [F1] is not located on the PC screen as a panel; it is only a function key on the keyboard. [F11] Advanced Panel Figure 3.00-10. Communications Settings Dialog Box 3.00-4 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) [F2] ENGINE: [F3] START-STOP: Figure 3.00-11. Engine Panel Figure 3.00-12. Start-Stop Panel Readings and Settings: • Ambient Air Temperature • Barometric Pressure • BK Intake Manifold Pressure • Boost Pressure • Coolant Pressure • Coolant Temperature • Engine Setpoint • Engine Speed • Engine Status Bar • Estimated Power • FT Intake Manifold Pressure • Fuel Pressure • Intake Manifold Temperature • Oil Pressure • Oil Temperature • Percent Rated Load • Pre-Filter Oil Pressure • Throttle Reserve User-Programmable Fields: • Cool Down • Main Fuel On RPM Adjustment • Post Lube Time • Prechamber Fuel On RPM Adjustment • Prelube Time • Purge Time • Starter Off RPM Adjustment Readings and Settings: • Boost Pressure • Bypass Position % • Coolant Temperature • Driven Equipment ESD • Engine Speed • Ignition Enable • Intake Manifold Pressure • Intake Manifold Temperature • Main Fuel On RPM • Main Fuel Valve • Oil Pressure • Pre/Post Lube • Prechamber Fuel On RPM • Prechamber Fuel Valve • Prelube Timer • Starter • Starter Off RPM • Starting Signal • Throttle Position % • Throttle Reserve • User ESD • User RUN/STOP • Wastegate Position % 3.00-5 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) [F4] GOVERNOR OPERATING STATUS: [F5] IGNITION OPERATING STATUS: Figure 3.00-13. Governor Operating Status Panel Figure 3.00-14. Ignition Operating Status Panel User-Programmable Fields: • Differential Gain Adjustment • Droop • High Idle • Integral Gain Adjustment • Load Inertia • Low Idle Adjustment • Proportional Gain Adjustment • Proportional Sync • Sync RPM Readings and Settings: • Alternate Dynamics • Average Intake Manifold Pressure • Bypass Position % • Engine Setpoint • Engine Speed • Engine Speed (Gauge) • Idle • Low Idle • Remote RPM • Remote RPM Setpoint • Throttle Error • Throttle Feedback • Throttle Position % • Throttle Reserve • Wastegate Position % User-Programmable Fields: • High Voltage Adjustment • Low Voltage Adjustment • No Spark Adjustment • NOx • User WKI Readings and Settings: • Engine Speed • High Voltage Limit • Ignition Enable • Ignition Energy • Ignition Timing (Left Bank) • Ignition Timing (Right Bank) • Intake Manifold Pressure • Knocking • Low Voltage Limit • Max Retard • No Spark Limit • Spark Reference # (Left Bank) • Spark Reference # (Right Bank) • User ESD • User WKI in Use 3.00-6 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) [F8] AFR SETUP: [F10] SYSTEM/SHUTDOWN STATUS: Figure 3.00-15. AFR Setup Panel Figure 3.00-16. System/Shutdown Status Panel User-Programmable Fields: • Ext O2 for Cal • Fuel Composition • Heated Power • Lower Heating Value • Manual Mode Check Box • Start Position • Stepper Motor Setup • Stepper Position Readings and Settings: • Ambient Air Temperature • Barometric Pressure • Cal Conditions • Calibrate O2 Sensors • Engine Speed • Engine Torque % • Intake Manifold • Lambda Setpoint • Max./Min. Stepper Position • Measure O2 • Min. Block Temp for Cal • Min. IMAP for Cal • O2 Block Temperature • O2 Cal Accept • O2 Cal Conditions • O2 Setpoint • O2 Sensor Readings and Settings: • Active Faults • Alternate Dynamics • Battery Voltage • Cal Loaded • ECU Hours • ECU Temperature • Engine Setpoint • Engine Knocking • Engine Speed • Faults Loaded • Idle • Ignition Alarm • Ignition Enable • Ignition Energy • Main Fuel Valve • Max Retard • Prechamber Fuel Valve • Remote RPM • Stats Loaded • System • User ESD • User RUN/STOP FORM 6331 First Edition 3.00-7 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) [F11] ADVANCED FUNCTIONS: Figure 3.00-17. Advanced Functions Panel User-Programmable Fields: • Coolant Temperature Offset • Intake Manifold Temperature Offset • MODBUS® Baud Rate • Oil Pressure Offset • Oil Temperature Offset • Slave ID • Reset Wastegate Learning Table Readings and Settings: • Oil Pressure Alarm Setpoint • Coolant Temperature Alarm Setpoint • Intake Manifold Temperature Alarm Setpoint • Oil Temperature Alarm Setpoint • Oil Pressure Shutdown Setpoint • Coolant Temperature Shutdown Setpoint • Intake Manifold Temperature Shutdown Setpoint • Oil Temperature Shutdown Setpoint • ESP Fault Identifier 3.00-8 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) OTHER ESP WINDOWS FAULT LOG To access the help file anytime while using the ESP software, press the [F1] function key on the keyboard or select Help Contents... from the Help menu. As an additional aid in troubleshooting, double-clicking a fault listed in the Fault Log will open E-Help directly to the troubleshooting information for that fault. See Section 4.00 Troubleshooting “E-Help” for more information. VERSION DETAILS Figure 3.00-18. Fault Log Window The ESM features extensive engine diagnostics capability. The ECU records system faults as they occur. A “fault” is any condition that can be detected by the ESM that is considered to be out-of-range, unusual, or outside normal operating conditions. One method of obtaining diagnostic information is by viewing the Fault Log in ESP (see Figure 3.00-18). ESP Fault Log displays the data provided by the ECU. The Fault Log can be viewed by selecting the “View Faults” button on the button bar. See “Fault Log Description” on page 3.00-13 for more information. E-HELP Figure 3.00-20. Version Details The Version Details window displays serial numbers, calibration and software version, and other information about the current configuration of the ESM. This information will be necessary to supply to Dresser Waukesha if any problems should arise with the ECU. To access version details, click “Version Details” button on the button bar in ESP. Figure 3.00-19 E-Help Main Screen ESP contains an electronic help file named E-Help (see Figure 3.00-19). E-Help provides fault code troubleshooting information when using ESP. The user can quickly and easily move around in E-Help through hypertext links from subject to subject. E-Help is automatically installed when the ESP software is installed. FORM 6331 First Edition 3.00-9 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) NAVIGATING ESP PANELS ESP consists of panels grouped by common engine functionality. Each of the panels displays engine status and operation information in color-coded text fields, gauges, and status bars. ESP panels can be set to display in either U.S. or metric measurement units. COMMON FEATURES 2 4 1 3 5 6 7 8 1 Title Bar The ESP Title Bar lists the ESP version number, ECU serial number, engine serial number, and calibration part number. Menu Bar The ESP Menu Bar consists of the File and Help menus. – File: Used for opening and closing of workspace files (training mode only), and for exiting the ESP program. – Help: Used for accessing E-Help and viewing the “About” information. 5 Engine Alarm This field provides a general overview of alarm status. When no alarms are active, the field is gray. If an alarm occurs, the field turns yellow and signals that “YES” at least one alarm is active. Communication Icon Displays the communication status between ESP and the ECU. See “Connection Status” on page 3.00-4. Display Fields Color-coded text fields, status bars, gauges, and programmable edit boxes. See “Display Fields” on page 3.00-11 for more information. Button Bar All ESP panels share a common button bar that allows for easy access to frequently used functions. See “Button Bar” on page 3.00-12 for more information. 2 6 7 3 Panel Tab Bar Click on the tabs to display the different ESP panels or by pressing the corresponding function key [F#] on the keyboard. Panel Title Shows the title of the current ESP panel being displayed. 8 4 3.00-10 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) DISPLAY FIELDS ESP displays engine information in several types of display fields. Text Field This type of field displays an engine operation value. TITLE BAR STATUS: Color Meaning Gray: Off (No Alarm) Green: On or Normal Pink: Low, Warmup, or Idle Red: Warning or Shutdown Figure 3.00-24. Status Field Gauges Figure 3.00-21. Text Field Text Field with Status Bar This field displays an engine operation value with a status bar underneath that displays alarm information. If a problem is detected, the status bar, under the affected sensor, will change from green to yellow, and a message will appear in the status bar informing the user that a problem with the associated field needs correction for proper operation. Until the fault is corrected, the field will display a default value, not the actual value (see Figure 3.00-22). NORMAL PROBLEM DETECTED Gauges use a needle to display an approximate engine value with the actual value displayed in the title below. Figure 3.00-25. Gauge Edit Boxes Edit box fields open a Quick Edit window that allows the user to enter multiple parameters in a data grid. The data grid can be viewed either on its horizontal or vertical axis. Displayed at the bottom of the Quick Edit window are the unit of measurement, and the minimum and maximum programmable values. STATUS BAR Figure 3.00-22. Text Field with Status Bar User-Programmable Field These fields allow the user to adjust engine parameters or to set operational limits. See Section 3.10 ESP Programming “Basic Programming in ESP” for more information. Figure 3.00-23. User-Programmable Field Status Field Status fields are used to identify the different states that an engine or ECU component is currently in. The fields have a gray title bar on the bottom and a colorcoded field above it displaying a short message about the item’s current state. Figure 3.00-26. Edit Box FORM 6331 First Edition 3.00-11 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) BUTTON BAR The button bar is located on the bottom of every ESP engine panel and provides access to commonly used functions, or for items not specific to any one engine panel. 1 2 3 5 7 9 11 4 6 8 10 12 Figure 3.00-27. Button Bar 1 “View Faults” This button displays the Fault Log window. See “Fault Log Description” on page 3.00-13 for more information. “Manual Actuator Calibration” This button allows the user to manually calibrate the actuators. See Section 3.10 ESP Programming “Actuator Calibration” for more information. “Reset Status LEDs” This button allows the user to reset the status LEDs on the ECU. See Section 3.10 ESP Programming “Reset Status LEDs on ECU” for more information. “Version Details” This button allows the user to view the serial number(s) and calibration number of the ECU and engine. This information is provided to verify that the ECU is calibrated correctly for the engine on which it is installed. 8 2 “Change Units” This button allows the user to change all the ESP panel fields to display in either U.S. units or in metric measurement units. See Section 3.10 ESP Programming “Changing Units – U.S. or Metric” for more information. “Save to ECU” This button is used to save programmed values to permanent memory in the ECU. Changes saved to permanent memory will not be lost if power to the ECU is removed. See Section 3.10 ESP Programming “Saving to Permanent Memory” for more information. “Stop Editing - Currently Editing” This button is used to toggle between editing modes in ESP. When this button is clicked and the caption reads “Stop Editing - Currently Editing,” the editing mode is active and the user is able to edit the programmable fields in ESP. When this button is clicked and the caption reads “Start Editing,” the editing mode is inactive and the user will be unable to edit the programmable fields in ESP. See Section 3.10 ESP Programming “Basic Programming in ESP” for more information. These buttons allow the user to reset either the last programming change or all programming changes made. You can only undo changes from up until the last “Save to ECU.” 9 3 4 10 “Start Editing” “Start Logging All” and “Stop Logging All” These buttons are used to log all active system 6 parameters during a user-determined period of time. The file that is saved is a binary file (extension .ACLOG) that must be extracted into a usable file format. See Section 3.10 ESP Programming “Logging System Parameters” for more information. 5 7 11 “Undo Last Change” and “Undo All Changes” 12 “Send Calibration to ECU” This button is used to send a calibration file to the ECU. 3.00-12 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) FAULT LOG DESCRIPTION One method of obtaining diagnostic information is by viewing the Fault Log in ESP. The Fault Log displays the data provided by the ECU and can be displayed either to list only the active faults or to list the history of all the faults that occurred in the lifetime of the ECU. The Fault Log displays the name of the fault, the first time the fault occurred since the fault was reset (in ECU hours:minutes:seconds), the last time the fault occurred since reset, the number of times the fault occurred since reset, and the total number of times the fault occurred in the lifetime of the ECU. All the fault information is resettable except for the total number of times the fault occurred during the lifetime of the ECU. The faults listed in the Fault Log can be sorted by clicking on a column name. For example, clicking on “Fault” will sort alarms/shutdowns in numerical order based on the fault code. Clicking on “First Occurrence” will sort alarms/shutdowns in order of occurrence. NOTE: As an additional aid in troubleshooting, double-clicking a fault listed in the Fault Log will open E-Help directly to the troubleshooting information for that fault. 1 Fault ALM212 IMAP LB/BK OC 2 First Occurrence 8079:12:10 3 Last Occurrence 8164:09:25 4 Total Since Reset 20 5 Lifetime Total 20 This is the only “active” fault listed in the Fault Log. This alarm condition is indicated on the [F2] Engine Panel and with flashing LEDs on the ECU. To troubleshoot this alarm, the user would double-click the fault description. 6 List Active Faults 7 Total Fault History 8 Reset Selected Fault 9 Fault Help 10 Refresh 11 Copy To Clipboard 12 Close Figure 3.00-28. Fault Log Window 1 “Fault” This field displays the fault code and description for the alarm or shutdown condition that exists. Alarm codes in ESP are identified with the letters “ALM” preceding a 3-digit alarm code. Emergency shutdown codes are identified with the letters “ESD” preceding a 3-digit shutdown code. Double-clicking a fault listed in the Fault Log will open E-Help directly to the troubleshooting information for that fault. “First Occurrence” This field displays the first time the fault listed occurred since the fault was reset (in ECU hours:minutes:seconds). This field is resettable. 3 “Last Occurrence” This field displays the last time the fault listed occurred since the fault was reset (in ECU hours:minutes:seconds). This field is resettable. “Total Since Reset” This field displays the number of times the fault occurred since the fault was reset. This field is resettable. “Lifetime Total” This field displays the total number of times the fault occurred in the lifetime of the ECU. This field is not resettable. 4 5 2 FORM 6331 First Edition 3.00-13 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) “List Active Faults” and “Total Fault History” These buttons allow the user to view either the 7 active fault listing or the total fault history. The Active Fault Log only lists active faults indicated by flashing status LEDs and alarm fields on the ESP panels. The Total Fault History lists all the faults that occurred in the lifetime of the ECU. 6 8 “Reset Selected Fault” This button resets the “First Occurrence,” “Last Occurrence,” and “Total Since Reset” back to zero of the selected (or highlighted) fault listed in the log. “Fault Help” This button allows the user to open E-Help. This button allows the user to update or refresh the Fault Log. When the Fault Log is open, the information is not automatically refreshed. For example, if the Fault Log is displayed on screen, and a fault is corrected, the Fault Log will not refresh itself to reflect the change in active faults. The user must refresh the Fault Log to view the updated information. This button copies the Fault Log information to the PC’s clipboard. The information can then be pasted as text in a word processing or spreadsheet application. 9 10 “Refresh” 11 “Copy To Clipboard” NOTE: The copied text is tab delimited and will need to be formatted after being pasted into the spreadsheet or word processing program to align columns and to display information as desired. 