TOPIC: Turbochargers

IDENT NO: 13-4036

DATE: October 2015

275GL+ * SUPERSEDES:

SUBJECT: 275GL+ Turbocharger Control Description in Manual Correction

NEW

MODELS AFFECTED: 275GL+

The purpose of this bulletin is to inform the field
about a correction to Form 6354-2, 275GL+ with
ESM Operation & Maintenance Manual.
Tape or staple the pages attached to the end of
this bulletin into Form 6354-2 as replacement
pages.
The manual states on page 2.25-3 that the
customer can reset the wastegate learning
table by clicking the “Reset BYC Boost Table”
button. However, it is actually necessary to click
all 3 buttons in the Reset Learning Tables
window (see Figure 1) to reset the wastegate
learning table.
Figure 1: Reset Learning Tables Window
The complete corrected information follows.
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 in at a given
rpm and IMAP. For a given rpm and IMAP, a
bypass position is mapped to ensure the engine
is operating at the optimal point in the turbo
compressor map.
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
IMAP. The throttle reserve map represents what
the desired reserve pressure should be in at a
given speed 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.
Once the wastegate has learned the new
position that provides proper throttle reserve for
a given speed and IMAP, 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.

* Trademark of INNIO Waukesha Gas Engines, Inc.

All other trademarks are the property of their respective owners.

10/20/2015
Copyright © 2015, INNIO Waukesha Gas Engines, Inc. Page 1 of 2
Service Bulletin No. 13-4036

There is a fixed, calibrated limit on the engine

and the wastegate position is allowed to deviate
from its initial, unlearned position map, while the
engine is running.
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
reserve to change (exhaust leaks, significant
changes in fuel or ambient conditions, etc.). The
wastegate control would begin to close in order
to increase reserve (or open to decrease
reserve), and that wastegate position could
then become the learned value for that given
speed and IMAP. When the problem that caused
the throttle reserve to change is fixed or Figure 3: Reset Learning Tables Window
ambient conditions return to a more normal
state, the map may have a bad value in that 4. Click all three buttons to reset the learning
particular spot. If the engine returns to that table. The turbocharger control will now
speed and IMAP point in the map, it may operate with the original table from when
become unstable and it could be necessary to the engine was built.
reset the learning tables. See RESETTING 5. Restart the engine, and allow the control to
LEARNING TABLES on page 2 for more information. relearn its positions.
RESETTING LEARNING TABLES
1. Shut engine down.
2. In ESP go to the [F11] Advanced panel (see
Figure 2).

Figure 2: Advanced Functions Panel

(16V 275GL + Shown)

3. Click the “Reset Wastegate Learning Table”

button to bring up the “Reset Learning
Tables” pop-up window (see Figure 3).

10/20/2015
Copyright © 2015, INNIO Waukesha Gas Engines, Inc. Page 2 of 2
ESP AND HMI FIELD DESCRIPTIONS
“SPARK REF #”
• ESP 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 IGNITION DIAGNOSTICS on
page 2.15-6 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.
“SPARK TIMING”
• HMI Screens: <ED3>, <ED4>, <ED5>
See “IGN TIMING (LEFT BANK)” on page 3.20-15.
“START COUNTDOWN”
• HMI Screen: <ED5>
See “PRELUBE TIME” AND “PRELUBE TIMER” on
page 3.20-19.
“STARTER”
• ESP 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”
• ESP 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.
3.20-20
“STARTING SIGNAL”
• ESP 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 (<3.3 volts), this field
is gray and displays “OFF”.
“STATS LOADED”
• ESP Panel: [F10]
Status field displaying if ECU has statistics loaded. The
“Stats Loaded” field should always be green and display
“OK”. If this field is red and displays “NO”, contact your
local INNIO Waukesha Distributor for technical support.
“STEPPER CURRENT POSITION”
• HMI Screens: <ED6>, <ST1>
This field displays the current position of the stepper
motor. Located under this field are buttons used to adjust
the stepper position while the engine is running. See
STEPPER CONTROL on page 3.30-1.
“STEPPER HIGH LIMIT”
• HMI Screens: <ED6>, <ST1>
This field allows the user to program the high stepper
limit. By defining the stepper motor adjustment range,
the user can maintain stable engine operation and set
limits for troubleshooting. See STEPPER CONTROL on
page 3.30-1.
“STEPPER LOW LIMIT”
• HMI Screens: <ED6>, <ST1>
This field allows the user to program the low stepper limit.
By defining the stepper motor adjustment range, the
user can maintain stable engine operation and set limits
for troubleshooting. See STEPPER CONTROL on page
3.30-1.
“STEPPER STARTING POSITION”
• HMI Screens: <ED6>, <ST1>
User-programmable field for setting the AGR steps
during starting. See STEPPER CONTROL on page
3.30-1.
“SYNC RPM”
• ESP Panel: [F4]
This field allows the user to program a synchronized rpm
to allow easier synchronization to the electric grid. The
rpm programmed in this field is added to the engine
setpoint rpm. The synchronous rpm can be programmed
from 0 to 64 rpm.
Form 6354-2
© Copyright 2019, INNIO Waukesha Gas
Engines, Inc.

