ELECTRONIC SERVICE PROGRAM (ESP)
INFORMATION ON SAVING ESM SYSTEM CALIBRATIONS
The ESM system is designed to be used with various Waukesha engine families and configurations. Conse-quently, it must be tailored to work with site-specific information. This is achieved by calibrating (program-ming) an ECU with information that is appropriate for the engine and the site-specific application.
The ECU is programmed for the engine, using the ESP software on a PC at the engine site. Although ESP is saved on a PC, all programmed information is saved to, and resides in, the ECU. You do not need to have a PC connected with ESP running to operate an engine with the ESM system. ESP is only the software used to monitor engine operation, trouble-shoot faults, log data, and load new calibrations to the ECU.
The ECU contains both volatile (non-permanent) ran-dom access memory (RAM) and non-volatile (perma-nent) random access memory (NVRAM).
Once an engine is programmed in ESP, the values are saved in RAM in the ECU and become the active val-ues. RAM is used to evaluate programmed values before storing them to the ECU’s permanent memory.
The contents of RAM are lost whenever power to the ECU is removed, however the contents remain in ECU RAM even if the PC loses power or is disconnected from the ECU.
Table 3.00-1 Color Key for ESP User Interface Panels
COLOR MEANING
Gray Off (No Alarm)
Teal (Blue-Green)
Readings and Settings
(General operating information such as temperature and pressure readings) White Dials and Gauges
Green On or Normal System Operation Pink Low, Warmup, or Idle Signal Yellow Alarm or Sensor/Wiring Check
Red Warning or Shutdown
Dark Blue
User Programmable
(Very little programming is required for ESM system operation – see Section 3.10 ESP Programming for programming information)
INTRODUCTION TO ESP
To permanently save programmed values, the user must complete the steps in ESP necessary to save to the ECU. The new values are then saved permanently to NVRAM. When values are saved to NVRAM, the information is not lost when power to the ECU is removed. Once the values are saved to permanent memory, the previous save to permanent memory can-not be retrieved. The user can save unlimited times to ECU NVRAM (permanent memory).
USER INTERFACE PANELS
NOTE: Complete ESP user interface panel descriptions are provided in Section 3.05 ESP Panel Descriptions. The descriptions provided in this section provide only a general overview of each panel.
The ESM ESP software displays engine status and information:
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 corre-sponding tab or by pressing the correcorre-sponding func-tion key ([F#]) on the keyboard. The following paragraphs briefly describe each of these panels.
NOTE: The [F1] function key displays ESP’s electronic help file called “E-Help.” E-Help provides general system and troubleshooting information. See
“E-Help” on page 3.00-5 for more information. [F1] is not located on the PC screen as a panel; it is only a function key on the keyboard.
[F2] ENGINE: The Engine Panel displays current sys-tem readings of engine speed, left and right bank intake manifold pressures, oil pressure, intake mani-fold temperature, coolant temperature, and oil temper-ature (see Figure 3.00-2). Displayed under the engine speed is the engine setpoint RPM, percent of rated load, and estimated power. If a sensor or wiring failure is detected, the status bar, under the affected sensor, will change from teal (blue-green) to yellow, and a message will appear in the status bar telling the user to check sensor and wiring for proper operation. Also, the “Engine Alarm” field in the upper right corner will change from gray (deactivated/no engine alarm) to yellow (alarm). In case of a shutdown, the deactivated (gray) status bar under the “Engine Setpoint RPM”
field turns red and a message signals the user of the emergency shutdown.
Figure 3.00-2 Engine Panel
[F3] START-STOP: The typical engine Start-Stop Panel displays engine speed, throttle position, bypass control information, fuel control valve information, average intake manifold pressure (IMAP), and oil pres-sure (see Figure 3.00-3). The display also has signals for pre/post lube state, starting, ignition enabled, starter engagement, main fuel and if there is an emer-gency or normal shutdown. This panel also allows the user to make Start-Stop adjustments by calibrating pre/post lube time, purge time, cooldown, fuel on RPM, starter off RPM, and driven equipment ESD speed.
