DESCRIPTION

ESM
The Waukesha Engine System Manager (ESM®) is a total engine management system designed
®
to optimize engine performance and maximize uptime. The ESM integrates spark timing control,
speed governing, knock detection, start-stop control, diagnostic tools, fault logging, engine safeties
and Air/Fuel Ratio (AFR) control.
Engine System Manager
An Engine Control Unit (ECU) is the central “brain” of ESM. The ECU is an engine-mounted,
sealed module with five connection points. The ECU features: non-volatile, flash memory;
digital and analog I/O; internal monitors for system voltage and internal box
temperature.
The ESM provides useful diagnostics through the Electronic Service Program
(ESP). This includes fault logging and an electronic help file (E-Help) for trouble-
shooting. The MODBUS® data stream facilitates remote data access.
The ESM is factory mounted, wired and tested and includes sensors for lube oil
pressure and temperature, intake manifold pressure and temperature, and jacket
water temperature. Customer connections are only required to the local panel, the
fuel valve, and for power supply.

FEATURES AND BENEFITS

LOWER COST TO OPERATE – ESM IPM-D (Ignition Power Module - Diagnostic)
optimizes spark timing for varying load and speed conditions and works with AFR
to lower fuel consumption at various loads and speeds. Advanced diagnostics help
keep the engine in top running condition.
MAXIMIZES ENGINE UPTIME – By continuously monitoring combustion
performance through accelerometers, the ESM adjusts timing to keep the engine
running through changes in fuel quality or ambient temperature changes. The
ESM detects faulty sensors or wiring and provides diagnostic help to quickly
resolve problems. IPM-D provides automatically controlled dual ignition voltage levels to maximize
spark plug life. Predictive diagnostics of spark reference numbers can be used to monitor each
cylinder spark plug life.
SPECIFICATIONS
REMOTE MONITORING AND CONTROL – Remote monitoring is facilitated through a standard
MODBUS RTU slave connection using RS-485 multidrop hardware. Basic engine information is
also available through 5 analog 4-20mA outputs. Remote control is done through a customer
• Enhances engine performance
supplied local control panel. • Reduces fuel consumption
START-STOP CONTROL – After a start signal is received, ESM controls all sequencing of pre- • Remote access capability
lube, engine cranking, purge time, and fuel valve opening. For a normal stop command, ESM • Integrated rich burn AFR
controls the sequencing of any cool down, fuel valve closing and ignition off. • Start-stop control
ENGINE PROTECTION – There are numerous engine safeties to protect your investment • Engine protection
including knock detection, low oil pressure, engine overspeed, engine overload, high intake
• Fault logging
manifold temperature and high coolant temperature. Factory pre-programmed safeties result in
reduced packaging time. • ESP software included
IMPROVED SERVICEABILITY – The ECU is the single point of control and information. • E-Help troubleshooting
The ESP is run on a personal computer and is connected to the ECU through a RS-232 harness. • CSA Certification, Class I,
It provides current status, as well as a permanent fault history for alarms and shutdowns. IPM-D Division 2, Group D
provides diagnostic information for both the primary and secondary sides of the ignition coil. The • System requires nominal 24 V DC
ESP includes E-Help with step-by-step troubleshooting of any alarm or shutdown code. Quick (18 to 32 V DC) power supply
connection harnesses are used throughout to speed removal of any component, if necessary.
• Average system current draw:
The ESM includes all on-engine harnesses, a power distribution box and 25 foot (7.6m) customer 4.2 amps
interface harnesses for connection from the ESM to the local control panel. In addition, 50 foot (15m)
customer harnesses are available as an option code. ESP CD with E-Help is provided on a
CD-ROM.
ESM WITH AFR
(Rich Burn Air/Fuel Ratio)
AFR FEATURES AND BENEFITS
OPTIMIZING PERFORMANCE – By working as a integrated part of the ESM the
AFR continuously monitors the engine and adjusts the air/fuel ratio to the desired
mixture. The AFR maintains consistent emissions, while providing maximum power
and also increasing engine stability at part load and promoting longer catalyst life.
LOW MAINTENANCE – The AFR is factory mounted and tested. It requires
a minimal amount of set up information that is entered by the user with the
ESP program.
ACTUATOR, GAS REGULATOR
(AGR) DESIGN – The AGR is a step-
per motor driven actuator that
changes the position of the gas
SPECIFICATIONS regulator. All electronics are neatly
• Rich Burn Control packaged with the stepper motor in
an integral enclosure. The proximity
• Maintains emissions through load
switch is located inside the actuator
and speed changes
housing to prevent accidental
• Single fuel applications with varying breakage. A powerful, high torque
fuel quality stepper motor ensures reliable per-
• Factory mounted and tested formance, even under the most de-
• Automatic integrated control or manding conditions.
manual mode
• User-adjustable to site specific parameters
The AGR is controlled using signals transmitted over the ESM CAN (Controller Area Network)
• Simple to use communication bus, minimizing control wiring while providing robust communication.
OPERATOR INTERFACE – The ESM AFR control is equipped with several features to inform site
SYSTEM DESCRIPTION personnel of system status. These features are brought out in the ESP software on dedicated panels.
Waukesha’s ESM Air/Fuel Ratio (AFR) controls Information includes exhaust temperature, oxygen sensor output, oxygen sensor target setting,
the engine’s air/fuel ratio (afr) by regulating the actuator position, actuator travel limits, and any system faults should they occur. In addition, user
quantity of oxygen present in the exhaust stream. settings are available for start position, AGR travel limits, and oxygen sensor set point offset based on
The ESM AFR is designed to function with intake manifold pressure.
Waukesha’s ESM controlled, VHP™ GSI engines.
The ESM AFR regulates the engine’s air/fuel ratio
as a completely integrated part of the ESM to
AFR COMPONENTS
optimize the engine performance through changes The AFR control adds to the ESM configuration (for each bank of the engine) an exhaust oxygen
of engine load, speed, fuel pressure, fuel quality sensor, an actuator for the gas regulator, and an exhaust temperature sensor. In addition, other
and environmental conditions. The AFR control is sensor inputs already available to the ESM system, such as intake manifold pressure, are used. The
part of the ESM system, with all sensor inputs, oxygen sensor continually reports the concentration of oxygen in the exhaust to the AFR routine in
control routines, and output actions handled by the the ECU. The ECU controls the actuator to adjust the gas over air pressure and affect air/fuel ratio,
system ECU. in order to maintain the desired concentration of oxygen in the exhaust. The exhaust temperature
sensor reports post turbine exhaust temperature to the ECU.
The AFR actively monitors the exhaust tempera-
ture and oxygen content to adjust the afr. The AFR AGR diagnostic information is relayed back to the ECU over the CAN bus, for fail-safe operation and
controls over a very broad adjustment range to ease of troubleshooting.
accommodate large changes in fuel composition SYSTEM WIRING – The AFR control adds a minimum of wiring to the ESM system - the exhaust
and atmospheric conditions. Although the oxygen and exhaust temperature sensors require connections back to the ECU, and the AGR unit
adjustment range is broad, small adjustment steps requires only power and a connection into the 2-wire CAN communication bus.
are taken for very precise afr control.
ESM AFR control minimizes exhaust emissions
while maintaining peak engine performance even
with changes in engine load, fuel pressure, fuel
quality, and conditions.
 4