12 “Close” This button closes the Fault Log. 3.00-14 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) USING A MODEM FOR REMOTE MONITORING NOTE: For best modem communications, use a “matched” pair (same brand) of modems. Temporary remote monitoring of an engine with the ESM is possible through the use of a modem. A modem is a device that enables a computer to transmit data over telephone lines. Using ESP and a modem, you can “dial up” the ECU to monitor ESM status and make programming changes remotely. NOTE: High-speed cable and satellite modems will not work with the ESM’s modem function. IMPORTANT! This manual assumes that you are already familiar with modem devices, modem initialization strings, other modem concepts, and HyperTermi“SERVICE INTERFACE” CONNECTION nal. If you need more information on these topics, refer to the user’s manual provided with the modem or with the modem manufacturer. To remotely monitor an engine through a modem, the following supplies are required: • “Modem to ECU” Connection •• RS-232 serial cable (P/N 740269A) available from Dresser Waukesha •• External Modem • “PC to Modem” Connection •• External/internal modem •• RS-232 cable (if external modem is used, connects modem to PC) SERIAL CABLE EXTERNAL MODEM INTERNAL/EXTERNAL (SHOWN) MODEM SERIAL CABLE (P/N 740269A) NOTE: Serial cable (P/N 740269A) is available from Dresser Waukesha. Modems, PC-to-modem cable, and PC supplied by customer. Figure 3.00-29. Modem Connections From ECU to PC SETTING UP MODEM TO ECU NOTE: The following steps in this section do not need to be performed if using the modem in Waukesha Engine’s Remote Programming Modem Tool Kit (P/N 489943), which comes preprogrammed from the factory. The modem connected to the ECU requires special setup programming so it will work with the ECU. The modem must be set in “auto answer” mode, a modem feature that accepts a telephone call and establishes the connection, and must be set at 38,400 baud. Auto answer mode and baud rate are programmed using HyperTerminal. HyperTerminal is a terminal software program that enables the modem to connect properly to the ECU. HyperTerminal is included as part of Microsoft® Windows® XP operating system. Complete the following steps: NOTE: Some modems may have dip switches (tiny toggle switches) that must be set to put the modem in auto answer mode. Refer to the user’s manual provided with the modem or contact the modem manufacturer. Set the dip switches as required and continue with Step 1. 1. Using a PC-to-modem cable, temporarily connect a PC to the external modem that will be connected to the ECU. 2. Start HyperTerminal. From the Windows® taskbar, click Start → All Programs → Accessories → Communications → HyperTerminal. NOTE: HyperTerminal is a terminal program included with Microsoft® Windows® XP operating system. If HyperTerminal is not installed, install the program using the Add/Remove Programs icon in the Control Panel. You may need your original Microsoft® Windows® CD-ROM for installation. FORM 6331 First Edition 3.00-15 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) 3. Give the HyperTerminal session a name. NOTE: To avoid resetting the baud rate, the modem being set up must be a “dedicated” modem and used only with the ECU. If the modem is used with another device, the baud rate setting may be overwritten. 8. In the Properties dialog box, set the baud rate between the PC and the modem to 38,400 Bits per second. Click “OK.” Figure 3.00-30. HyperTerminal – Connection Description Dialog Box 4. Select an icon. 5. Click “OK.” 6. Click the selection arrow on the “Connect using” drop-down menu and select the COM port your modem is connected to (not the modem name). 7. When you select the COM port, the other fields on the dialog box are deactivated (grayed). Click “OK.” Figure 3.00-32. HyperTerminal – “COM1 Properties” Window 9. After HyperTerminal window opens (allowing control to the modem with commands) type “AT” and press [Enter]. The modem should reply with “OK.” Figure 3.00-31. HyperTerminal – “Connect To” Dialog Box Figure 3.00-33. HyperTerminal – Session Window 3.00-16 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) NOTE: If unable to enter the AT command in the HyperTerminal session window, or the “OK” message does not appear, there is a communication problem between the PC and the modem. Verify that the communication port and settings are correct. NOTE: In the following steps, type the number zero (“0”), not the letter “O.” Turn auto answer mode on by typing: “ATS0=1” and press [Enter]. 10. Save the change to NVRAM by typing “AT&W0” and press [Enter]. 11. Turn the modem off and then on again. 12. Type “ATI4”. 13. The modem will respond with multiple lines that look similar to: Current Settings............ B0 *B0 E1 L4 M1 *D0 N5 *E0 Q0 *F0 V1 X5 *I0 *L0 *M0 *P9 *Q2 *S0 &B1 &C1 &D2 &G0 &H3 &J0 &K4 &L0 &M0 &N0 &P0 &R1 &S0 &X &Y1 *C0 *G0 17. Click “Yes” to save the HyperTerminal session. Figure 3.00-35. Save Session Dialog Box 18. Continue with “Connecting Modem To ECU And PC.” CONNECTING MODEM TO ECU AND PC An RS-232 serial cable (P/N 740269A), available from Dresser Waukesha, is used to connect a modem to the ECU. This cable has a 25-pin RS-232 connection that plugs into the modem and an 8-pin Deutsch® connector that plugs into the ECU. Complete the following: 1. Obtain an RS-232 serial cable (P/N 740269A) from Dresser Waukesha for modem use. 2. Connect the 25-pin end of the RS-232 serial cable to the external modem (see Figure 3.00-29). Connect to the “dedicated” modem you set up for use with the ECU following the steps in the section “Setting Up Modem to ECU”. 3. Connect the 8-pin Deutsch® connector of the serial cable to the “Service Interface” connection on the side of the ECU. 4. Connect PC to modem (see Figure 3.00-29 for sample setup). STARTING ESP FOR MODEM ACCESS 1. Apply power to the ECU. 2. Turn on power to PC. 3. Start ESP for modem use by one of the following methods: • Double-click the “ESP (Modem Access)” icon on your desktop. S00=001 S05=008 S10=007 S15=002 S20=002 S25=000 S30=000 S35=032 S40=000 S45=100 S50=000 S55=000 OK S01=000 S02=043 S03=01 S04=010 S09=006 S14=002 S19=000 S24=138 S29=000 S34=030 S39=032 S44=000 S49=134 S54=000 S59=000 S06=003 S11=070 S16=000 S21=178 S26=000 S31=017 S36=000 S41=000 S46=028 S51=000 S56=000 S07=060 S12=000 S17=018 S22=000 S27=156 S32=019 S37=000 S42=000 S47=064 S52=000 S57=000 S08=002 S13=000 S18=000 S23=105 S28=068 S33=255 S38=000 S43=008 S48=000 S53=000 S58=000 14. Although the lines in Step 13 may not be exactly what is shown on your PC, make sure that the parameter S00=001 is listed. Parameter S00=001 is the programming code to the modem that enables the auto answer mode. 15. Exit HyperTerminal. 16. Click “Yes” to disconnect. Figure 3.00-34. Disconnect Warning Dialog Box • From the Windows® taskbar (lower-left corner of your desktop), click Start → All Programs → Waukesha Engine Controls → Engine System Manager (ESM) → ESP (Modem Access). FORM 6331 First Edition 3.00-17 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) 4. On program startup, ESP will check for a modem. Once ESP finds the modem on the PC, a dialog box appears asking to attempt a connection. Click “Yes.” 5. Enter the phone number for the engine modem you wish to connect in the Modem Connection Wizard dialog box. Enter phone number without spaces or dashes. 9. Modem wizard will reattempt to “dial up” the modem. Note the following: • If connection is successful, ESP will run, displaying the engine panels. Installation is complete. Monitor engine operation or program ESP as necessary. • If connection is unsuccessful, click “Cancel.” Continue with Step 10. 10. If your modem dials but does not connect with the answering modem, or if you have problems getting or staying connected, you might need to adjust the modem initialization string. Click the “Advanced Settings” check box on the Modem Connection Wizard dialog box. Figure 3.00-36. Modem Connection Wizard 6. The modem wizard will attempt to “dial up” the modem. Note the following: • If connection is successful, ESP will run, displaying the engine panels. Setup is complete. Monitor engine operation or program ESP as necessary. Figure 3.00-38. Modem Connection Wizard • If connection is unsuccessful, click “Retry.” If connection is still unsuccessful, continue with Step 7. NOTE: Always use CAPITAL letters (upper case) for the modem initialization string in the “Advanced Settings check box.” 11. Enter the modem’s initialization string (command) in CAPITAL letters (upper case). Most connection problems are resolved with the proper modem initialization string. The initialization string gives the modem a set of instructions for how to operate during a call. Almost every modem brand and model has its own variation of “ATCommand Set” and “S-register” settings. Figure 3.00-37. Unsuccessful Connection Dialog Box 7. Check the telephone number typed in the Modem Connection Wizard dialog box. 8. Retry connection. Click “Connect.” 3.00-18 FORM 6331 First Edition INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) NOTE: Detailed discussion of modem initialization strings is beyond the scope of this manual. You can get an initialization string from the user’s manual provided with the modem, from the modem manufacturer, or from a variety of Internet web sites. 12. Click “Connect.” 13. The modem wizard will attempt to “dial up” the modem. Note the following: • If connection is successful, ESP will run, displaying the six engine panels. Installation is complete. Monitor engine operation or program ESP as necessary. • If connection is unsuccessful, click “Retry.” 14. If connection continues to be unsuccessful, refer to the user’s manual provided with the modem or contact the modem manufacturer. 15. Make sure all connections are secure. FORM 6331 First Edition 3.00-19 INTRODUCTION TO ELECTRONIC SERVICE PROGRAM (ESP) 3.00-20 FORM 6331 First Edition SECTION 3.05 ESP PANEL AND FIELD DESCRIPTIONS [F2] ENGINE PANEL The [F2] Engine Panel contains the most common information needed while operating the engine. [F2] 1 6 14 2 15 16 3 7 4 10 5 11 12 13 18 8 9 17 # 18 17 2 3 15 14 FIELD Ambient Air Temperature Barometric Pressure BK Intake Manifold Pressure Boost Pressure Coolant Pressure Coolant Temperature # 7 6 10 9 1 16 FIELD Engine Setpoint Engine Speed Engine Status Bar Estimated Power FT Intake Manifold Pressure Fuel Pressure # 5 13 11 8 12 4 FIELD Intake Manifold Temperature Oil Pressure Oil Temperature Percent Rated Load Pre-Filter Oil Pressure Throttle Reserve FORM 6331 First Edition 3.05-1 ESP PANEL AND FIELD DESCRIPTIONS [F3] START-STOP PANEL The [F3] Start-Stop Panel contains the fields that affect starting and stopping of the engine. [F3] 1 2 3 4 13 14 15 5 6 7 8 9 10 11 12 16 17 18 19 20 21 22 23 24 25 28 26 29 27 30 # 13 14 3 26 27 28 1 8 30 20 FIELD Average Intake Manifold Pressure Boost Pressure Bypass Position % Cool Down Coolant Temperature Driven Equipment ESD Engine Speed Ignition Enable Intake Manifold Temperature Main Fuel On RPM # 19 9 16 25 6 22 21 10 17 18 FIELD Main Fuel On RPM Adjustment Main Fuel Valve Oil Pressure Post Lube Time Pre/Post Lube Prechamber Fuel On RPM Prechamber Fuel On RPM Adjustment Prechamber Fuel Valve Prelube Time Prelube Timer # 29 7 24 23 5 2 15 12 11 4 Purge Time Starter FIELD Starter Off RPM Starter Off RPM Adjustment Starting Signal Throttle Position % Throttle Reserve User ESD User RUN/STOP Wastegate Position % 3.05-2 FORM 6331 First Edition ESP PANEL AND FIELD DESCRIPTIONS [F4] GOVERNING OPERATING STATUS PANEL The [F4] Governor Operating Status Panel contains the fields that monitor or adjust parameters to ESM speed governing. [F4] 7 1 8 11 2 9 10 12 3 13 4 5 14 6 15 17 19 21 23 16 18 20 22 # 12 5 9 23 22 2 1 8 FIELD Alternate Dynamics Average Intake Manifold Pressure Bypass Position % Differential Gain Adjustment Droop Engine Setpoint Engine Speed Engine Speed (Gauge) # 14 13 21 15 17 16 19 20 High Idle Idle FIELD # 11 3 18 4 7 6 10 Remote RPM FIELD Remote RPM Setpoint Sync RPM Throttle Feedback Throttle Position % Throttle Reserve Wastegate Position % Integral Gain Adjustment Load Inertia Low Idle Low Idle Adjustment Proportional Gain Adjustment Proportional Sync FORM 6331 First Edition 3.05-3 ESP PANEL AND FIELD DESCRIPTIONS [F5] IGNITION OPERATING STATUS PANEL The [F5] Ignition Operating Status Panel contains the fields necessary for adjusting and monitoring the ignition system. [F5] 12 1 2 3 4 14 13 15 16 17 18 5 6 19 7 8 9 10 11 20 # 5 6 12 13 8 7 1 Engine Speed FIELD Average Intake Manifold Pressure High Voltage Adjustment High Voltage Limit Ignition Enable Ignition Energy Ignition Timing (Left Bank) # 4 10 14 15 9 16 17 Knocking FIELD Ignition Timing (Right Bank) Low Voltage Adjustment Low Voltage Limit Max Retard No Spark Adjustment No Spark Limit # 18 2 3 11 19 20 NOx FIELD Spark Reference # (Left Bank) Spark Reference # (Right Bank) User ESD User WKI User WKI in Use 3.05-4 FORM 6331 First Edition ESP PANEL AND FIELD DESCRIPTIONS [F8] AFR SETUP PANEL The [F8] AFR Setup Panel contains the fields that monitor or adjust parameters to the engine’s air-fuel ratio. [F8] 1 2 12 17 25 3 5 7 4 13 18 6 8 14 19 21 22 15 9 16 10 11 23 24 26 20 # 7 10 8 19 24 23 20 1 22 FIELD Ambient Air Temperature Average Intake Manifold Pressure Barometric Pressure Cal Conditions Cal Min Block Temp Cal Min IMAP Calibrate O2 Sensor Engine Speed External O2 for Calibration # 25 11 3 26 12 13 6 9 21 FIELD Fuel Composition Heater Power Lambda Setpoint Lower Heating Value Manual Mode Check Box Max/Min Stepper Position Measured O2 O2 Block Temperature O2 Calibration Accept # 18 5 4 2 15 14 17 16 FIELD O2 Calibration Conditions O2 Sensor O2 Setpoint Percent Rated Load Start Position Stepper Motor Setup Stepper Operating Mode Stepper Position FORM 6331 First Edition 3.05-5 ESP PANEL AND FIELD DESCRIPTIONS [F10] SYSTEM/SHUTDOWN STATUS PANEL The [F10] System/Shutdown Status Panel displays the fields that affect the operation of the ECU. [F10] 1 4 7 10 11 14 19 20 2 5 8 15 3 6 9 12 16 21 13 17 22 18 23 # 7 13 9 10 4 6 23 8 Active Faults FIELD # 5 11 15 21 19 20 17 22 Engine Speed Faults Loaded Idle Ignition Alarm Ignition Enable Ignition Energy FIELD # 18 14 16 12 3 1 2 FIELD Prechamber Fuel Valve Remote RPM Starter Stats Loaded System User ESD User RUN/STOP Alternate Dynamics Battery Voltage Cal Loaded ECU Hours ECU Temperature Engine Knocking Engine Setpoint Main Fuel Valve Max Retard 3.05-6 FORM 6331 First Edition ESP PANEL AND FIELD DESCRIPTIONS [F11] ADVANCED FUNCTIONS PANEL The [F11] Advanced Functions Panel allows the user to adjust alarm and shutdown setpoints and displays a cylinder chart for identifying the correct cylinder in certain fault code messages. [F11] 1 2 3 4 # 4 1 FIELD Alarm and Shutdown Setpoints Baud Rate # 3 FIELD Reset Wastegate Learning Table # 2 Slave ID FIELD FORM 6331 First Edition 3.05-7 ESP PANEL AND FIELD DESCRIPTIONS FIELD DESCRIPTIONS Refer to the panel descriptions on page 3.05-1 through page 3.05-7 for the location of each field. “Active Faults” • Panel: [F10] Displays the number of active faults of the ECU. View the fault log for a detailed list of active faults. See Section 3.00 Introduction to Electronic Service Program (ESP) “Fault Log Description” for more information. Alarm and Shutdown Setpoints • Panel: [F11] These fields allow the user to adjust the alarm and shutdown setpoints of the oil pressure, coolant temperature, intake manifold temperature, and oil temperature. Adjusting these setpoints enables the user to fine-tune when an alarm or shutdown will occur or can be used for testing. Setpoints are only adjustable in a safe direction from the factory settings. See Section 3.10 ESP Programming “Programming Alarm and Shutdown Setpoints” for more information on programming these fields. “Alternate Dynamics” • Panels: [F4], [F10] This field signals when the Alternate Governor Dynamics digital input is high (8.6 – 36 volts) or low (< 3.3 volts). During the time the alternate dynamics input is high, the field is green and displays “ON”. During the time the alternate dynamics input is low, the field is gray and displays “OFF”. When Alternate Dynamics is enabled, throttle gain is reduced, which provides better speed stability at low loads and speed. “Ambient Air Temperature” • Panels: [F2], [F8] This field displays combustion inlet air temperature. If an ambient air temperature sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “Average Intake Manifold Pressure” • Panels: [F3], [F4], [F5], [F8] This field displays the average of the front and back intake manifold pressures. Units are kPa (in-Hg) absolute. If one of the intake manifold pressure sensors fails, the field displays only the reading from the working sensor. If both sensors fail, the field is unable to display the actual value and a default value is displayed instead. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “Barometric Pressure” • Panels: [F2], [F8] Displays the engine’s ambient barometric pressure. Units are in kPa (in-Hg) absolute. If a barometric pressure sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “BK Intake Manifold Pressure” • Panel: [F2] This field displays the engine’s BacK intake manifold pressure. Units are in kPa (in-Hg) absolute. If an intake manifold pressure sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “Battery Voltage” • Panel: [F10] Displays the current battery voltage. If the battery voltage goes below 21 VDC, the status bar beneath the field will warn the user by turning yellow and displaying the message “TOO LOW.” The “Battery Voltage” field does not display the actual voltage if it falls outside the acceptable range of 21 – 32 volts. ALM454 will becomes active if the battery voltage remains below 21 VDC for longer than 30 seconds. If the battery voltage falls below 18 VDC, the engine will shut down. See Section 4.05 ESM Maintenance “Battery Maintenance” for more information. “Baud Rate” • Panel: [F11] This field allows the user to program MODBUS® baud rate to 1200, 2400, 9600, or 19,200 bps (bits per second). The baud rate to be programmed is determined by the MODBUS® master. 