Waukesha VHP Series Four 7042GL/GSI Engine System Manager Operation & Maintenance manual

ESM VHP ® Series Four ® , 7042GL/GSI Engine System Manager Operation & Maintenance Fourth Edition This document contains proprietary and trade secret information and is given to the receiver in confidence. The receiver by recep- tion and retention of the document accepts the document in confidence and agrees that, except as with the prior expressed written permission of Waukesha Engine, 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 Waukesha Engine, Dresser, 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 ® , WKI ® , ENGINATOR ® , SERIES FOUR ® , VGF ® , VHP ® , 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 6295 Waukesha Engine Dresser, Inc. Waukesha, Wisconsin 53188 Printed in U.S.A. 07/2007 © Copyright 2001, 2003, 2005, 2007, Dresser, Inc. All rights reserved. ®

CONTENTS FORM 6295 Fourth Edition i 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 Acids ...................................................................... 1.00-2 Batteries ................................................................. 1.00-2 Body Protection...................................................... 1.00-2 Chemicals .............................................................. 1.00-2 General ........................................................... 1.00-2 Cleaning Solvents ........................................... 1.00-2 Liquid Nitrogen/Dry Ice ................................... 1.00-2 Components........................................................... 1.00-2 Heated Or Frozen ........................................... 1.00-2 Interference Fit................................................ 1.00-2 Cooling System...................................................... 1.00-3 Electrical ................................................................ 1.00-3 General ........................................................... 1.00-3 Ignition ............................................................ 1.00-3 Exhaust .................................................................. 1.00-3 Fire Protection........................................................ 1.00-3 Fuels ...................................................................... 1.00-3 General ........................................................... 1.00-3 Gaseous ......................................................... 1.00-3 Liquid .............................................................. 1.00-4 Intoxicants And Narcotics ...................................... 1.00-4 Pressurized Fluids/Gas/Air .................................... 1.00-4 Protective Guards .................................................. 1.00-4 Springs ................................................................... 1.00-4 Tools ...................................................................... 1.00-4 Electrical ......................................................... 1.00-4 Hydraulic ......................................................... 1.00-4 Pneumatic ....................................................... 1.00-5 Weight .................................................................... 1.00-5 Welding .................................................................. 1.00-5 General ........................................................... 1.00-5 On Engine ....................................................... 1.00-5 Section 1.05 – General Information English/Metric Conversions ................................... 1.05-1 Torque Values........................................................ 1.05-2 Wiring Requirements ............................................. 1.05-5 Section 1.10 – Description of Operation Introduction ............................................................ 1.10-1 ESM System Components ..................................... 1.10-4 Engine Control Unit (ECU) ..................................... 1.10-4 Description Of ECU ........................................ 1.10-4 ECU Status LEDs ........................................... 1.10-4 ESM Electronic Service Program (ESP) ................ 1.10-5 Description Of ESP ......................................... 1.10-5 E-Help ............................................................. 1.10-5 User Interface Panels ..................................... 1.10-5 ESM System Diagnostics....................................... 1.10-6 Safety Shutdowns .................................................. 1.10-7 Start-Stop Control .................................................. 1.10-7 Ignition System ...................................................... 1.10-8 Description Of Ignition System ....................... 1.10-8 Ignition Theory ............................................... 1.10-8 Ignition Diagnostics ........................................ 1.10-9 Detonation Detection ............................................. 1.10-9 Description Of Detonation Detection .............. 1.10-9 Detonation Theory........................................ 1.10-11 Method Of Detonation Detection and Timing Control .............................................. 1.10-11 ESM System Speed Governing........................... 1.10-12 Description Of Speed Governing ................. 1.10-12 Governing Theory ........................................ 1.10-12 Speed Governing Modes ............................. 1.10-13 Speed Control ....................................... 1.10-13 Load Control ......................................... 1.10-13 Governor Inputs And Calibrations ................ 1.10-13 Feedforward Control (Load Coming Control) .......................... 1.10-13 Synchronizer Control (Alternate Dynamics) ............................ 1.10-13 AFR Control Description...................................... 1.10-14 Stoichiometric Oxygen Sensor ..................... 1.10-15 Lambda ........................................................ 1.10-15 Stepper......................................................... 1.10-16 Theory Of Operation .................................... 1.10-16 Control Routine ..................................... 1.10-16 Setup for Catalyst Control ..................... 1.10-17 Dithering................................................ 1.10-17 Definitions............................................................ 1.10-18 CHAPTER 2 – PACKAGER’S GUIDE Section 2.00 – Power Requirements Power Requirements ............................................. 2.00-1 Battery Requirements............................................ 2.00-2 Non Extender Series Engines – Power Supply with Air Start and Alternator .... 2.00-3 Power Supply by Customer ............................ 2.00-4 Power Supply with Electric Start and Alternator........................................................ 2.00-5 Extender Series Engines – Power Supply with Air Start and Alternator .... 2.00-6 Power Supply by Customer ............................ 2.00-7 Power Supply with Electric Start and Alternator........................................................ 2.00-8 Section 2.05 – Power Distribution Junction Box Theory of Operation .............................................. 2.05-1 Power Distribution Junction Box............................ 2.05-1 24 VDC Power ............................................... 2.05-1 Making Power Connection Inside Power Distribution Junction Box ............. 2.05-1 Power Distribution Junction Box Connection (Non Extender Series Engines) ...................... 2.05-3 Power Distribution Junction Box Connection (Extender Series Engines) ............................. 2.05-3 Engine Shutdown Information ........................ 2.05-4 External Power Distribution Junction Box Local Control Options Harness ...................... 2.05-4 +24VFOR U and GND FOR U ................ 2.05-4 ESTOP SW ............................................. 2.05-4

