ESM Gas Engine Waukesha

ESM SYSTEM COMPONENTS

The ESM system including the modules and cables meets Canadian Standards Association (CSA) Class I, Division 2, Groups A, B, C, and D hazardous location requirements.

The ESM system includes the following equipment:

• Engine Control Unit (ECU)

• Ignition Power Module with Diagnostics (IPM-D)

• PC-based Electronic Service Program (ESP)

• Electric throttle actuation

• Prechamber control valve (VHP7042GL)

• Stepper(s) for the gas regulator (one per engine bank) (AFR equipped)

The ESM system includes the following engine mounted and wired sensors:

• Oil pressure sensor (1)

• Oil temperature sensor (1)

• Intake manifold pressure sensor(s)

• Intake manifold temperature sensor (1)

• Jacket water temperature sensor (1)

• Magnetic pickups (2)

• Knock sensors

• Oxygen sensor(s) (AFR equipped)

• Exhaust temperature sensor(s) (AFR equipped)

ENGINE CONTROL UNIT (ECU)

DESCRIPTION OF ECU

The Engine Control Unit (ECU) is the central module or “hub” of the ESM system (see Figure 1.10-2).  is the single entry point of system control for easy interface and usability. The entire ESM system 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 configuration allows for simple electrical connections and simple setup. The ECU is CSA approved for Class I, Division 2, Groups A, B, C, and D (T4 temperature rating), hazardous location requirements.

All ESM system 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® slave) communication to local panel or customer PLC (MODBUS® master)

• PC-based ESM Electronic Service Program via an RS-232 connection

ECU STATUS LEDS

The ECU has three Status LEDs on the cover: green (power), yellow (alarm), and red (shutdown). The green LED is on whenever power is applied to the ECU, the yellow LED flashes alarm codes, and the red LED flashes shutdown codes. The yellow and red LEDs flash codes that allow you to obtain information on the status of the system when an alarm or shutdown occurs. All codes have three digits, and each digit can be a number from 1 to 5. 

The codes display in the order that they occur (with the oldest code displayed first and the most recent code displayed last). At the start of the code sequence, both the red and yellow LEDs will flash three times simultaneously. If there are any shutdown faults, the red LED will flash a three-digit code for each shutdown fault that occurred. 

If there are any alarm faults, the yellow LED will flash a three-digit code for each alarm that occurred. Between each three-digit code, both yellow and red LEDs will flash once at the same time to indicate that a new code is starting. Once the fault is corrected, the Status LEDs on the

ECU will remain flashing until one of two things happens: (1) the LEDs are cleared using the ESM Electronic Service Program or (2) the engine is restarted

The ECU Status LEDs are not considered to be the primary means of obtaining information on the status of the system, but rather a way of alerting the site technician that there is a problem and what that problem is (even if a PC with the Electronic Service Program is unavailable). See “ESM Electronic Service Program (ESP)” for more information.

ESM ELECTRONIC SERVICE PROGRAM  (ESP)

DESCRIPTION OF ESP

The PC-based ESM 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 1.10-4). If the user needs help, system information, or troubleshooting information while using the ESP software, an electronic help file is included. See “E-Help” on page 1.10-5 for more information. E-Help is accessed by pressing the [F1] function key on the keyboard. ESP is a diagnostic tool and is 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 icon that appears on your desktop after loading the software on your PC. To open the ESP software, double-click on the icon.

E-HELP

ESP contains an electronic help file named E-Help

(see Figure 1.10-3 for a sample screen). E-Help provides general system and troubleshooting information in an instant as long as the user is using the PC with the ESP software. The user can quickly and easily move around in E-Help through electronic links (or hypertext links) from subject to subject. E-Help is automatically installed when the ESP software is installed. 

To access the help file any time while using the ESP software, press the [F1] function key on the keyboard or select Help Contents… from the Help menu in ESP.

USER INTERFACE PANELS

The ESM ESP software displays engine status and information on eight panels:

These panels display system and component status, current pressure and temperature readings, alarms, ignition status, governor status, air/fuel control status (AFR equipped), 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. 

Refer to Section 3.05 ESP Panel Descriptions for a complete description of each panel.

[F2] Engine Panel [F6] AFR Primary Fuel Panel*

[F3] Start-Stop Panel [F8] AFR Setup Panel*

[F4] Governor Panel [F10] Status Panel

[F5] Ignition Panel [F11] Advanced Panel

*The [F6] and [F8] panels are viewable on AFR equipped engines.

These panels display system and component status, current pressure and temperature readings, alarms,

ignition status, governor status, air/fuel control status (AFR equipped), 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.  Refer to Section 3.05 ESP Panel Descriptions for a complete description of each panel.