3.05-8 FORM 6331 First Edition ESP PANEL AND FIELD DESCRIPTIONS “Boost Pressure” • Panels: [F2], [F3] This field displays the boost pressure. If a boost pressure sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “Bypass Position %” • Panels: [F3], [F4] This field displays the percent the bypass valve is open. The main purpose of the bypass control is to prevent turbocharger surge. The bypass control is nonadjustable. “Cal Conditions” • Panel: [F8] Displays a list of conditions that must be inactive to perform an O2 sensor calibration. A condition that is gray indicates that a condition is inactive, while a condition that is yellow indicates that a condition is active. All conditions must be inactive (gray) to ensure that a reliable and accurate calibration takes place during stable, normal operating conditions with minimum values for load and heater block temperature achieved. – “MISFIRING:” Misfire has been detected through the ignition module. – “KNOCKING” Engine knock has been detected. – “LOAD TOO LOW” Minimum load has not been reached. It is desired to calibrate the O2 sensor near the load at which the engine will typically run. – “O2 SNSR UNSTABLE” The O2 sensor signal is fluctuating too much for a reliable calibration, possibly due to a load change or other external factor. – “BLOCK TEMP OUT OF RANGE” The heater block temperature is not at the nominal operating value for a reliable O2 calibration. – “O2 SNSR INVALID” A problem has been detected with the O2 sensor reading. – “O2 TOO LOW” The O2 level must be near the desired operating range of the engine, and within limits of the sensor specifications, before a reliable calibration can take place. “Cal Loaded” • Panel: [F10] Displays if the calibration is loaded for the ECU. The “Calibration Loaded” field should always be green and display “OK.” If this field is red and displays “NO,” contact your local Dresser Waukesha Distributor for technical support. “Cal Min Block Temp” • Panel: [F8] Displays the minimum temperature at which the O2 heater block can be at to ensure an accurate O2 reading before calibrating the O2 sensor. “Cal Min. IMAP” • Panel: [F8] Displays the minimum load, as indicated by intake manifold pressure, to ensure an accurate O2 reading before calibrating the O2 sensor. “Calibrate O2 Sensor” • Panel: [F8] This button is used to enter an external O2 value into the system to calibrate the ESM O2 sensor. This should only be done when “OK to Calibrate” is lit. A correct value must then be entered into the “Ext O2 for Cal” field. This external O2 value would likely be obtained from a piece of test equipment sampling from the exhaust stack. “Cool Down” • Panel: [F3] This field allows the user to program engine cooldown. Cooldown is the amount of time that the engine will continue to run after a normal shutdown is activated. Cooldown can be programmed from 0 to 10,800 seconds (0 to 180 minutes). Cooldown is bypassed when an emergency shutdown is performed. “Coolant Pressure” • Panel: [F2] This field displays the engine’s coolant pressure. Units are kPa (psi). If a coolant pressure sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. FORM 6331 First Edition 3.05-9 ESP PANEL AND FIELD DESCRIPTIONS “Coolant Temp” • Panels: [F2], [F3] Displays the engine’s coolant temperature at the outlet of the engine. Units are °C (°F). If a coolant temperature sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “Differential Gain Adj” This functionality is not active on the 16V275GL. “ECU Hours” • Panel: [F10] Displays the number of hours the currently connected ECU has been in operation. NOTE: This value does not necessarily represent the amount of hours the engine has been in operation. “ECU Temp” • Panel: [F10] Displays the internal temperature of the ECU. Units are °C (°F). If the ECU temperature is too high, the status bar beneath the field turns yellow and displays the message “HIGH.” If the ECU temperature increases beyond the maximum recommended operating temperature, ALM455 will become active. “Engine Knocking” • Panel: [F10] This field alerts the user when knock is present in a cylinder when timing is fully retarded. When knock is sensed with at least one cylinder, the field turns yellow and displays “YES.” The user can determine which cylinder(s) is knocking by looking at the individual cylinder timings displayed on the [F5] Ignition Panel. If no knock is present, the field is gray and displays “NO.” “Engine Setpoint RPM” • Panels: [F2], [F4], [F10] Displays the engine speed (rpm) setpoint. The engine speed setpoint is determined by a user input, not internal calibrations. See Section 2.30 ESM Speed Governing for more information on engine setpoints. “Engine Speed RPM” • Panels: [F2], [F3], [F4], [F5], [F8], [F10] This field displays current engine speed in rpm. Engine Status Bar • Panel: [F2] This field signals the user that an emergency shutdown is in process. When the engine is operating or is off, the field remains deactivated (gray). If the engine shuts down due to an emergency, this field will turn red and display a message indicating an emergency shutdown is in process. When the shutdown is complete, the field deactivates (turns gray) and the shutdown is recorded in the fault log history. However, the field remains active (in shutdown mode) if any E-Stop (emergency stop) switch on the engine is pushed in, or if a customer-supplied emergency switch is activated. • Panel: [F4] User-programmable field to adjust differential gain by a multiplier of 0 – 1.100. Differential gain is a correction function to speed error that is based on direction and rate of change. When an error exists between actual engine speed and engine speed setpoint, a differential gain calibrated by Dresser Waukesha is multiplied to the derivative of the speed error. This is done to increase or decrease throttle response to correct or reduce speed error. Although the user can program the differential gain multiplier with this field to fine-tune throttle response, it is typically not adjusted. “Proportional Gain Adj” and “Integral Gain Adj” are also used to correct speed error. “Driven Equipment ESD” • Panel: [F3] User-programmable field for setting an overspeed shutdown value to protect driven equipment. Driven equipment overspeed can be programmed from 0 to 2200 rpm. If programmed driven equipment overspeed exceeds engine overspeed, the engine overspeed value takes precedence. For example: a 1500 rpm engine will have a factory-programmed engine overspeed trip point of 1605 rpm. If the driven equipment overspeed is set to 1700 rpm, and the engine speed exceeds 1605 rpm, the engine will be shut down. If the driven equipment overspeed is set to 1100 rpm, and the engine speed exceeds 1100 rpm but is less than 1605 rpm, the engine will be shut down. “Droop (%)” • Panel: [F4] User-programmable field for adjusting the percent of droop. Droop allows steady-state speed to drop as load is applied. Droop is expressed as a percentage of normal average speed. Droop can be programmed from 0 to 5%. 3.05-10 FORM 6331 First Edition ESP PANEL AND FIELD DESCRIPTIONS “Engine Torque %” • Panel: [F8] This field displays the engine output as a percentage of rated torque. “Estimated Power” • Panel: [F2] This field displays an approximation (±5%) of actual engine power in kW (BHP). The approximation is based on ECU inputs and assumes correct engine operation. “Ext O2 for Cal” • Panel: [F8] This field is to enter an externally measured O2 value to be used in conjunction with the “Calibrate O2 Sensor” operation. This external O2 value would likely be obtained from a piece of test equipment sampling from the exhaust stack. “Faults Loaded” • Panel: [F10] Status field displaying if ECU has faults loaded. The “Faults Loaded” field should always be green and display “OK.” If this field is red and displays “NO”, contact your local Dresser Waukesha Distributor for technical support. “FT Intake Manifold Pressure” • Panel: [F2] This field displays the engine’s FronT intake manifold pressure. Units are in kPa (in-Hg) absolute. If an intake manifold pressure sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. Fuel Composition • Panel: [F8] This control allows the user to enter the type of fuel being used, either from a generally known assessment of incoming fuel, or a calorimeter sample. This information is used by calculations in the AFR Control routine for more accurate control. The “Fuel Type” button allows the user to chose a predetermined fuel composition. If “other” is selected as a fuel choice, use the “Manual Entry” button to bring up the Quick Edit window where the separate fuel constituents can be entered manually. “Fuel Pressure” • Panel: [F2] This field displays the engine’s fuel rail pressure. Units are in kPa (in-Hg) absolute. If a fuel rail pressure sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “Heater Power” • Panel: [F8] This drop down box is used to turn power to the O2 heater block either “On” or “Off” while the engine is not running. If “On” is selected from the drop-down box, the heater block will remain powered even if the engine is not running. If “Off” is selected from the drop-down box, the heater block power will be off when the engine is not running. NOTE: O2 heater block power is always on when the engine is running. “High Idle” • Panel: [F4] User-programmable field for adjusting the high idle rpm. The high idle setting is used when the rated speed/idle speed digital input is high (8.6 – 36 volts) and “Remote RPM” is OFF. The high idle rpm can be programmed from 800 to 2200 rpm (not to exceed a preprogrammed maximum speed). Internal calibrations prevent the engine from running faster than rated speed +10%. NOTE: Although customer connections determine the rpm setpoint in variable speed applications, the high idle setting must be programmed to a “safe” value in case an out-of-range speed setpoint is detected or if the wire that enables remote rpm operation fails. “High Voltage Adj.” and “High Voltage Limit” • Panel: [F5] These fields allow the user to view and adjust the high voltage alarm limit setting. See Section 2.10 Ignition System “Ignition Diagnostics” and Section 3.10 ESP Programming “IPM-D Programming” for more information. FORM 6331 First Edition 3.05-11 ESP PANEL AND FIELD DESCRIPTIONS “Idle” • Panels: [F4], [F10] This field indicates whether low idle rpm or high idle rpm is active. Low or high idle rpm is determined by a customer digital input. When the input is low (< 3.3 volts), the field will display “LOW”. When the input is high (8.6 – 36 volts), the field will display “HIGH.” See “High Idle RPM” on page 3.05-11 and “Low Idle RPM” on page 3.05-13 for values of high and low idle. “Ignition Alarm” • Panel: [F10] This field displays if the currently connected ECU is receiving an alarm from the IPM-D because of one of the following: – One or both of the E-Stop (emergency stop) switches on the side of the engine are engaged. – The IPM-D is not receiving 24 volts. – The IPM-D is not working correctly. When one of these conditions exists, the field will turn yellow and display “ALARM.” If no problems exist, the field is gray and displays “OK.” “Ignition Enable” • Panels: [F3], [F5], [F10] This field signals when the IPM-D is enabled and is ready to receive a signal from the ECU to fire each spark plug. During the time the IPM-D is enabled, the field is green and displays “ON.” During the time the ignition is disabled, the field is gray and displays “OFF.” “Ignition Energy” • Panels: [F5], [F10] This field displays the level of energy the IPM-D is firing the spark plugs. The ignition level will either be at “Level 1” (low/normal) or at “Level 2” (high). See Section 2.10 Ignition System “Monitoring Ignition Energy Field” for more information. “IGN TIMING” (Left Bank) • Panel: [F5] These fields display individual cylinder timing in degrees before top dead center (°BTDC). “IGN TIMING” (Right Bank) • Panel: [F5] These fields display individual cylinder timing in degrees before top dead center (°BTDC). “Intake Mnfld Temp” • Panels: [F2], [F3] This field displays the engine’s intake manifold temperature. Units are in °C (°F). If an intake manifold temperature sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “Integral Gain Adj” • Panel: [F4] User-programmable field for adjusting the integral gain by a multiplier between 0 – 1.102. Integral gain is a correction function to speed error that is based on the amount of time the error is present. When an error exists between actual engine speed and engine speed setpoint, an integral gain calibrated by Dresser Waukesha is multiplied to the integral of the speed error. This is done to increase or decrease throttle response to correct or reduce speed error. Although the user can program the integral gain multiplier with this field to fine-tune injector response, it is typically not adjusted. “Proportional Gain Adj” and “Differential Gain Adj” are also used to correct speed error. See speed error correction equation under the description for “Proportion Gain Adj.” “Knocking” • Panel: [F5] See “Engine Knocking” on page 3.05-10. “Lambda Setpoint” • Panel: [F8] This field displays the current lambda setpoint. The lambda setpoint is determined by the air-fuel ratio control routine, and is derived from a table in the calibration that is adjusted by other environmental and performance factors. This value then converted to an O2 setpoint. 3.05-12 FORM 6331 First Edition ESP PANEL AND FIELD DESCRIPTIONS “Load Inertia” • Panel: [F4] User-programmable field for programming the load inertia value. By programming the load inertia or rotating mass moment of inertia of the driven equipment, the governor gain is preset correctly, aiding rapid startup of the engine. If this field is programmed correctly, there should be no need to program gain adjustments (“Proportional Gain Adj,” “Integral Gain Adj,” and “Differential Gain Adj”). The rotating mass moment of inertia must be known for each piece of driven equipment and then added together. See Section 3.10 ESP Programming “Programming Load Inertia” for more information. NOTE: Rotating moment of inertia is not the weight or mass of the driven equipment. It is an inherent property of the driven equipment and does not change with engine speed or load. Contact the coupling and/or driven equipment manufacturer for the moment of inertia value. “Low Idle RPM” and “Low Idle Adj” • Panel: [F4] These fields allow the user to view and program the low idle rpm setting. The low idle setting is used when the rated speed/idle speed digital input is low (< 3.3 volts) and “Remote RPM” is OFF. The “Low Idle RPM” field displays the actual programmed low idle rpm setting. The blue “Low Idle Adj” field allows the user to adjust the actual setting by entering a value from -50 to +100 rpm. When an adjustment is entered, the actual “Low Idle RPM” is updated to reflect the adjustment. NOTE: The low idle rpm cannot be set above the high idle rpm. NOTE: Although customer connections determine the rpm setpoint in variable speed applications, the low idle setting must be programmed to a “safe” value in case an out-of-range speed setpoint is detected or if the wire that enables remote rpm operation fails. “Low Voltage Adj.” and “Low Voltage Limit” • Panel: [F5] These fields allow the user to view and adjust the high voltage alarm limit setting. See Section 2.10 Ignition System “Ignition Diagnostics” and Section 3.10 ESP Programming “IPM-D Programming” for more information. “Lower Heating Value” • Panel: [F8] User-programmable field for setting the lower heating value. Units are in MJ/Nm3 (Btu/scf). The lower heating value (LHV) should be obtained through fuel analysis. This information is used by calculations in the air-fuel ratio control routine for more accurate control. “Main Fuel On RPM” and “Main Fuel On RPM Adj” • Panel: [F3] These fields allow the user to view and program the rpm at which the fuel valve is turned on. The green “Fuel On RPM” field displays the actual programmed rpm setting. The blue “Fuel On RPM Adj” field allows the user to adjust the actual setting by entering a value from -50 to +100 rpm. When an adjustment is entered, the actual “Fuel On RPM” is updated to reflect the adjustment. “Main Fuel Valve” • Panels: [F3], [F10] This field signals when the main fuel valve is engaged by the ECU. During the time the main fuel valve is engaged, the field is green and displays “ON”. During the time the main fuel valve is disengaged, the field is gray and displays “OFF”. FORM 6331 First Edition 3.05-13 ESP PANEL AND FIELD DESCRIPTIONS “Manual Mode