CONTENTS ii FORM 6295 Fourth Edition G LEAD (Non Extender Series) .............. 2.05-4 GOVSD+24V and GOV SD+................... 2.05-5 Maintenance .......................................................... 2.05-5 Troubleshooting ..................................................... 2.05-5 Section 2.10 – System Wiring Overview Wiring Diagram............................................... 2.10-1 Customer Interface Harness .......................... 2.10-1 Required Connections .................................... 2.10-4 Optional Connections ..................................... 2.10-6 Local Control Option Harness ........................ 2.10-6 Governor Connections ................................... 2.10-6 Section 2.15 – Start-Stop Control Start-Stop Control .................................................. 2.15-1 Prelubing the Engine Without Starting ........... 2.15-2 Cranking the Engine Over Without Starting and Without Fuel ............................................ 2.15-2 Air-Start Valve ....................................................... 2.15-2 Air Prelube Valve ................................................... 2.15-3 Section 2.20 – Governing Governor/Speed Control........................................ 2.20-1 Speed Control Mode ...................................... 2.20-1 Fixed Speed ............................................ 2.20-1 Variable Speed........................................ 2.20-1 Load Control Mode ......................................... 2.20-3 Rotating Moment of Inertia / Adjusting Gain... 2.20-4 Feedforward Control (Load Coming) .............. 2.20-4 Actuator Automatic Calibration ....................... 2.20-4 Section 2.25 – Fuel Valve Fuel Valve.............................................................. 2.25-1 WKI ........................................................................ 2.25-2 Section 2.30 – Safeties Overview Individual Safety Shutdowns ................................. 2.30-1 Engine Overspeed.......................................... 2.30-1 Low Oil Pressure ............................................ 2.30-1 Oil Over-Temperature .................................... 2.30-1 Coolant Over-Temperature ............................ 2.30-1 Intake Manifold Over-Temperature ................ 2.30-1 Engine Emergency Stop Buttons ................... 2.30-2 Uncontrollable Engine Knock ......................... 2.30-2 Engine Overload............................................. 2.30-2 Customer-Initiated Emergency Shutdown ...... 2.30-2 Overcrank ....................................................... 2.30-2 Engine Stall .................................................... 2.30-2 Magnetic Pickup Problems ............................. 2.30-2 ECU Internal Faults ........................................ 2.30-2 Security Violation............................................ 2.30-2 Alarms ................................................................... 2.30-2 Section 2.35 – ESM System Communications MODBUS ® (RS-485) Communications ................. 2.35-1 Wiring ............................................................. 2.35-1 Protocol .......................................................... 2.35-2 How Do I Get MODBUS ® for My PLC?.......... 2.35-2 Personal Computers....................................... 2.35-2 Functionality ................................................... 2.35-2 Fault Code Behavior ....................................... 2.35-2 Data Tables .................................................... 2.35-3 MODBUS ® Exception Responses .................. 2.35-3 Additional Information on MODBUS ® Addresses 30038 – 30041 ............................ 2.35-10 Local Control Panel .............................................. 2.35-10 Local Displays Such as a Tachometer ......... 2.35-10 User Digital Inputs ........................................ 2.35-11 CHAPTER 3 – ESP OPERATION Section 3.00 – Introduction to ESP Electronic Service Program (ESP) ......................... 3.00-1 Description of ESP.......................................... 3.00-1 Minimum Recommended Computer Equipment for ESM ESP Operation................ 3.00-2 Conventions Used with ESM ESP Programming .......................................... 3.00-2 Information on Saving ESM System Calibrations ........................................ 3.00-2 User Interface Panels ..................................... 3.00-3 Fault Log ......................................................... 3.00-5 E-Help ............................................................. 3.00-6 Section 3.05 – ESP Panel Descriptions Introduction ............................................................ 3.05-1 [F2] Engine Panel Description ............................... 3.05-2 [F3] Start-Stop Panel Description .......................... 3.05-4 [F4] Governor Panel Description............................ 3.05-8 [F5] Ignition Panel Description ............................. 3.05-14 [F6] AFR Primary Fuel Panel Description ............ 3.05-20 [F8] AFR Setup Panel Description ....................... 3.05-26 [F10] Status Panel Description ............................ 3.05-30 [F11] Advanced Panel Description....................... 3.05-36 Fault Log Description ........................................... 3.05-38 Section 3.10 – ESP Programming Introduction to ESP Programming ......................... 3.10-1 Outline of Section 3.10........................................... 3.10-1 Initial Engine Startup .............................................. 3.10-2 Downloading ESP to Hard Drive ............................ 3.10-3 Installing ESP CD to Hard Drive ............................ 3.10-4 Connecting PC to ECU .......................................... 3.10-4 Starting ESP .......................................................... 3.10-5 Basic Programming in ESP.................................... 3.10-5 Saving to Permanent Memory ............................... 3.10-7 Programming WKI Value ....................................... 3.10-8 Programming Load Inertia ..................................... 3.10-9 Programming Air/Fuel Ratio................................. 3.10-11 Programming NOx Level – LT Engine Applications Only ................................ 3.10-13 Programming Alarm And Shutdown Setpoints..... 3.10-14 Actuator Calibration ............................................. 3.10-16 Programming Automatic Calibration ............. 3.10-16 Performing Manual Calibration ..................... 3.10-17 Governor Programming ....................................... 3.10-18 Variable Speed Applications ......................... 3.10-18 Fixed Speed Applications ............................. 3.10-19 Feedforward Control (Load Coming) ............ 3.10-19 Synchronizer Control (Alternate Dynamics)..3.10-20 IPM-D Programming ............................................ 3.10-20