Figure 3.00-3 Start-Stop Panel
[F4] GOVERNOR: The Governor Panel displays engine speed, throttle feedback, throttle position per-centage, engine and remote RPM setpoints, and aver-age intake manifold pressure (see Figure 3.00-4). In addition, this display shows the current state of the alternate governing dynamics, load coming input, throttle alarm, remote RPM, and idle rpm activity. This panel also allows the user to make governor adjust-ments by calibrating gain, droop, load inertia, idle and other ESM system governing control features such as synchronization speed, feedforward adjustments, and auto actuator calibration.
[F2] Engine Panel [F8] AFR Setup Panel [F3] Start-Stop Panel [F10] Status Panel [F4] Governor Panel [F11] Advanced Panel [F5] Ignition Panel
If a sensor or wiring failure is detected, the status bar informs the user.
INTRODUCTION TO ESP
Figure 3.00-4 Governor Panel
[F5] IGNITION: The Ignition Panel displays engine speed, intake manifold pressure, ignition timing for each cylinder, ignition enabled, ignition level, maxi-mum retard, WKI value used, and knock detection (see Figure 3.00-5). This panel also allows the user to make IPM-D adjustments by calibrating high voltage, low voltage, and no spark limits. In addition, the WKI value and NOx emission levels are calibrated on the Ignition Panel.
Figure 3.00-5 Ignition Panel
[F8] AFR SETUP: The AFR Setup Panel is used to program and fine-tune the AFR system (see Figure 3.00-6). This panel displays intake manifold pressure, ambient air temperature, engine speed and torque, percent bypass, percent fuel control valve open, engine mechanical kW, generated kW, kW dif-ference, and kW transducer value. This panel also is used to enter the engine oxygen adjustment, parasitic load, transducer output, the start (or home) position, minimum/maximum stepper positions, gain, and gen-erator efficiency. The user can change from automatic to manual mode and adjust stepper position using the arrow buttons.
Figure 3.00-6 AFR Setup Panel
[F10] STATUS: The typical Status Panel displays the number of faults occurring in the system, if any type of shutdown is in process, if there is an engine alarm, and the engine start readiness (see Figure 3.00-7).
The ignition system status displays if the IPM-D is enabled, ignition energy level, maximum retard, and if there is engine knocking. The ECU status displays ECU temperature, battery voltage, ECU hours, and if calibrations, faults, and statistics are loaded. The engine status displays engine speed, engine setpoint, if remote RPM is enabled, low or high idle, state of the alternate governor dynamics, and if the main fuel valve is engaged.
The Status Panel also makes it possible for the user to view a log of all the current and historical faults (see
“Fault Log” in this section for more information), reset status LEDs, manually calibrate the throttle actuator, change all ESP panels from U.S. to metric units, and to view version details.
Figure 3.00-7 Status Panel
INTRODUCTION TO ESP
[F11] ADVANCED: The Advanced Panel is used to program MODBUS® settings and to program alarm and shutdown setpoints for oil pressure, jacket water temperature, intake manifold temperature, and oil tem-perature. Alarm and shutdown setpoints can only be programmed in a safe direction and cannot exceed factory limits.
In addition, all active system parameters can be logged into readable text. This allows the user to review, chart, and/or trend the data logged as desired.
Users can also send updated calibration information to the ECU, and to signify if a Waukesha alternator is installed (see Figure 3.00-8).
Figure 3.00-8 Advanced Panel FAULT LOG
The ESM system features extensive engine diagnos-tics capability. The ECU records system faults as they occur. A “fault” is any condition that can be detected by the ESM system that is considered to be out-of-range, unusual, or outside normal operating conditions. One method of obtaining diagnostic information is by view-ing the Fault Log usview-ing the ESM ESP software (see Figure 3.00-9). ESP displays the data provided by the ECU.
Figure 3.00-9 Fault Log
The Fault Log can be viewed by selecting the “View Faults” button on the [F10] Status Panel using the ESP software. 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.
E-HELP
ESP contains an electronic help file named E-Help (see Figure 3.00-10 for a sample screen). E-Help pro-vides 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 auto-matically 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. As an additional aid in troubleshooting, dou-ble-clicking a fault listed in the Fault Log will open E-Help directly to the troubleshooting information for that fault. See “E-Help” for more information.
Figure 3.00-10 Sample E-Help Screen