Check Box” • Panel: [F8] This field allows the user to change the air-fuel ratio system mode of operation from automatic to manual mode. The “Stepper Operating Mode” field will change to reflect the current operating mode that has been selected. Normally the air-fuel ratio system operates in automatic mode; however, the user can change the system to manual mode by checking the check box. While the engine is running, manual mode allows the user to adjust stepper position using the arrow buttons under the “Stepper Position” field. When changed into manual mode, the AFR system will not make automatic stepper adjustments; it will only move stepper position with user adjustment. When engine is not running, “Start Position” is used to adjust the stepper position. “Max Retard” • Panels: [F5], [F10] This field alerts the user when any cylinder’s timing has reached the maximum retard in timing allowed. If any cylinder is at maximum retard, the field turns yellow and displays “YES.” The user can determine which cylinder(s) is at maximum retard by looking for the lowest individual cylinder ignition timing displayed on the [F5] Ignition Panel. When none of the cylinders are at maximum retard, the field is gray and displays “NO.” “Max/Min Stepper Position” • Panel: [F8] This field allows the user to program maximum and minimum stepper positions at various levels of intake manifold pressure. By clicking on the “Max…” or “Min…” button, a programming table is opened. The AFR system adjusts the stepper motor between two programmable limits to maintain the AFR. By defining the stepper motor adjustment range, the user can maintain stable engine operation and set limits for troubleshooting. “Measured O2” • Panel: [F8] This field displays the dry O2% value, derived from the measured wet O2% value. “No Spark Adj.” and “No Spark Limit” • Panel: [F5] These fields allow the user to view and adjust the high voltage alarm limit setting. See Section 2.10 Ignition System “Ignition Diagnostics” and Section 3.10 ESP Programming “IPM-D Programming” for more information. “NOx” • Panel: [F5] This field allows the user to set the desired NOx emissions level (engine out at the exhaust stack) at which the engine will run. The field displays the programmed NOx level, not the actual level. Units are in g/BHP-hr or g/nm3 (n) @ 0° C, 101.25 kPa, 5% O2. The range that NOx can be programmed is 0.7 – 2.0 g/BHP-hr (0.3 – 0.8 g/nm3). See Section 3.10 ESP Programming “Programming NOx Level” for more information. NOTE: To correct for differences in the actual engine-out NOx emissions and that of the programmed NOx level, the user input should be adjusted in the appropriate direction until the actual engine-out emissions meet the user’s desired level (e.g., the NOx field may require a value of 1.5 g/BHP-hr [0.6 mg/m3] to achieve 1.0 g/BHP-hr [0.4 mg/m3] NOx emissions at the exhaust stack). “O2 Block Temperature” • Panel: [F8] The temperature of the O2 heater block as measured by an RTD located in the block itself. “O2 Cal Accept” • Panel: [F8] This field alerts the user if the O2 calibration is not accepted. If the O2 calibration fails, the field turns yellow and displays “NOT OK.” If the O2 calibration has been accepted, the field is green and displays “OK.” “O2 Cal Conditions” • Panel: [F8] This field indicates if it is OK to attempt an O2 sensor calibration using the “Calibrate O2 Sensor” button. The field will display “OK TO CALIBRATE” when none of the “CAL CONDITIONS” are lit. If it is not OK, review “CAL CONDITIONS” fields to determine which errors are present. 3.05-14 FORM 6331 First Edition ESP PANEL AND FIELD DESCRIPTIONS “O2 Sensor” • Panel: [F8] This field displays the raw O2 sensor voltage output before it is converted to O2%, and is provided as a diagnostic aid. “O2 Setpoint” • Panel: [F8] This is the dry O2% setpoint derived from the “Lambda Setpoint”, and is the value the air-fuel ratio routine will seek to match with the measured O2%. “Oil Pressure” • Panels: [F2], [F3] This field displays the engine’s oil pressure in the main oil header. Units are kPa (psi). “Oil Pressure Pre-filter” • Panel: [F2] This field displays the engine’s pre-filter oil pressure. Units are in kPa (in-Hg) absolute. If a pre-filter oil pressure sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. “Oil Temp” • Panel: [F2] This field displays the engine’s oil temperature in the main oil header. Units are °C (°F). If an oil temperature sensor or wiring fault occurs, the status bar beneath this field turns yellow and displays a message to fix the sensor or wiring. NOTE: When a sensor or wiring fault is detected, the field displays a default value, not the actual value. Percent Rated Load • Panels: [F2], [F8] This field displays an approximation of percent rated load (torque). The approximation is based on ECU inputs and engine operating factors. “Post Lube Time” • Panel: [F3] This field allows the user to program engine postlube timing. Units are in seconds. Postlube timing can be programmed from 0 – 10,800 seconds (0 – 180 minutes). “Pre/Post Lube” • Panel: [F3] This field signals when the oil pump is engaged and is either in pre or postlube. During the time the prelube oil pump is engaged, the field is green and displays “ON”. During the time the prelube oil pump is disengaged, the field is gray and displays “OFF”. “PreCh Fuel On RPM” and “PreCh Fuel On RPM Adj” • Panel: [F3] These fields allow the user to view and program the rpm at which the prechamber fuel valve is turned on. The green “PreCh Fuel On RPM” field displays the actual programmed rpm setting. The blue “PreCh On RPM Adj” field allows the user to adjust the actual setting by entering a value from -50 to +300 rpm. When an adjustment is entered, the actual “Pre Ch On RPM” is updated to reflect the adjustment. “Prechamber Fuel Valve” • Panels: [F3], [F10] This field signals when the prechamber fuel valve is turned on. During the time the prechamber fuel valve is engaged, the field is green and displays “ON”. During the time the prechamber fuel valve is disengaged, the field is gray and displays “OFF”. “PreLube Time” and “PreLube Timer” • Panel: [F3] The “PreLube Time” field allows the user to program engine prelube timing. Units are in seconds. Prelube timing can be programmed from 0 – 10,800 seconds (0 – 180 minutes). The “PreLube Timer” field will display the remaining time left for a prelube event. For example: if 300 seconds has been entered in the “PreLube Time” field, the “PreLube Timer” field will display zero until a start is requested. After the start request, the prelube timer will start counting down from 300 seconds. FORM 6331 First Edition 3.05-15 ESP PANEL AND FIELD DESCRIPTIONS “Proportion Gain Adj” • Panel: [F4] User-programmable field for adjusting the proportional gain by a multiplier of 0.500 – 1.050. Proportional gain is a correction function to speed error that is proportional to the amount of error. When an error exists between actual engine speed and engine speed setpoint, a proportional gain calibrated by Dresser Waukesha is multiplied to the speed error. This is done to increase or decrease throttle response to correct speed error. Although the user can program the proportional gain multiplier with this field to fine-tune injector response, it is typically not adjusted. “Integral Gain Adj” and “Differential Gain Adj” are also used to correct speed error. “Proportional Sync” • Panel: [F4] User-programmable field for adjusting proportional synchronous gain by a multiplier of 0.500 – 1.050. Proportional synchronous gain is a correction function to speed error that is proportional to the amount of error. Proportional synchronous gain is a lower multiplier than proportional gain because of the need to synchronize to the electric grid. When an error exists between actual engine speed and engine speed setpoint, a Dresser Waukesha-calibrated proportional synchronous gain is multiplied to the speed error. This is done to increase or decrease throttle response to correct speed error. Although the user can program the proportional synchronous gain multiplier with this field to fine-tune throttle response, it is typically not adjusted. “Integral Gain Adj” and “Differential Gain Adj” are also used to correct speed error. “Purge Time” • Panel: [F3] This field allows the user to program the amount of time after first engine rotation that must expire before the fuel valve and ignition are turned on. Units are in seconds. NOTE: Although purge time can be programmed from 0 to 1800 seconds (30 minutes), a purge time greater than 20 seconds will prevent the engine from starting. “Remote RPM” • Panels: [F4], [F10] This field displays if remote rpm is currently active. Remote rpm is determined by a customer digital input. When the input is high (8.6 – 36 volts), remote rpm is active, turning this field green and displaying “ON.” During the time the remote rpm input is low (< 3.3 volts), remote rpm is inactive, turning this field gray and displaying “OFF.” When remote rpm is inactive, engine speed is based on the current “Idle” state and the corresponding values in “High Idle RPM” and “Low Idle RPM” fields. “Remote RPM Setpoint” • Panel: [F4] This field displays the remote rpm setpoint if the remote rpm input 4 – 20 mA (0.875 – 4.0 V) is active. The setpoint is only displayed in mA. “Reset Wastegate Learning Table” • Panel: [F11] This button opens a dialog box that allows the user to reset the BYC Boost tables. “Slave ID” • Panel: [F11] This field allows the user to program a unique identification number for each ECU (up to 32) on a multi-ECU networked site. The identification number that can be programmed can range from 1 to 247. By programming an identification number, the user can communicate to a specific ECU through MODBUS® using a single MODBUS® master when multiple ECUs are networked together. “SPARK REF #” • Panel: [F5] These fields display the spark reference number for each cylinder. The spark reference numbers can be used to represent spark plug electrode wear (gap) and can be monitored and trended to predict the time of spark plug failure. See Section 2.10 Ignition System “Ignition Diagnostics” for more information. NOTE: When checking faults in ESP, the cylinder number is in firing order. For example, if #5 cylinder triggers an alarm for having a worn-out spark plug, the user should check the spark plug of the 5th cylinder in the firing order. View the [F11] Advanced Panel for firing order information. 3.05-16 FORM 6331 First Edition ESP PANEL AND FIELD DESCRIPTIONS “Start Position” • Panel: [F8] User-programmable field for setting the AGR steps during starting. “Starter” • Panels: [F3], [F10] This field signals when the starter motor is engaged. The starter motor is engaged based on “Starter Off RPM” and “Purge Time” settings. During the time the starter motor is engaged, the field is green and displays “ON.” During the time the starter motor is disengaged, the field is gray and displays “OFF.” “Starter Off RPM Adj” and “Starter Off RPM” • Panel: [F3] These fields allow the user to view and program the rpm at which the starter motor is turned off. The “Starter Off RPM” field displays the actual programmed rpm setting. The blue “Starter Off RPM Adj” field allows the user to adjust the actual setting by entering a value from 0 to +100 rpm. When an adjustment is entered, the actual “Starter Off RPM” is updated to reflect the adjustment. “Starting Signal” • Panel: [F3] This field shows the current state of the digital start signal, a digital input to the ECU. When the start signal is high (8.6 – 36 volts), this field is green and displays “ON.” When the start signal is low (0 AMBIENT TEMP ENG BEING DRIVEN INTERNAL FAULT DESCRIPTION Fuel rail pressure sensor/wiring fault Ignition energy level is at Level 2 (or highest level) – at least one spark plug on the engine is getting worn and should be replaced High temperature coolant pressure sensor/wiring fault Stepper has reached lean limit Stepper has reached rich limit Coolant temperature sensor/wiring fault Stepper communication fault Oil prefilter pressure sensor/wiring fault Message transmission issue on the CANBUS Throttle actuator/wiring fault Wastegate actuator/wiring fault Barometric pressure sensor/wiring fault Bypass actuator/wiring fault Remote rpm analog input is outside of acceptable range; wiring fault Battery voltage out of specification ECU’s temperature above maximum recommended operating temperature Differential pressure between the oil header and prefilter oil sensors above upper limit Fuel pressure above upper limit Coolant pressure below its lower alarm limit Initial calibration of the lean burn oxygen sensors has not been completed. Sum of fuel constituents is not between 97% and 103% User digital input changed state Start engine signal remained on after engine started. Must be off while the engine is running; otherwise engine will immediately restart upon shutdown Ambient temperature sensor/wiring fault Engine is being rotated by the driven equipment; sparks and fuel have been cut by the ECU Internal error identified by ECU; contact your local Waukesha Distributor for technical support. *NOTE: See Table 4.00-4 for cylinder identification. FORM 6331 First Edition 4.00-7 TROUBLESHOOTING Table 4.00-3. ESM Shutdown Fault Codes SHUTDOWN FAULT CODE ESD212 ESD214 ESD221 ESD222 ESD223 ESD224 ESD231 ESD232 ESD251 ESD312 ESD313 ESD315 ESD333 ESD335 ESD424 ESD532 ESD551 ESD553 ESD555 SHUTDOWN CONDITION CRANK MAG PICKUP CAM MAG PICKUP OVERSPEED ENGINE CUST ESD LOW OIL PRESS KNOCK ### CYL OVERCRANK ENGINE STALL OVERSPEED DRIVE EQUIP OVERLOAD LOCKOUT/IGNITION HIGH IMAT HIGH COOLANT TEMP KNOCK ABS THRESHOLD HIGH OIL TEMP COOLANT PRESS LOW UPDATE ERROR/FAULT SECURITY VIOLATION INTERNAL FAULT DESCRIPTION ECU detects fewer crankshaft pulses between camshaft pulses than it was expecting Too many crankshaft pulses are identified between cam magnetic pickup pulses (or no cam magnetic pickup pulses are detected) Engine overspeed; engine reached ESM upper limit Critical ESD – Shutdown has been triggered by an external action; by customer equipment Critical ESD – Oil pressure below lower shutdown limit Cylinder was at its maximum retard timing due to knock * Time the engine has been cranking has exceeded a maximum crank time Engine stopped rotating independent of ECU which did not receive a signal to stop Customer-set overspeed limit exceeded Engine was overloaded Critical ESD – Lockout or E-Stop (emergency stop) button on the engine is “ON” or there is a power problem with the IPM-D module (either it is not powered up or the internal fuse is blown) Intake manifold air temperature above upper shutdown limit Engine coolant temperature above upper shutdown limit A knock sensor output value exceeded an absolute threshold programmed to ECU Oil temperature above upper shutdown limit Critical ESD – Coolant pressure below lower limit Update error/fault Engine type that is factory-coded in the ECU does not match with the downloaded calibration Serious internal error in ECU; call the factory; do not attempt to restart engine. Contact your local Waukesha Distributor for technical support. *NOTE: See Table 4.00-4 for cylinder identification. IMPORTANT! The following critical ESDs (shown in bold in table above) will prevent post-shutdown functionality from occurring: • ESD222 CUST ESD • ESD223 LOW OIL PRESS • ESD313 LOCKOUT/IGNITION • ESD532 COOLANT PRESS LOW To clear a critical ESD (to allow a restart or enable recirculation), you must cycle either of the E-Stop switches at the engine. 4.00-8 FORM 6331 First Edition TROUBLESHOOTING Table 4.00-4. 16V275GL Cylinder Identifier (Firing Order) 16V275GL CYLINDER IDENTIFIER FAULT DESCRIPTION 1ST CYLINDER 2ND CYLINDER 3RD CYLINDER 4TH CYLINDER 5TH CYLINDER 6TH CYLINDER 7TH CYLINDER 8TH CYLINDER 9TH CYLINDER 10TH CYLINDER 11TH CYLINDER 12TH CYLINDER 13TH CYLINDER 14TH CYLINDER 15TH CYLINDER 16TH CYLINDER CYLINDER LOCATION 1R 1L 4R 4L 7R 7L 6R 6L 8R 8L 5R 5L 2R 2L 3R 3L FORM 6331 First Edition 4.00-9 TROUBLESHOOTING NON-CODE ESM TROUBLESHOOTING Table 4.00-5 provides non-code troubleshooting for the ESM. Non-code troubleshooting includes any system faults that do not have ALM or ESD alarm codes that are logged in the Fault Log in ESP. NOTE: Prior to following non-code ESM troubleshooting procedures, resolve all active alarm and shutdown faults listed in the fault log[F10] Status panel. Table 4.00-5. Non-Code System Troubleshooting IF Engine does not rotate when start is initiated. THEN a. View the [F10] Status Panel in ESP. and verify that the status fields are either gray or green to indicate that the ESM is OK or that there are NO shutdowns active. If there are any active shutdowns, correct the problem indicated in the Fault Log. b. If the [F10] Status Panel in ESP indicates no shutdowns, view the [F3] Start-Stop Panel and verify that the “Starting Signal” field turns green when you press the start button. If the “Starting Signal” field does not turn green, check the wiring. c. Verify that +24 VDC power is applied to the wires: ESD and RUN/STOP. Correct power supply if necessary. d. After an emergency shutdown and RPM is zero, ESD input should be raised to high to reset the ESM. If ESD input remains low, ESM reset will be delayed and engine may not start for up to 1 minute. Engine is not running at desired speed. a. View the [F2] Engine Panel in ESP and verify that the “Engine Setpoint RPM” field and the “Engine Speed RPM” field are the same. Note the following: •If the “Engine Setpoint RPM” and “Engine Speed RPM” fields are the same, there is an electrical problem. Continue with “b. Electrical Problem” below. •If the “Engine Setpoint RPM” and “Engine Speed RPM” fields are not the same, there is an engine problem. Continue with “c. Engine Problem” below. b. Electrical Problem Fixed Speed Mode 1.Verify the status of the high/low idle digital input. The GOVHL IDL must be at a nominal 24 VDC to be running at the high idle speed. Correct input as required. 