Application Notes
REMOTE MONITORING WITH ENGINE
SYSTEM MANAGER (ESM*)
Waukesha Engine now supplies an advanced engine controlling sys-
tem on the complete Series Four* engine line called Engine System
Manager (ESM). ESM has numerous engine control functions built
into one device, including spark timing control, speed governing,
detonation detection, Air/Fuel ratio control, stop/start sequences,
diagnostics, fault logging and engine safeties. In order for the con-
troller to analyze multiple engine parameters, numerous sensors are
fed into the “Brain Box” of the ESM system called the Engine Control
Unit (ECU). The ECU is continuously monitoring engine parameters
and it controls the engine based on discrete inputs to optimize engine
performance. In addition to controlling the engine, the ECU allows
the user to view engine parameters with the use of the Waukesha
Engine supplied software Electronic Service Program (ESP). Also,
it has the capability of transmitting engine parameters through a
MODBUS® protocol via an RS485 serial link.
VIEWING DATA LOCALLY
Figure 1 displays one of the ways that the ESM information can be
viewed locally using the ESP software. The ESP software allows the
user to access all information utilized by the ECU. Through ESP, the
user has the ability to set selected engine parameters such as the
pre/postlube time, min/max allowable RPM setting, etc. An interface
cable, Waukesha part number 740269, allows the user to connect
the ECU to a PC using a RS232 service port on the PC.
Figure 1
VIEWING DATA REMOTELY
Figure 2 shows data can be viewed remotely through ESP software
by connecting Waukesha’s 740269A ECU interface cable to a mo-
dem and transmitting the data over a phone line. The ESM Operation
and Maintenance manual describes the steps necessary to connect
to the ECU via modem. Information viewed remotely is displayed
in the same manner as if the ECU were connected locally to a PC.
Figure 2
REMOTE MONITORING WITH ESM
Remote Monitoring is becoming more advantageous with the small
population of field technicians available to work on a continually
growing population of engines. Waukesha Engine Dresser has im-
plemented a new ESM controls system that allows easy access to in-
formation for remote monitoring. Remote monitoring is the electronic
gathering done by two machines communicating with each other.
The MODBUS® protocols can be used in two different modes: RTU
(Remote Terminal Unit) and ASCII (American Standard Code of
Information Interchange). The ESM system works only in the RTU
mode. The ECU is a MODBUS® slave that provides data to a MOD-
BUS® master device. The data available includes a combination of
filtered analog input values and derived values. No control is done
through MODBUS®.
REMOTE MONITORING USING RADIO WAVES
Remotely monitoring with radio waves allows a user to transfer data
collected up to 20 miles from the site. Figure 3 shows the layout for
remotely monitoring via a radio wave connection. This type of data
transfer allows the user to create a cost effective system if the units
to be monitored are all located within a 20-mile radius of the central
station. A MODBUS® RS485 serial interface to radio wave converter
is required to transmit the data via radio wave signaling. The signal
is converted from a serial RS485 input to a radio wave output.
The radio wave is transmitted from the on-site converter to a receiver
found at the central data station. When the receiver gets the signal, it
collects the data for conversion to a network readable format. Once
you have sent the data to the Supervisory Control And Data Acquisi-
tion (SCADA) web hosting network, it can be uploaded to a database
and utilized to monitor the equipment running on site.
The data hosting network may require data conversions in order to
utilize the data sent.
Application Notes

Remotely Monitoring the ESM® system through MODBUS®

Engine Mounted
ESM Communicating
via Modbus RS 485
Customer
Supplied PLC

RadioModem
Radio

RadioModem

`
Satellite Network
Connection
Satellite Receiver Internet
Backhaul End User

Communications Cellular
Cellular Receiver
Converter `
SCADA Web
Host
Modem

Ethernet
Phone Connection
Modem

Figure 3. The schematic shows the five main types of remote monitoring equipment: radio frequencies,
cellular communications, satellite communications, a direct internet connection, and modem connections.