CONTENTS FORM 6295 Fourth Edition iii Monitoring Ignition Energy Field ................... 3.10-21 Monitoring Spark Reference Number ........... 3.10-21 High Voltage Adjustment .............................. 3.10-21 Low Voltage Adjustment ............................... 3.10-22 No Spark Adjustment .................................... 3.10-22 Changing Units – U.S. or Metric .......................... 3.10-23 Reset Status LEDs on ECU ................................. 3.10-23 Copying Fault Log Information to the Clipboard ..3.10-23 Taking Screen Captures of ESP Panels .............. 3.10-24 Logging System Parameters................................ 3.10-24 Create Text File ............................................ 3.10-25 Creating .TSV File ........................................ 3.10-27 Programming Baud Rate (MODBUS ® Applications) .................................... 3.10-28 Programming ECU MODBUS ® Slave ID ............................................ 3.10-29 Programming Remote ECU for Off-Site Personnel ................................................ 3.10-29 Introduction ................................................... 3.10-29 Modem Setup ............................................... 3.10-30 Using a Modem.................................................... 3.10-32 Setting Up Modem to ECU for Proper Connection ........................................ 3.10-32 Starting ESP for Modem Access .................. 3.10-34 Connecting Modem To ECU And PC ........... 3.10-35 CHAPTER 4 – TROUBLESHOOTING AND MAINTENANCE Section 4.00 – Troubleshooting Important ................................................................ 4.00-1 Additional Assistance...................................... 4.00-1 Introduction ............................................................ 4.00-1 Where to Begin ...................................................... 4.00-1 Determining Fault Code by Reading ECU Status LEDs ............................. 4.00-2 Determining Fault Code by Using ESP Fault Log ...................................... 4.00-2 Using Fault Code for Troubleshooting ................... 4.00-3 E-Help .................................................................... 4.00-3 Using E-Help................................................... 4.00-3 E-Help Window Description ............................ 4.00-4 Using the Command Bar ......................... 4.00-4 Using the Navigation Pane ...................... 4.00-5 Using the Document Pane....................... 4.00-6 ESM System Fault Codes ...................................... 4.00-7 Non-Code ESM System Troubleshooting ............ 4.00-10 Section 4.05 – ESM System Maintenance Maintenance Chart................................................. 4.05-1 ESP Total Fault History.......................................... 4.05-2 Throttle Actuator Linkage ....................................... 4.05-2 Adjusting Linkage ........................................... 4.05-2 Inspection and Maintenance of Throttle Actuator Linkage................................ 4.05-6 Alternator Belts ...................................................... 4.05-7 Inspection of Alternator Belts .......................... 4.05-7 Alternator Belt Tension ................................... 4.05-7 Knock Sensors ....................................................... 4.05-9 Installing Knock Sensors ................................ 4.05-9 Verifying Knock Sensor Is Seated Flat ............................................ 4.05-10 Oxygen Sensor Replacement ............................. 4.05-10 Stepper Maintenance .......................................... 4.05-11 ESM System Wiring ............................................ 4.05-13 Battery Maintenance ........................................... 4.05-13 External Inspection....................................... 4.05-13 Battery Indicated State of Charge ................ 4.05-13 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