2.Verify that the high idle speed on the [F4] Governor Panel is set correctly. Correct speed setting as required. Variable Speed Mode 1.Verify that the Remote Speed digital input of the ECU is at a nominal 24 VDC. See the [F4] Governor Panel to verify the status of the Remote Speed digital input. Correct input as required. 2.Verify the value of the Remote RPM Setpoint in mA on the [F4] Governor Panel. If you are using the Remote RPM speed input as either a voltage or milliamp input, the equivalent milliamp value is shown in ESP. Should the equivalent milliamp value fall below 2 mA or above 22 mA, the ESM system will assume there is a wiring problem and will run at either the high or low idle speed, depending on the status of the high/low idle digital input (GOVHL IDL). Check wiring. 3.If you are unable to reach the lowest speed the engine is allowed to run at, change the “Low Idle Adj” calibration on the [F4] Governor Panel to -50 rpm. c. Engine Problem 1.If the engine speed is slower than the setpoint, there is an ignition, turbocharger, or fuel problem; or the engine is overloaded. Correct as required. 2.If the engine speed is higher than the setpoint, the throttle linkage is probably misadjusted and is not allowing the throttle to close all the way. Correct as required. 4.00-10 FORM 6331 First Edition TROUBLESHOOTING POWER DISTRIBUTION JUNCTION BOX Table 4.00-6 lists possible solutions if you experience problems with the Power Distribution Junction Box. Table 4.00-6. Power Distribution Junction Box Troubleshooting IF Power Distribution Junction Box has no LED lights on when the cover is removed. THEN Verify nominal 24 VDC input power across the positive and negative terminals. Status LEDs inside Power Distribution Junction Box are very Check input power to ensure there is a nominal 24 VDC. Check for loose, cordim or flashing on and off. roded, or damaged positive and negative terminals. One of the Power Distribution Junction Box outputs is turned Cycle power to the Power Distribution Junction Box. off. One or more LEDs turn off frequently, which turn off the associated output. Power Distribution Junction Box will not turn on, distribute power, or turn on status LEDs even with 24 VDC applied. Disconnect power to Power Distribution Junction Box and inspect wiring and terminations for wire degradation and/or shorts. Replace Power Distribution Junction Box. FORM 6331 First Edition 4.00-11 TROUBLESHOOTING 4.00-12 FORM 6331 First Edition SECTION 4.05 ESM MAINTENANCE Table 4.05-1 provides a list of the recommended maintenance items and includes a description of the service required, the service interval, and the page number where specific maintenance information is found for that item in this manual. Table 4.05-1 Maintenance Chart for ESM Components ITEM SERVICE NOTE: Continue to perform standard engine maintenance as provided in the engine’s operation and maintenance manual. INTERVAL INFORMATION PROVIDED ON PAGE page 4.05-2 Actuator Linkage Inspect Every year Batteries Inspect Semiannual page 4.05-4 ESM Wiring Inspect Every year page 4.05-3 ESP Total Fault History Review Every month page 3.00-13 Knock Sensors Inspect Every year page 4.05-2 Stepper (AGR) Inspect, Clean, Lubricate, Test Every year page 4.05-2 FORM 6331 First Edition 4.05-1 ESM MAINTENANCE ACTUATOR LINKAGE Every year, or as needed, the actuator linkages must be inspected, lubricated, and adjusted. To perform maintenance to the actuator linkages refer to the latest edition of Form 6333, 16V275GL Operation and Maintenance manual. KNOCK SENSORS Every year each knock sensor must be inspected for an accumulation of dirt or grit, connector wear, and corrosion. If a knock sensor has an accumulation of dirt, carefully clean visible end of knock sensor and surrounding area. If a knock sensor connector looks worn or if corrosion is evident, remove the knock sensor to clean or replace as necessary. To reinstall a knock sensor, complete the steps in “Replacing Knock Sensors” in the next section. The knock sensors must be properly tightened and seated flat against the mounting surface. REPLACING KNOCK SENSORS 1. Knock sensors are installed on the upper deck of the cylinder heads (see Figure 4.05-1). Thoroughly clean the knock sensor mounting hole located in the capscrew. Figure 4.05-2. Knock Sensor Seating Surface 4. Install and remove knock sensor. 5. Examine imprint left by blueing agent on the crankcase and sensor seating surface. • If the imprint on the crankcase and sensor seating surface is uniform, the sensor has full-face contact with mounting surface. • If the imprint on the crankcase and sensor seating surface is NOT uniform, the sensor does not have full-face contact with mounting surface. The mounting hole will have to be plugged and re-tapped to make the hole perpendicular to the mounting surface. 6. Place hex head screw through knock sensor and install into cylinder head deck. D o n o t ov e r t i g h t e n capscrew. Overtightening will cause damage to the knock sensor. Disregarding this information could result in product damage and/or personal injury. CAUTION 7. Tighten capscrew to 20 N·m (177 in-lb) dry. 8. Repeat this mounting procedure for each knock sensor. Figure 4.05-1. Knock Sensor AGR (STEPPER) MAINTENANCE Every year the stepper must be inspected, cleaned, and lubricated. To perform yearly maintenance to the stepper, refer to and complete the following: 1. Remove power from ESM. 2. Disconnect harness from stepper. 3. Remove stepper Figure 4.05-3). from fuel regulator (see Do not drop or mishandle knock sensor. If knock sensor is dropped or mishandled, it must be replaced. Disregarding this information could result in product damage and/or personal injury. CAUTION 2. Verify that the cylinder head knock sensor contact area is free of surface imperfections and polished smooth. 3. Apply a very thin coat of a blueing paste, such as Permatex® Prussian Blue (or equivalent), to seating surface of knock sensor (see Figure 4.05-2). 4. Lubricate stepper shaft with CITGO Lithoplex Grease NLGI 2 (service temperature range: -7°– 121° C [20°– 250° F]). 4.05-2 FORM 6331 First Edition ESM MAINTENANCE 5. Lubricate washer on regulator’s diaphragm (where spring makes contact) with CITGO Lithoplex Grease NLGI 2. 6. Replace O-ring if required. 7. Install control spring and secure stepper into pilot body with capscrews. NOTE: If stepper harness does not have the length to connect to the stepper after securing into the pilot body, it may be necessary to adjust the stepper orientation with the use of additional o-rings. 8. Reconnect harness to stepper. ESM SYSTEM WIRING NOTE: The Customer Interface Harness must be properly grounded to maintain CE compliance. WARNING Do not install, set up, maintain, or operate any electrical components unless you are a technically qualified individual who is familiar with the electrical elements involved. Electrical shock could result in severe personal injury or death. WARNING Disconnect all electrical power supplies before making any connections or servicing any part of the electrical system. Electrical shock could result in severe personal injury or death. Disconnect all engine harnesses and electronically controlled devices before welding with an electric arc welder on or near an engine. Failure to disconnect the harnesses and electronically controlled devices could result in product damage and/or personal injury. CAUTION 1 2 3 Perform the following every year: • Inspect all ESM wiring harnesses for damage and verify all connections are secure. • Inspect all ground connections. 4 • Remove cover from the Power Distribution Junction Box and verify all terminals are tight, secure, and corrosion free. • Verify connections in Power Distribution Junction Box are secure. 5 1) O-Ring 2) Spacer 3) Spring 4) Actuator 5) Electrical Connector • Verify incoming power is within specifications. • Verify the bolts securing the Power Distribution Junction Box to the bracket and engine are tight. For information on ESM wiring, harness connections, and power supply requirements, refer to Section 2.00 System Power and Wiring. Figure 4.05-3. Actuator, Gas Regulator (Stepper) FORM 6331 First Edition 4.05-3 ESM MAINTENANCE BATTERY MAINTENANCE BATTERY INDICATED STATE OF CHARGE NOTE: The battery must be fully charged for several hours before testing. If batteries have been receiving a charge current within the previous few hours, the open-circuit voltage may read misleadingly high. The surface charge must be removed before testing. To remove surface charge, the battery must experience a load of 20 amps for 3-plus minutes. 1. Use a temperature-compensated hydrometer to measure the electrolyte specific gravity readings in each cell. Record the readings. 2. Measure the open circuit voltage across the terminals. Record the reading. 3. Using the recorded values, determine the state of charge (see Table 4.05-2). 4. See Table 4.05-4 troubleshooting chart. The state of charge listed is an approximation. The relationship between state of charge and voltage varies by CCA rating and size. Voltage below 11.90 V may mean that the battery has a shorted cell or that the plates are sulfated and cannot accept a charge. Table 4.05-2 Determining State of Charge VOLTAGE 12.70 & Above 12.50 12.30 12.10 11.90 & Below WARNING Comply with the battery manufacturer’s recommendations for procedures concerning proper battery use and maintenance. Disregarding this information could result in severe personal injury or death. WARNING Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxygen gases. Keep any device that may cause sparks or flames away from the battery to prevent explosion. Batteries can explode, resulting in severe personal injury or death. WARNING Always wear protective glasses or goggles and protective clothing when working with batteries. You must follow the battery manufacturer’s instructions on safety, maintenance, and installation procedures. Failure to follow the battery manufacturer’s instructions could result in severe personal injury or death. NOTE: Perform an external inspection of the battery before checking the indicated state of charge to verify that the battery is in good physical condition. EXTERNAL INSPECTION Periodically inspect batteries and determine their condition. The cost of replacing other components, if they have been damaged by electrolyte corrosion, could be alarmingly high and accidental injuries could ensue. Any batteries that have cracks or holes in the container, cover, or vents, through which electrolyte will leak, should be replaced. Batteries contaminated with electrolyte (caused by over-topping with water) that have corroded terminal posts or low electrolyte levels should be cleaned or replaced if necessary. 1. Examine the battery externally. 2. Verify electrolyte levels are correct. 3. See Table 4.05-4 troubleshooting chart. STATE OF CHARGE 100% 75% 50% 25% Discharged SPECIFIC GRAVITY 0.280 0.240 0.200 0.170 0.140 Table 4.05-3 Cranking Amps – Commercial Batteries 4D CCA @ -18° C (0° F) CA @ 0° C (32° F) RC minutes @ 25 A CCA = Cold Cranking Amps CA = Cranking Amps RC = Reserve Capacity 1000 A 1200 A 320 min. 8D 1300 A 1560 A 435 min. 4.05-4 FORM 6331 First Edition ESM MAINTENANCE Table 4.05-4 Battery Troubleshooting IF Has cracks or holes in the container or cover. Battery Appearance Has corroded terminals posts. Has black deposits on underside of vent plugs. Has black “tide-marks” on inside walls about 1 inch below the cover. Is low. Electrolyte Level Is adjusted frequently. Is 75% or greater. Is between 25% and 75%. State of Charge Is less than 25%. Measured open circuit voltage is lower than value given in Table 4.05-2. Specific Gravity of Cells Odd cells with specific gravity readings 0.050 lower than other cells. Is uniformly low. Replace battery. Replace battery (internal short-circuit). Verify battery charger is operating correctly and settings are correct, recharge battery (see NOTE 1). Battery has been overcharged (see NOTE 4). Verify battery charger is operating correctly and settings are correct. Fill electrolyte to correct level. Battery is receiving too much charging current. Verify battery charger is operating correctly and settings are correct. Verify battery is good with a high rate load test (see NOTE 3). Recharge battery (see NOTE 2). THEN Replace battery. NOTE 1: Batteries which have low but uniform specific gravities in each cell and which clearly require an extended recharge may have become deeply discharged. This may be nothing more than a battery charger problem, but the system should be checked out before the battery is returned to service. NOTE 2: Batteries that have less than 75% state of charge need recharging before proceeding with any further tests. When the charger is switched on, observe that the battery does accept a charging current, even though it may be small in amperes. The battery must be fully charged for several hours before testing. If batteries have been receiving a charge current within the previous few hours, the open-circuit voltage may read misleadingly high. The surface charge must be removed before testing. To remove surface charge, the battery must experience a load of 20 amps for 3-plus minutes. NOTE 3: High-Rate Load Test – If the state-of-charge is 75% or higher, the battery should be given a high-rate load test. Typically, the high-rate load tester will discharge a battery through an adjustable carbon-pile resistance and indicate the terminal voltage as the discharge proceeds. After 15 seconds, the battery voltage will not drop below a specified value (typically 9.6 V) if the battery is in good condition and if the current is set at about 50% of the Cold Cranking Amps (CCA) (see Table 4.05-3). The minimum acceptable voltage reading will vary as battery temperature decreases. Read and follow the manufacturer’s instructions for the tester. NOTE 4: Overcharging – Batteries that have suffered as a result of considerable overcharging may show extremely low electrolyte levels, black deposits on the underside of the vent plugs, or black “tide-marks” on the inside walls of the container from about 1 inch below the cover. If these signs are present, the battery charger setting must be checked and reset according to the manufacturer’s instructions before a battery is returned to service; batteries in which electrolyte levels have to be adjusted frequently are clearly receiving too much charging current. FORM 6331 First Edition 4.05-5 ESM MAINTENANCE 4.05-6 FORM 6331 First Edition APPENDIX A – INDEX A Acronyms ............................................... 1.05-8 Actuator Linkage ..................................... 4.05-2 Adjusting Gain ........................................ 2.30-6 AFR Setup ............................................ 3.10-19 AGR Maintenance ................................... 4.05-2 AGR .................................................See Stepper Air Starter ............................................... 2.05-5 Air-Fuel Control Components ....................................... Description ......................................... Operation ........................................... System Wiring ..................................... Theory of Operation .............................. User Settings ...................................... 2.20-1 2.20-1 2.20-1 2.20-4 2.20-4 2.20-5 Cranking Engine Without Starting and Without Fuel ............................... 2.05-5 Customer Interface Harness Description ......................................... 2.00-6 Loose Wire Identification Table ............... 2.00-6 Optional Connections ......................... 2.00-10 Required Connections .......................... 2.00-8 D Definitions .............................................. 1.05-3 Actuator, Gas Regulator ........................ AGR.................................................. Air-Fuel Power Module.......................... Air-Fuel Ratio ...................................... Alternate Dynamics .............................. Analog Signals .................................... Baud Rate .......................................... Boost Pressure.................................... Bus ................................................... Bypass .............................................. Calibration .......................................... CAN .................................................. CD-ROM ............................................ Closed-Loop Control............................. Combustion Stability Limit...................... DB Connector ..................................... Dead Band ......................................... Detonation.......................................... Digital Signals ..................................... Droop ................................................ ECU .................................................. E-Help ............................................... Electronic Service Program .................... Engine Control Unit .............................. ESP .................................................. Fault ................................................. Fault Log............................................ Feedforward Control ............................. Freewheeling Diode ............................. Function Keys ..................................... Graphical User Interface........................ Hard Drive .......................................... High Signal ......................................... Home Position..................................... Icon .................................................. Ignition Power Module .......................... IMAP ................................................. IPM-D................................................ Isochronous ........................................ Knock ................................................ Knock Frequency ................................. Knock Sensor ..................................... 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-3 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-4 1.05-5 1.05-5 1.05-5 1.05-5 A-1 Air-Fuel Power Module (AFPM) Overview ............................................ 1.10-4 Air-Fuel Ratio Programming ................... 3.10-17 Alarm and Shutdown Setpoints................. 3.05-8 Programming .................................... 3.10-16 Alarms.................................................... 2.35-3 Fault Code List .................................... 4.00-6 Alternate Dynamics Synchronizer Control ............................ 2.30-5 B Back Intake Manifold Pressure ................. 3.05-8 Battery External Inspection ............................... 4.05-4 Maintenance ....................................... 4.05-4 Requirements ...................................... 2.00-1 Wiring Diagram Power Supplied by Batteries ................. 2.00-2 Power Supply by Customer .................. 2.00-3 Button Bar ............................................ 3.00-12 Bypass Reserve Map .............................. 2.25-2 Bypass Valve Overview ............................................ 1.10-5 C Changing Units – U.S. or Metric ............. 3.10-10 Component Location Left Bank ............................................ 1.10-2 Right Bank .......................................... 1.10-2 Top View ............................................ 1.10-3 Connection Status ................................... 3.00-4 Conversions ........................................... 1.05-9 FORM 6331 First Edition APPENDIX A – INDEX Lambda ............................................. Lean Burn Air-Fuel Ratio....................... LED .................................................. Load Coming ...................................... Load Control ...................................... Load Inertia ........................................ Log File Processor............................... Low Signal ......................................... Magnetic Pickup.................................. Master-Slave Communications ............... MODBUS .......................................... Modem.............................................. NVRAM ............................................. O2 Heater Block.................................. Open Circuit ....................................... Panel ................................................ PC ................................................... PLC .................................................. Pulse Width Modulation ........................ PWM ................................................ RAM ................................................. RS-232 ............................................. RS-485 ............................................. Sample Window .................................. Scale High ......................................... Scale Low .......................................... Short Circuit ....................................... Slave Communications ......................... Speed Control .................................... Start Position ...................................... Step ................................................. Stepper Gain ...................................... Stepper Lean Limit .............................. Stepper Motor..................................... Stepper Rich Limit ............................... Synchronizer Control............................ Temperature Compensation .................. Throttle Reserve ................................. Training Tool ...................................... Turbocharger...................................... Turbocharger Surge ............................. User Interface ..................................... Wastegate Valve ................................. Windowing ......................................... WKI .................................................. Workspace......................................... 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-5 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-6 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 1.05-7 Display Fields ....................................... 3.00-11 Edit Boxes ........................................ Gauges ............................................ Status Field ...................................... Text Field ......................................... Text Field with Status Bar .................... User-Programmable Field .................... 3.00-11 3.00-11 3.00-11 3.00-11 3.00-11 3.00-11 E ECU Connecting To Modem ........................ 3.00-17 Connecting To PC ................................ 3.00-3 Internal Faults ..................................... 2.35-2 Overview ............................................ 1.10-3 Resetting LEDs ................................... 3.10-7 Status LEDs........................................ 4.00-2 Edit Boxes ............................................ 3.00-11 E-Help.................................................... 4.00-3 Command Bar ..................................... 4.00-4 Description ......................................... 4.00-3 Document Pane ................................... 4.00-5 Navigation Pane .................................. 4.00-5 Overview ............................................ 1.10-9 .....................................................................3.00-9 Window Description .............................. 4.00-4 Electronic Service Program Overview ............................................ 1.10-9 Emergency Safety Shutdowns Overview ... 2.35-1 Engine Control Unit (ECU) ................... See ECU Engine Stall ............................................ 2.35-2 English/Metric Conversions ...................... 1.05-9 ESD Fault Code List .................................... 4.00-8 ESM Alarm Code List ................................... 4.00-6 Alarms ............................................... 2.35-3 Components ....................................... 1.10-3 Diagnostics Overview ......................... 1.10-10 E-Help ............................................... 1.10-9 Fault Codes ........................................ 4.00-6 Local Control Panel ............................ 2.40-10 Safety Shutdowns .............................. 1.10-10 Shutdown Code List ............................. 4.00-8 ESM Definitions ...................................... 1.05-3 Determining Fault Code Using ECU Status LEDs ....................... 4.00-2 Using ESP ......................................... 4.00-2 A-2 FORM 6331 First Edition APPENDIX A – INDEX ESP Basic Programming .............................. 3.10-2 Button Bar ........................................ 3.00-12 Common Features.............................. 3.00-10 Connection Status ................................ 3.00-4 Display Fields .................................... 3.00-11 Icon ................................................... 1.10-9 Installing ESP From CD ......................... 3.00-3 Modem Access .................................. 3.00-17 Navigation ........................................ 3.00-10 Recommended System Requirements ...... 3.00-1 Saving To Permanent Memory ................ 3.10-3 Starting .............................................. 3.00-4 User Interface Panels Overview ............ 1.10-10 .................................................................... 3.00-4 Exiting ESP Without Saving ..................... 3.10-3 Calibrate O2 Sensors ........................... 3.05-9 Calibration Loaded ............................... 3.05-9 Cool Down ......................................... 3.05-9 Coolant Pressure ................................. 3.05-9 Coolant Temperature .......................... 3.05-10 Differential Gain Adj ........................... 3.05-10 Driven Equipment ESD ....................... 3.05-10 Droop(%) ......................................... 3.05-10 ECU Hours ....................................... 3.05-10 ECU Temp ....................................... 3.05-10 Engine Knocking................................ 3.05-10 Engine Setpoint RPM ......................... 3.05-10 Engine Speed RPM ............................ 3.05-10 Engine Status Bar .............................. 3.05-10 Engine Torque % ............................... 3.05-11 Estimated Power ............................... 3.05-11 Ext O2 for Cal ................................... 3.05-11 Faults Loaded ................................... 3.05-11 Front Intake Manifold Pressure ............. 3.05-11 Fuel Composition ............................... 3.05-11 Fuel Pressure ................................... 3.05-11 Heated Power ................................... 3.05-11 High Idle .......................................... 3.05-11 High Voltage Adj. ............................... 3.05-11 High Voltage Limit .............................. 3.05-11 Idle ................................................. 3.05-12 IGN TIMING (Left Bank) ...................... 3.05-12 IGN TIMING (Right Bank) .................... 3.05-12 Ignition Alarm .................................... 3.05-12 Ignition Enable .................................. 3.05-12 Ignition Energy .................................. 3.05-12 Intake Mnfld Temp ............................. 3.05-12 Integral Gain Adj ................................ 3.05-12 Knocking .......................................... 3.05-12 Lambda Setpoint ............................... 3.05-12 Load Inertia ...................................... 3.05-13 Low Idle ........................................... 3.05-13 Low Idle Adj ...................................... 3.05-13 Low Voltage Adj................................. 3.05-13 Low Voltage Limit .............................. 3.05-13 Lower Heating Value .......................... 3.05-13 Main Fuel on RPM ............................. 3.05-13 Main Fuel on RPM Adjustment ............. 3.05-13 Main Fuel Valve................................. 3.05-13 Manual Mode Check Box..................... 3.05-14 Max Retard....................................... 3.05-14 Max/Min Stepper Position .................... 3.05-14 Measured O2 .................................... 3.05-14 No Spark Adjust ................................ 3.05-14 No Spark Limit .................................. 3.05-14 NOx ................................................ 3.05-14 O2 Block Temperature ........................ 3.05-14 O2 Cal Accept ................................... 3.05-14 A-3 F [F2] Engine Panel.................................... [F3] Start-Stop ........................................ [F4] Governing Operating Status .............. [F5] Ignition Operating Status ................... [F8] AFR Setup Panel .............................. [F10] System/Shutdown Status................. [F11] Advanced Functions........................ Fault 3.05-1 3.05-2 3.05-3 3.05-4 3.05-5 3.05-6 3.05-7 Alarm Codes ....................................... 4.00-6 Definition ............................................ 1.05-4 Shutdown Codes.................................. 4.00-8 Fault Codes ............................................ 4.00-6 Fault Log Definition ............................................ 1.05-4 Description ....................................... 3.00-13 Overview ............................................ 3.00-9 Feedforward Control Description ......................................... 2.30-5 Field Description ..................................... 3.05-8 Active Faults ....................................... Alarm and Shutdown Setpoints ............... Alternate Dynamics .............................. Ambient Air Temperature ....................... Average Intake Manifold Pressure ........... Baro Pressure ..................................... Battery Voltage .................................... Baud Rate .......................................... Boost Pressure .................................... Bypass Position ................................... Cal Conditions ..................................... Cal Min. Block Temp ............................. Cal Min. IMAP ..................................... FORM 6331 First Edition 3.05-8 3.05-8 3.05-8 3.05-8 3.05-8 3.05-8 3.05-8 3.05-8 3.05-9 3.05-9 3.05-9 3.05-9 3.05-9 APPENDIX A – INDEX 3.05-14 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-15 3.05-16 3.05-16 3.05-16 3.05-16 3.05-16 3.05-16 3.05-16 3.05-17 3.05-17 3.05-17 3.05-17 3.05-17 3.05-17 3.05-17 3.05-17 3.05-17 3.05-17 3.05-18 3.05-18 3.05-18 3.05-18 3.05-18 3.05-18 3.05-18 3.05-18 3.05-16 3.05-18 Fixed Speed .......................................... 2.30-2 Logic Diagram .................................... 2.30-4 O2 Cal Conditions .............................. O2 Sensor ........................................ O2 Setpoint ....................................... Oil Pressure ...................................... Oil Pressure Pre-filter .......................... Oil Temp .......................................... Percent Rated Load ............................ Post Lube Time.................................. Pre/Post Lube.................................... PreCh Fuel On RPM ........................... PreCh Fuel On RPM Adjust .................. Prechamber Fuel Valve ....................... Prelube Time ..................................... Prelube Timer .................................... Proportion Gain Adj ............................ Proportional Sync ............................... Purge Time ....................................... Remote RPM..................................... Remote RPM Setpoint ......................... Slave ID ........................................... SPARK REF # ................................... Start Position ..................................... Starter.............................................. Starter Off RPM ................................. Starter Off RPM Adj ............................ Starting Signal ................................... Stats Loaded ..................................... Stepper Motor Setup ........................... Stepper Operating Mode ...................... Stepper Position................................. Sync RPM ........................................ System............................................. Throttle Feedback .............................. Throttle Position % ............................. Throttle Reserve % ............................. User ESD ......................................... User RUN/STOP ................................ User WKI .......................................... User WKI in Use ................................ Wastegate ........................................ Wastegate Position % ......................... G Gauges ................................................ 3.00-11 Governing .............................................. 2.30-1 Feedforward Control ............................. Inputs and Calibrations.......................... Synchronizer Control ............................ Theory ............................................... 2.30-5 2.30-1 2.30-5 2.30-1 H Heater Block Assembly............................ 2.20-3 How to Use This Manual .............................. 1-v I Ignition Diagnostics ......................................... 2.10-3 Level ................................................. 2.10-3 Monitoring Ignition Energy Field .............. 2.10-3 Monitoring Spark Reference Number ....... 