1 IGNITION POWER MODULE - DIAGNOSTIC (IPM-D) 3 GOVERNING CONTROLS

The spark timing is determined by calibration and can vary with engine The governor controls engine speed by controlling the amount of air/fuel
speed, intake manifold pressures, the WKI value and several other mixture supplied to the engine. The ESM ECU contains the governor logic
variables that optimize engine performance. that controls the actuator.
The IPM-D automatically controls dual voltage levels. IPM-D provides Governor control can be customized by inputs in the electronic service program.
diagnostic information for both primary and secondary sides of the ignition The ESM can be set to run in speed control or load control.
coil. The IPM-D detects shorted spark plugs and ignition leads,
as well as spark plugs that require a boosted energy level to fire or do The driven equipment’s rotating moment of inertia is the only customer
not fire at all. input that is required by the ESM.
Protected by U.S. Patent 6,567,774.
2 AFR
The AFR controls the engine’s air/fuel ratio by regulating the quantity of 4 ENGINE CONTROL UNIT (ECU)
oxygen present in the exhaust stream. The AFR control is part of the The ECU is the central module or hub of the ESM system. The ECU is
ESM with all sensor inputs, control routines and output actions handled by the single entry point of system control for easy interface and usability.
the ECU. Based on system inputs, the ECU logic and circuitry drive all of the
individual subsystems.
The ECU controls the actuator to adjust the gas over air pressure and
affect air/fuel ratio in order to maintain the desired concentration of oxygen
in the exhaust.
 ENGINE SYSTEM MANAGER (ESM)

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® 98 SE/Me/NT4 based environment.
The PC used to run the ESP software connects to the
ECU via a serial cable (RS-232).

COMMUNICATIONS
ESM uses MODBUS® (RS-485) communications. The ECU is capable of acting as a
MODBUS RTU slave at up to 19,200 baud over the RS-485 communications link.
The baud rate can be changed by using ESP to 1200, 2400, 9600 or 19,200 baud.
The lower baud rates are available to accommodate slower communications links
such as radio or microwave modems.
The MODBUS wiring consists of a two wire half duplex RS-485 interface.
RS-485 is ideal for networking multiple devices to one MODBUS master. Two
MODBUS wires are available at the end of the customer interface harness.
The ESM system has five 4-20 mA outputs that can be either read into a PLC or read
with a local display. The displays can be used for tachometer, oil pressure, coolant
temperature, or intake manifold pressure.

WAUKESHA ENGINE Consult your local Waukesha Distributor for system application
DRESSER, INC. assistance. The manufacturer reserves the right to change or
modify without notice, the design or equipment specifications as
1101 West St. Paul Avenue
herein set forth without incurring any obligation either with
Waukesha, WI 53188-4999 respect to equipment previously sold or in the process of
Phone: (262) 547-3311 Fax: (262) 549-2795 construction except where otherwise specifically guaranteed by
waukeshaengine.dresser.com the manufacturer.
Bulletin 7110 0905
Waukesha, VHP and ESM are trademarks/registered trademarks of Waukesha Engine, Dresser , Inc. All other registered trademarks, service marks, logos, slogans and tradenames are the properties of their respective
users. ©Copyright 2004 Waukesha Engine, Dresser, Inc. All rights reserved.