“SYSTEM”
• ESP Panel: [F10]
This field alerts the user when the ESM activates a
shutdown. During an ESM shutdown, the field turns red
and displays “E-SHUTDOWN”. When this field indicates
E-SHUTDOWN, a 24 VDC signal to the customer is
provided through the Customer Interface Harness.
When the engine is not in an emergency shutdown
mode, the field is gray and displays “OK”.
“THROTTLE FEEDBACK”
• ESP Panel: [F4]
This field displays the throttle actuator’s position in mA.
4 mA = 0%; 20 mA = 100%.
“THROTTLE POSITION %”
• ESP Panels: [F3], [F4]
• HMI Screens: <Q3>, <ED2>
This field displays throttle position in terms of the
percentage the throttle valve is open.
“THROTTLE RESERVE”
• ESP Panels: [F2], [F3], [F4]
This field displays the engine’s pressure differential
across the carburetor and throttle plate. Units are in kPa
(in.-Hg) absolute.
“USER ADJUSTABLE ALARM AND SHUTDOWN
SETPOINTS”
• ESP 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
PROGRAMMING ALARM AND SHUTDOWN
SETPOINTS on page 3.25-14 for more information on
programming these fields.
“USER ESD”
• ESP Panels: [F3], [F5], [F10]
This field signals that an emergency shutdown is in
process based on a customer input. During an
emergency shutdown, the field is red and signals the
user that an emergency stop is active by displaying
“E-STOP”. When “E-STOP” is displayed, the engine
cannot be restarted. When the engine is not in an
emergency shutdown mode, the field is gray and
displays “RUN”.
3.20-21
ESP AND HMI FIELD DESCRIPTIONS
“USER RUN/STOP”
• ESP Panels: [F3], [F10]
This field signals that a normal shutdown is in process
based on customer input. During a normal shutdown, the
field is red and displays “STOP”. When “STOP” is
displayed, the engine cannot be restarted. When the
engine is not in a shutdown mode, the field is gray and
displays “RUN”.
“USER WKI”
• ESP Panel: [F5]
User-programmable field for entering the INNIO
Waukesha Knock Index (WKI) value of the fuel. This field
must be programmed by the user for proper engine
operation.
“USER WKI IN USE”
• ESP Panel: [F5]
This field displays the INNIO Waukesha Knock Index
(WKI) value and indicates whether WKI value used by
the ESM is based on the user-defined value
programmed in “User WKI” or is remotely inputted to the
ECU using a 4 – 20 mA optional user input. When the
WKI value is programmed in ESP, the field indicates
“User WKI in Use”. When the WKI value is being inputted
in real time through the optional analog user input, the
field indicates “Remote WKI in Use”.
“VOLTAGE (VOLT)”
• HMI Screen: <ED5>
See “BATTERY VOLAGE” on page 3.20-11.
“WASTEGATE POSITION %”
• ESP Panels: [F3], [F4]
• HMI Screen: <ED2>
This field displays the percentage that the wastegate
valve is open.
“WKI”
• HMI Screen: <ED3>
See “USER WKI” on page 3.20-21.
Form 6354-2
© Copyright 2019, INNIO Waukesha Gas
Engines, Inc.
 TURBOCHARGER DESCRIPTION
Bypass, Wastegate and Throttle Reserve Maps Resetting Learning Tables
The bypass valve position is controlled by a bypass map. 1. Shut engine down.
This bypass map represents the position the bypass 2. In ESP go to the [F11] Advanced panel (see Figure
valve should be in at a given rpm and IMAP. For a given 2.25-3).
rpm and IMAP, a bypass position is mapped to ensure
the engine is operating at the optimal point in the turbo
compressor map.
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 IMAP. The throttle reserve
map represents what the desired reserve pressure
should be in 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
Figure 2.25-3: Advanced Functions Panel
increase reserve. In order for the wastegate control to (16V 275GL + Shown)
learn a new position, the engine speed and throttle must
be stable. 3. Click the “Reset Wastegate Learning Table...”
button to bring up the “Reset Learning Tables” pop-
Once the wastegate has learned the new position that up window (see Figure 2.25-4).
provides proper throttle reserve for a given speed and
IMAP, 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 fixed, calibrated limit on the engine and the
wastegate position is allowed to deviate from its initial,
unlearned position map, while the engine is running.
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 reserve to change (exhaust leaks,
significant changes in fuel or ambient conditions, etc.).
The wastegate control would begin to close in order to
increase reserve (or open to decrease reserve), and that
wastegate position could then become the learned value
Figure 2.25-4: Reset Learning Tables Window
for that given speed and IMAP. When the problem that
caused the throttle to go wide open is fixed or ambient 4. Click all three buttons to reset the learning table. The
conditions return to a more normal state, the map may turbocharger control will now operate with the
have a bad value in that particular spot. If the engine original table from when the engine was built.
returns to that value, it may become unstable and it could 5. Restart the engine, and allow the control to relearn
be necessary to reset the BYC IMAP learning table. See its positions.
Resetting Learning Tables on page 2.25-3 for more
information.

Form 6354-2
2.25-3 © Copyright 2019, INNIO Waukesha Gas
Engines, Inc.