2.10-3 System Overview ............................... 1.10-11 Theory ............................................... 2.10-2 Initial Engine Startup ............................... 3.10-1 Installing ESP From Download ................. 3.00-1 IPM-D Overview ............................................ 1.10-4 Programming .................................... 3.10-17 K Knock .................................................... 2.35-2 Detection and Timing Control ................. 2.15-2 Promoters And Reducers....................... 2.15-2 Theory ............................................... 2.15-1 Knock Detection Overview .......................................... 1.10-11 Knock Sensor ......................................... 4.05-2 Definition ............................................ 1.05-5 Fuel Valve Description......................................... 2.05-6 Function Codes ...................................... 2.40-3 A-4 FORM 6331 First Edition APPENDIX A – INDEX L Lean Burn Oxygen Sensor ....................... 2.20-2 LEDs Determining Fault Code ......................... 4.00-2 Resetting ............................................ 3.10-7 Load Control Mode .................................. 2.30-5 Definition ............................................ 1.05-5 Load Inertia .......................................... 3.10-14 O Overcrank .............................................. 2.35-2 Overspeed ............................................. 2.35-2 P Panels ................................................. 1.10-10 Permanent Memory Saving ............................................... 3.10-3 Power Distribution Junction Box ............... 2.00-4 Connecting Ground .............................. 2.00-5 Connecting Power................................ 2.00-5 Overview............................................ 1.10-4 Recommended Wiring .......................... 2.00-4 Troubleshooting................................. 4.00-11 Power Supply Requirements .................... 2.00-1 Local Control Option Harness................. 2.00-11 Local Control Panel Description ....................................... 2.40-10 Logging System Parameters .................... 3.10-7 Create Text File ................................... 3.10-8 Creating .TSV File ................................ 3.10-9 Low Oil Pressure ..................................... 2.35-1 M Magnetic Pickup ...................................... 2.10-2 Definition ............................................ 1.05-5 Safety Shutdown .................................. 2.35-2 Prelubing Engine Without Starting ............ 2.05-5 Programming Basic Programming .............................. 3.10-2 Conventions ....................................... 1.05-2 Load Inertia ...................................... 3.10-14 NOx Level ........................................ 3.10-20 Panel Color Key .................................. 1.05-2 Remote ECU .................................... 3.10-11 Saving To Permanent Memory ............... 3.10-3 Using A Modem For Remote Monitoring... 3.00-15 Maintenance Actuator Linkage .................................. Battery ............................................... Chart ................................................. Power Distribution Junction Box .............. Stepper .............................................. System Wiring ..................................... 4.05-2 4.05-4 4.05-1 4.05-3 4.05-2 4.05-3 2.40-1 1.05-5 2.40-3 2.40-2 2.40-4 2.40-4 2.40-5 2.40-6 2.40-2 2.40-3 2.40-2 2.40-2 2.40-1 R Reading MODBUS Addresses ................. 2.40-3 Remote Monitoring ................................ 3.00-15 Connecting Modem To ECU And PC ..... 3.00-17 Setting Up Modem to ECU ................... 3.00-15 Starting ESP ..................................... 3.00-17 Resetting Learning Tables ....................... 2.25-2 MODBUS ............................................... Definition ............................................ Exception Responses ........................... Fault Code Behavior ............................. Function Code 01 Table ........................ Function Code 02 Table ........................ Function Code 03 Table ........................ Function Code 04 Table ........................ Protocol ............................................. Reading Address ................................. Use with PC ........................................ Use with PLC ...................................... Wiring ................................................ Resetting LEDs On ECU ......................... 3.10-7 Rotating Moment of Inertia Adjusting Gain..................................... 2.30-6 RS-232 .................................................. 1.05-6 RS-485 .................................................. 1.05-6 N Navigating ESP Panels .......................... 3.00-10 Non-Code Troubleshooting .................... 4.00-10 FORM 6331 First Edition A-5 APPENDIX A – INDEX S Safety Batteries ............................................ Body Protection .................................. Chemicals.......................................... Cleaning Solvents ............................... Electrical ........................................... Emergency Shutdown .......................... Equipment Repair And Service............... Exhaust ............................................. Fire Protection .................................... Handling Components .......................... Intoxicants and Narcotics ...................... Programming...................................... Protective Guards................................ Safety Tags and Decals ........................ Tools 1.00-3 1.00-3 1.00-3 1.00-3 1.00-2 1.00-4 1.00-1 1.00-3 1.00-3 1.00-4 1.00-4 1.00-4 1.00-4 1.00-1 Speed Control Mode ............................... 2.30-2 Fixed Speed ....................................... 2.30-2 Variable Speed .................................... 2.30-3 Speed Governing. ....................... See Governing Starting ESP ........................................... 3.00-4 Start-Stop Control Description ......................................... 2.05-1 Emergency Shutdown Sequence............. 2.05-2 Emergency Stop Flow Diagram ............... 2.05-5 Normal Shutdown Sequence .................. 2.05-2 Overview .......................................... 1.10-11 Start Flow Diagram............................... 2.05-3 Start Sequence.................................... 2.05-1 Stop Flow Diagram ............................... 2.05-4 Status Field .......................................... 3.00-11 Stepper .................................................. 2.20-4 Overview ............................................ 1.10-4 Electrical ....................................... 1.00-4 Pneumatic ..................................... 1.00-4 Synchronizer Control Description ......................................... 2.30-5 System Block Diagram ............................ 1.10-1 Safety Shutdowns .................................. 2.35-1 Customer-Initiated Emergency Shutdown .. 2.35-2 Description......................................... 2.35-1 ECU Internal Faults ............................. 2.35-2 Engine Overload ................................. 2.35-2 Engine Overspeed ............................... 2.35-2 Engine Stall........................................ 2.35-2 E-Stop Switches.................................. 2.35-1 High HT Jacket Water Coolant Temperature ................ 2.35-2 High Intake Manifold Air Temperature ...... 2.35-2 High Oil Temperature ........................... 2.35-2 Low HT Jacket Water Coolant Pressure ... 2.35-2 Low Oil Pressure ................................. 2.35-1 Magnetic Pickups ................................ 2.35-2 Overcrank .......................................... 2.35-2 Overview .......................................... 1.10-10 Security Violation ................................ 2.35-2 Uncontrollable Engine Knock ................. 2.35-2 Security Violation ................................... 2.35-2 System Requirements ............................. 3.00-1 T Text Field ............................................. 3.00-11 Text Field with Status Bar ...................... 3.00-11 Throttle Actuator Overview ............................................ 1.10-5 Throttle Reserve ..................................... 2.25-4 Throttle Reserve Map .............................. 2.25-2 Torque Values ...................................... 1.05-10 Troubleshooting Additional Assistance ............................ 4.00-1 Determining Fault Code......................... 4.00-2 E-Help ............................................... 4.00-3 Fault Codes ........................................ 4.00-6 Non-Code Troubleshooting .................. 4.00-10 Power Distribution Junction Box ............ 4.00-11 Where to Begin.................................... 4.00-1 Sensor Location Front/Rear View .................................. 1.10-6 Top View ........................................... 1.10-5 Turbocharger Control Description ......................................... 2.25-2 Shutdown Fault Codes Turbocharger Surge ................................ 2.25-3 ....................................... 4.00-8 Spark Reference Number........................ 2.10-3 A-6 FORM 6331 First Edition APPENDIX A – INDEX U User Digital Inputs ................................. 2.40-11 User Interface Panels ............................ 1.10-10 [F10] System/Shutdown Status ............... [F11] Advanced Functions...................... [F2] Engine ......................................... [F3] Start-Stop ..................................... [F4] Governor Operating Status............... [F5] Ignition Status ............................... [F8] AFR Setup .................................... Definition ............................................ 3.00-7 3.00-8 3.00-5 3.00-5 3.00-6 3.00-6 3.00-7 1.05-7 3.00-4 User Interface Panels Overview ............... User-Programmable Field ...................... 3.00-11 V Variable Speed ....................................... 2.30-3 Logic Diagram ..................................... 2.30-4 Version Details ........................................ 3.00-9 W Wastegate Actuator Overview ............................................ 1.10-5 Wastegate Reserve Map.......................... 2.25-2 Waukesha Knock Index (WKI) .................. 2.15-3 Wiring Maintenance ....................................... 4.05-3 Wiring Requirements ............................... 1.05-1 WKI Definition ............................................ 1.05-7 FORM 6331 First Edition A-7 APPENDIX A – INDEX A-8 FORM 6331 First Edition DRESSER WAUKESHA, INC. - EXPRESS LIMITED WARRANTY COVERING PRODUCTS USED IN CONTINUOUS DUTY APPLICATIONS INTRODUCTION CONTINUOUS DUTY DEFINITION: The highest load and speed which can be applied, subject to Waukesha’s approved ratings in effect at time of sale. I. TERMS OF EXPRESS LIMITED WARRANTY A. Waukesha Engine warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any Genuine Waukesha Service Part installed on an engine, or Enginator®, or product (hereinafter referred to as “Products”) manufactured by Waukesha, which proves to have had a defect in material or workmanship. Waukesha Engine further warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any component of the Waukesha Product damaged as the direct result of a warrantable defect in a Product during the term of coverage. This coverage shall commence upon initial new Products start-up date and shall expire upon the earlier of the following: 1. 12 months after the initial new Products start-up date; or 2. 24 months after the original shipment date of the covered Products by Waukesha Engine. Notwithstanding the foregoing, Waukesha further warrants that the cylinder block casting, cylinder head castings, connecting rod forgings, and crankshaft forging will be free from defects in material or workmanship. This additional warranty only covers failures of the specific items noted within this subparagraph. This coverage shall expire upon the earlier of the following: 1. 60 months after the initial new Products start-up date; or 2. 25,000 hours of operation of the covered Products; or 3. 72 months after the original shipment date of the covered Products by Waukesha Engine. NOTE: No damage from other sources, such as damage from the loss of a crankshaft bearing, shall be considered as a forging defect. B. II. TERM LIMITATIONS OF EXPRESS LIMITED WARRANTY A. B. III. WAUKESHA’S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY Waukesha shall be responsible for: A. B. C. The repair or replacement, at Waukesha’s election, of covered defective parts and all reasonable labor required regarding a warranted failure during the express limited warranty term. All such labor shall be provided by Waukesha’s authorized contractor or distributor. Reasonable and necessary travel and expenses incurred by Waukesha’s authorized contractor or distributor. Replacement of lubricating oil, coolant, filter elements, or other normal maintenance items that are contaminated and/or damaged as a direct result of a warranted failure. IV. OWNER’S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY Owner shall be responsible for: A. B. C. D. E. F. G. H. The operation and maintenance of the Products within the guidelines established by Waukesha. Making the Products available to Waukesha or Waukesha’s authorized contractors or distributors for any warranty repair, during normal business hours. All additional costs incurred for premium or overtime labor, should owner request that repairs be made on a premium or overtime schedule. All costs incurred as the result of removal or reinstallation of the Products as may be required to effect any warranted repair. All administrative costs and expenses resulting from a warranted failure. Any costs of transportation, towing, repair facilities, or associated costs. All labor, travel, mileage, and other related costs and expenses associated with a claim made pursuant to subparagraph II (B) above. Loss of revenue and loss of/or damage to real and/or personal property. V. LIMITATION OF WAUKESHA’S OBLIGATIONS The obligations of Waukesha under this express limited warranty shall be waived and voided, and Waukesha shall not, thereafter, be responsible for: A. B. C. D. E. F. G. H. I. Any failure resulting from owner or operator abuse or neglect, including but not by way of limitation, any operation, installation, application, or maintenance practice not in accordance with guidelines or specifications established by Waukesha; or Any failure resulting from unauthorized modifications or repairs of the Products; or Any failure resulting from overload, overspeed, overheat, accident, improper storage; or Failure of owner to promptly provide notice of a claimed defect; or Failure of Products for which Waukesha did not receive properly completed start-up reports; or Repairs of a covered failure performed with non-genuine Waukesha parts; or Repairs of a covered failure performed by non-authorized contractors or distributors; or Failure to make Products available to Waukesha or its authorized representatives; or Failure to supply documents such as drawings and specifications relating to the specific application of the Products. VI. APPLICABILITY AND EXPIRATION The warranties set out above are extended to all owners in the original chain of distribution. The warranties and obligations of Waukesha shall expire and be of no further effect upon the dates of expiration of the applicable warranty periods. THE FOREGOING SETS FORTH WAUKESHA’S ONLY OBLIGATIONS AND OWNERS’ EXCLUSIVE REMEDY FOR BREACH OF WARRANTY, WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY), OR OTHER THEORIES, AND THE FOREGOING IS EXPRESSLY IN LIEU OF OTHER WARRANTIES WHATSOEVER EXPRESSED, IMPLIED, AND STATUTORY, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Notwithstanding the preceding, in no event shall Waukesha be liable for any direct, special, incidental, or consequential damages (whether denominated in contract, tort strict liability, negligence, or other theories) arising out of this Agreement or the use of any Products provided under this Agreement. Any action arising hereunder or relating hereto, whether based on breach of contract, tort (including negligence and strict liability), or other theories must be commenced within two (2) years after the cause of action accrues or it shall be barred. BINDING ARBITRATION (a) Buyer and Seller shall attempt, in good faith, to resolve any dispute arising out of or relating to this agreement, or the products and/or services provided hereunder, promptly by negotiation between executives. If the matter has not been resolved within sixty (60) days of a party’s request for negotiation, either party may initiate arbitration as herein after provided. (b) Any dispute arising out of or related to this agreement or the products and/or services provided hereunder which has not been resolved by the negotiation procedure described above, shall be settled by binding arbitration administered by the American Arbitration