CONTENTS iv FORM 6295 Fourth Edition

HOW TO USE THIS MANUAL FORM 6295 Fourth Edition v Your purchase of the Waukesha Engine System Man- ager (ESM) system was a wise investment. In the industrial engine field, the name Waukesha Engine stands for quality and durability. With normal care and maintenance this equipment will provide many years of reliable service. Before placing the ESM system in service, read Chap- ter 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 con- version tables, torque values of metric and standard capscrews, and wiring information. Section 1.10 – “Description of Operation” – Provides basic data on the ESM system such as system description, theory of operation, and definitions. 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 system. There are four chapters within the manual, and each chapter contains one 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 Waukesha Distributor or Waukesha Engine Service Operations Department for any information on subjects beyond the scope of this manual.

HOW TO USE THIS MANUAL vi FORM 6295 Fourth Edition

CHAPTER 1 – SAFETY AND GENERAL FORM 6295 Fourth Edition CONTENTS SECTION 1.00 – SAFETY SECTION 1.05 – GENERAL INFORMATION SECTION 1.10 – DESCRIPTION OF OPERATION

CHAPTER 1 – SAFETY AND GENERAL FORM 6295 Fourth Edition

Waukesha VHP Series Four 7042GL/GSI Engine System Manager Operation & Maintenance manual

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