Association in accordance with its Commercial Arbitration Rules and judgment on the award rendered by the arbitrator(s) may be entered in any court having jurisdiction thereof. (c) Unless Buyer and Seller otherwise agree in writing, the arbitration panel shall consist of three arbitrators. The arbitrator(s) shall have no authority to award punitive or other damages not measured by the prevailing party’s actual damages and may not, in any event, make any ruling, finding or award that does not conform to the terms and condition of this agreement. The law of Texas shall govern. (d) The arbitration proceeding shall be conducted in English, in Dallas, Texas. See form M464 for the most current warranty terms. Effective February 22, 2006 W-1 DRESSER WAUKESHA, INC. - EXPRESS LIMITED WARRANTY FOR GENUINE WAUKESHA SERVICE PARTS AND WAUKESHA FACTORY REMANUFACTURED SERVICE PARTS INTRODUCTION This warranty only applies to Genuine Waukesha Service Parts and Waukesha Factory Remanufactured Service Parts (to include assemblies and short blocks) (hereinafter referred to as “Service Parts”) sold by Waukesha Engine and used for repair, maintenance, or overhaul of Waukesha Products. I. TERMS OF EXPRESS LIMITED WARRANTY A. B. Waukesha Engine warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any Genuine Waukesha Service Part installed on an engine, or Enginator®, or product (hereinafter referred to as “Products”) manufactured by Waukesha, which proves to have had a defect in material or workmanship. Waukesha Engine Division further warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any component of the Waukesha Product damaged as the direct result of a warrantable defect in a Product during the term of coverage. II. TERM LIMITATIONS OF EXPRESS LIMITED WARRANTY This coverage shall commence upon the date the Service Part is installed and shall expire upon the earlier of the following: A. 12 months after the date the part is installed; or B. 24 months after the purchase date from an authorized Waukesha Distributor. III. WAUKESHA'S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY Waukesha shall be responsible for: A. The repair or replacement, at Waukesha's election, of covered defective Service Parts and progressive damage as explained in Paragraph 1B of this warranty. B. Labor time to repair or replace the defective part as established by the Waukesha Labor Guide Manual. All reimbursable labor costs shall be provided by Waukesha’s authorized Distributor. C. The reimbursement of documented Distributor expenses covering Freight, Customs, Brokers Fees, and Import Duties to obtain the replacement Service Part from Waukesha. IV. OWNER'S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY Owner shall be responsible for: A. The operation and maintenance of the Products/Service Parts within the guidelines established by Waukesha. B. Making The Products/service Parts available to Waukesha or Waukesha's authorized Distributors for any warranty repair, during normal business hours. C. All additional costs incurred for premium or overtime labor, should owner request that repairs be made on a premium or overtime schedule. D. All costs incurred as the result of removal or reinstallation of the Products as may be required to effect any warranted repairs. E. All administrative costs and expenses resulting from a warranted failure. F. Any costs of transportation, towing, repair facilities, or associated costs. G. All travel, mileage, and other related Distributor costs and expenses associated with repair under the terms of this Service Parts Warranty. H. All additional labor time in excess of Waukesha's Labor Guide for the warrantable repair. I. Loss of revenue and loss of/or damage to real and/or personal property. V. Limitation Of Waukesha's Obligations The obligations of Waukesha under this express limited warranty shall be waived and voided, and Waukesha shall not, thereafter, be responsible for: A. Any failure resulting from owner or operator abuse or neglect, including but not by way of limitation, any operation, installation, application, maintenance, or assembly practice not in accordance with guidelines or specifications established by Waukesha; or B. Any failure resulting from unauthorized modifications or repairs of the Products or Service Parts; or C. Any failure resulting from overload, overspeed, overheat, accident; or D. Failure of owner to promptly provide notice of a claimed defect; or E. Failure of Service Parts for which Waukesha did not receive proper documentation concerning the Service Parts purchase date from an authorized Waukesha Engine Distributor; or F. Repairs of a covered failure performed with non-genuine Waukesha parts; or G. Repairs of a covered failure performed by non-authorized contractors or distributors; or H. Failure to make Products and Service Parts available to Waukesha or its authorized representative; or I. Failure to supply documents such as drawings and specifications relating to the specific application of the Products; or J. Any failure of Service Parts resulting from misapplication or improper repair procedures; or K. Any failure or damage resulting from the improper or extended storage of a Service Part; or L. Freight, Customs, Broker Fees, and Import Duties if appropriate documentation is not provided; or M. Normal wear items or consumable parts such as belts, spark plugs, lubricating oil filters, air filters, etc. are not considered defective if in need of routine replacement, rebuild, or maintenance during the term of the warranty. VI. APPLICABILITY AND EXPIRATION The warranty set out above is extended to the original purchaser of the Genuine Waukesha Service Parts. The warranty and obligations of Waukesha shall expire and be of no further effect upon the date of expiration of the applicable warranty period. VII. WARRANTY ADMINISTRATION This warranty is administered exclusively by an authorized Waukesha Distributor. The invoice for the failed Service Parts must be provided to the distributor to determine whether the warranty is applicable. Contact the nearest authorized Waukesha Distributor for assistance with warranty matters or questions. The location of the nearest authorized Distributor is available by contacting Waukesha Engine at (262) 547-3311. THE FOREGOING SETS FORTH WAUKESHA'S ONLY OBLIGATIONS AND OWNERS' EXCLUSIVE REMEDY FOR BREACH OF WARRANTY, WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY), OR OTHER THEORIES, AND THE FOREGOING IS EXPRESSLY IN LIEU OF OTHER WARRANTIES WHATSOEVER EXPRESSED, IMPLIED, AND STATUTORY, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Notwithstanding the preceding, In no event shall Waukesha be liable for any direct, special, incidental, or consequential damages (whether denominated in contract, tort strict liability, negligence, or other theories) arising out of this Agreement or the use of any products provided under this Agreement. Any action arising hereunder or relating hereto, whether based on breach of contract, tort (including negligence and strict liability), or other theories must be commenced within two (2) years after the cause of action accrues or it shall be barred. BINDING ARBITRATION (a) Buyer and Seller shall attempt, in good faith, to resolve any dispute arising out of or relating to this agreement, or the products and/or services provided hereunder, promptly by negotiation between executives. If the matter has not been resolved within sixty (60) days of a party's request for negotiation, either party may initiate arbitration as hereinafter provided. (b) Any dispute arising out of or related to this agreement or the products and/or services provided hereunder which has not been resolved by the negotiation procedure described above, shall be settled by binding arbitration administered by the American Arbitration Association in accordance with its Commercial Arbitration Rules and judgment on the award rendered by the arbitrator(s) may be entered in any court having jurisdiction thereof. (c) Unless Buyer and Seller otherwise agree in writing, the arbitration panel shall consist of three arbitrators. The arbitrator(s) shall have no authority to award punitive or other damages not measured by the prevailing party's actual damages and may not, in any event, make any ruling, finding or award that does not conform to the terms and conditions of this agreement. The law of Texas shall govern. (d) The arbitration proceeding shall be conducted in English, in Dallas, Texas. See Form M-463 for the most current warranty terms; effective February 22, 2006. W-2 DRESSER WAUKESHA, INC. EXPRESS LIMITED WARRANTY FOR PRODUCTS OPERATED IN EXCESS OF CONTINUOUS DUTY RATINGS INTRODUCTION This warranty only applies to engines which Waukesha Engine has approved to operate in excess of the continuous duty rating. APPLICATIONS COVERED BY THIS WARRANTY Standby Service Applications: This rating applies to those systems used as a secondary or backup source of electrical power. This rating is the output the system will produce continuously (no overload), 24 hours per day for the duration of the prime power source outage. Intermittent Service Applications: This rating is the highest load and speed that can be applied in variable speed mechanical system applications only (i.e., blowers, pumps, compressors, etc.). Operation at this rating is limited to a maximum of 3500 hours/year. For continuous operation for any length of time between the continuous and intermittent ratings, see the Peak Shaving Application rating procedure. Peak Shaving Applications: The rating for a peak shaving application is based on the number of horsepower-hours available per year at site specific conditions. All applications using a peak shaving rating require a signed Special Application Approval (SAA) from Waukesha's Application Engineering Department. I. TERMS OF EXPRESS LIMITED WARRANTY A. B. Waukesha Engine warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any Genuine Waukesha Service Part installed on an engine, or Enginator®, or product (hereinafter referred to as “Products”) manufactured by Waukesha, which proves to have had a defect in material or workmanship. Waukesha Engine Division further warrants that it will repair or replace, AT ITS ELECTION AND EXPENSE, any component of the Waukesha Product damaged as the direct result of a warrantable defect in a Product during the term of coverage. II. TERM LIMITATIONS OF EXPRESS LIMITED WARRANTY A. This coverage shall commence upon initial new Products start-up date and shall expire upon the earlier of the following: 1. 60 months or 3500 hours, whichever occurs first, after the initial new Products start-up date; or 2. 72 months after the original shipment date of the covered Products by Waukesha Engine. B. Notwithstanding the foregoing, Waukesha further warrants that the cylinder block casting, cylinderhead castings, connecting rod forgings, and crankshaft forging will be free from defects in material or workmanship. This additional warranty only covers failure of the specific items noted within this subparagraph. This coverage shall expire upon the earlier of the following: 1. 60 months after the initial new Products start-up date; or 2. 25,000 hours of operation of the covered Products; or 3. 2 months after the original shipment date of the covered Products by Waukesha Engine. NOTE: No damage from other sources, such as damage from the loss of a crankshaft bearing, shall be III. WAUKESHA'S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY Waukesha shall be responsible for: A. The repair or replacement, at Waukesha's election, of covered defective parts and all reasonable labor required regarding a warranted failure during the express limited warranty term. All such labor shall be provided by Waukesha's authorized contractor or distributor. B. Reasonable and necessary travel and expenses incurred by Waukesha's authorized contractors or distributor. C. Replacement of lubricating oil, coolant, filter elements, or other normal maintenance items that are contaminated and/or damaged as a direct result of a warranted failure. NOTWITHSTANDING THE FOREGOING, WAUKESHA SHALL NOT BE RESPONSIBLE FOR LABOR COSTS ASSOCIATED WITH WARRANTY CLAIMS BROUGHT PURSUANT TO SUBPARAGRAPH II (B). IV. OWNER'S RESPONSIBILITIES UNDER THE EXPRESS LIMITED WARRANTY Owner shall be responsible for: A. The operation of the Product within the allowable HP-HR/YR rating granted by the specific Special Application Approval for the Product. B. The operation and maintenance of the Products within the guidelines established by Waukesha. C. Making the Products available to Waukesha or Waukesha's authorized contractors or distributors for any warranty repair, during normal business hours. D. All additional costs incurred for premium or overtime labor, should owner request that repairs be made on a premium or overtime schedule. E. All costs incurred as the result of removal or reinstallation of the Products as may be required to effect any warranted repair. F. All administrative costs and expenses resulting from a warranted failure. G. Any costs of transportation, towing, repair facilities, or associated costs. H. All labor, travel, mileage, and other related costs and expenses associated with a claim made pursuant to subparagraph II (B) above. I. Loss of revenue and loss of/or damage to real and/or personal property. V. LIMITATION OF WAUKESHA'S OBLIGATIONS The obligations of Waukesha under this express limited warranty shall be waived and voided, and Waukesha shall not, thereafter, be responsible for: A. Any failure resulting from owner or operator abuse or neglect, including but not by way of limitation, any operation, installation, application, or maintenance practice not in accordance with guidelines or specifications established by Waukesha; or B. Any failure resulting from unauthorized modifications or repairs of the Products: or C. Any failure resulting from overload, overspeed, overheat, accident, improper storage; or D. Failure of owner to promptly provide notice of a claimed defect; or E. Failure of Products for which Waukesha did not receive properly completed start-up reports; or F. Repairs of a covered failure performed with non-genuine Waukesha parts; or G. Repairs of a covered failure performed by non-authorized contractors or distributors; or H. Failure to make Products available to Waukesha or its authorized representatives; or I. Failure to supply documents such as drawings and specifications relating to the specific application of the Products. VI. APPLICABILITY AND EXPIRATION The warranties set out above are extended to all owners in the original chain of distribution. The warranties and obligations of Waukesha shall expire and be of no further effect upon the dates of expiration of the applicable warranty periods. THE FOREGOING SETS FORTH WAUKESHA'S ONLY OBLIGATIONS AND OWNERS' EXCLUSIVE REMEDY FOR BREACH OF WARRANTY, WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY), OR OTHER THEORIES, AND THE FOREGOING IS EXPRESSLY IN LIEU OF OTHER WARRANTIES WHATSOEVER EXPRESSED, IMPLIED, AND STATUTORY, INCLUDING WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Notwithstanding the preceding, in no event shall Waukesha be liable for any direct, special, incidental, or consequential damages (whether denominated in contract, tort strict liability, negligence, or other theories) arising out of this Agreement or the use of any Products provided under this Agreement. Any action arising hereunder or relating hereto, whether based on breach of contract, tort (including negligence and strict liability), or other theories must be commenced within two (2) years after the cause of action accrues or it shall be barred. BINDING ARBITRATION (a) Buyer and Seller shall attempt, in good faith, to resolve any dispute arising out of or relating to this agreement, or the products and/or services provided hereunder, promptly by negotiation between executives. If the matter has not been resolved within sixty (60) days of a party's request for negotiation, either party may initiate arbitration as herein after provided. (b) Any dispute arising out of or related to this agreement or the products and/or services provided hereunder which has not been resolved by the negotiation procedure described above, shall be settled by binding arbitration administered by the American Arbitration Association in accordance with its Commercial Arbitration Rules and judgment on the award rendered by the arbitrator(s) may be entered in any court having jurisdiction thereof. (c) Unless Buyer and Seller otherwise agree in writing, the arbitration panel shall consist of three arbitrators. The arbitrator(s) shall have no authority to award punitive or other damages not measured by the prevailing party's actual damages and may not, in any event, make any ruling, finding or award that does not conform to the terms and condition of this agreement. The law of Texas shall govern. (d) The arbitration proceeding shall be conducted in English, in Dallas, Texas. See Form 467 for the most current warranty terms, effective February 22, 2006. W-3