REMOTE MONITORING USING CELLULAR
COMMUNICATIONS
Remotely monitoring with a cellular interface also requires a MOD-
BUS® conversion. Figure 3 shows the layout for remotely monitoring
via a cellular transfer. This type of data transfer allows the user to
monitor remote locations as long as there are cellular towers within
reach of the cellular transmitter. The RS485 serial cable is run from
the ECU unit to a communications gateway which converts the
MODBUS® RS485 serial input to a transmittable cellular signal.
The cellular signal is then transmitted from one cellular tower to
the next until it reaches the final destination. A cellular receiver is
required to receive the signal and transmit the data to a central net-
work. Once the data is sent to a SCADA web hosting network it can
be uploaded to a database and utilized to monitor the equipment
running on site.
The network where the data is hosted may require data conversions
in order to utilize the data being sent.
REMOTE MONITORING USING SATELLITE
COMMUNICATIONS
Remotely monitoring with satellite communications requires a MOD-
BUS® conversion and gateway to satellite communications. Figure 3
shows the layout for remotely monitoring via a satellite data transfer.
This type of data transfer is available anywhere that a satellite signal
can be sent into the sky.
There are two different types of data transfer allowed with satellites:
geosynchronous and Low Earth Orbiting (LEO) satellite communica-
tion. Geosynchronous satellites orbit so they are always in the same
position relative to any given location on the earth. These satellites
are mainly used by large broadcasting companies and require
southern exposure by the satellite transmitter. The user should be
able to communicate between the network and the engine as long as
southern exposure is not lost. The data can be sent instantaneously;
however, transmitting large amounts of data can be expensive.
The second type of satellite communication is LEO satellites which
orbit the earth at a much faster speed than the earth revolves. Many
LEO satellites pass by a site numerous times an hour. This type
of communication only requires exposure to the sky and can be
reached in almost any location. This communication can be much
more cost effective when compared to geosynchronous satellites.
The RS485 serial cable is run from the ECU unit to a communica-
tions gateway which converts the MODBUS® RS485 serial input to
a transmittable satellite signal.
The satellite signal is then transmitted from the transmitter to either
a geosynchronous or Low Earth Orbiting satellite and then back to
a satellite receiver. When the receiver gets the signal, it collects the
data for conversion to a network readable format.
Once the data is housed on a SCADA web hosting network the user
can utilize the data. The data can be uploaded to a database and
utilized to monitor the equipment running on site.
Application Notes

REMOTE MONITORING THROUGH NETWORK Governing/Speed Control

CONNECTION
The ability to remotely monitor equipment through a direct network
connection is only allowable when a local internet connection is
available on site. If a local internet connection is available on site,
the customer would be required to install a MODBUS® communica-
tions gateway with one Ethernet output and one RS485 serial input.
The converter will take the MODBUS® serial link and convert the
signal to an Ethernet compatible output. The information could then
be hosted on a web site and monitored remotely from any network
connected to the worldwide web. This would require security if only
specified users are to have access to the site. Once the information
is accessible on the internet it is up to the user to determine how they
would like to use the information.
REMOTE MONITORING USING MODEM
COMMUNICATIONS
Remotely monitoring with a typical phone modem requires a MOD-
BUS® conversion. Figure 3 shows the layout for remotely monitoring
via a standard telephone connection. This type of data transfer is
limited to the availability of a dedicated telephone line. The RS485
serial cable is run from the ECU unit to the communications gateway.
In this instance the gateway could be in a separate module to convert
the serial MODBUS® signal to an appropriate signal capable of be-
ing transmitted directly through a standard modem.
Once the data is housed on a SCADA web hosting network the user
can utilize the data. The data can be uploaded to a database and
utilized to monitor the equipment running on site.
ESM Engine System Manager
ESM controls and monitors your engine with precision, enabling it
to continuously perform at its best and achieve the highest possible
productivity. In short, equipping your engine with ESM is like having
an engine operator on-site around the clock. Also standard with ESM, knock detection helps automatically protect
Ignition Power Module Diagnostics
• Optimizes spark timing for varying loads and speeds.
• Provides cylinder-specific ignition system diagnostics.
• Maximizes engine uptime by continuously monitoring engine
performance.
• Provides diagnostics and offers troubleshooting via E-help if faulty
sensors or wiring are detected.
• Adjusts automatically according to changing load conditions.
Start/Stop Logic
• Controls all sequencing upon receiving a start signal including
pre- and post-lube.
Engine Protection
• Detects per cylinder engine knock and monitors low oil pres-
sure, engine over-speed, driven equipment over-speed, engine
overload, high intake manifold temperature, and high coolant
temperature.
E-Help
• Offers electronic help files that walk users through troubleshooting.
Electronic Service Program (ESP)
• Includes software that allows you to view what the engine is doing
and adjust user parameters at no additional charge.
ESM Air Fuel Ratio Control
Integrated into the ESM module, the Air Fuel Ratio (AFR) control
comes standard with ESM and keeps your engine running smoothly
and efficiently.
• Offers catalyst rich-burn control .995 Lambda
• Option available on low-pressure fuel systems.
• Arrives factory-mounted and tested.
• Maintains emissions through load and speed changes.
• Features a self-contained stepper motor.
• Offers default settings, but user-adjustable to site conditions.
• Uses a more accurate Lambda control than O2 voltage.
• Uses dithering to provide a wider catalyst compliance window.
• Designed for ease of use.
ESM Knock Detection
your engine with a series of valuable features.
• Self-calibrating.
• Monitors every firing event.
• Controls timing proportionally depending on knock severity.
• Records cylinder-specific shutdowns in the ESM fault file.
• Field Proven.

INNIO* is a leading solutions provider of gas

engines, power equipment, a digital platform
and related services for power generation and
gas compression at or near the point of use. With
our Jenbacher* and Waukesha* product brands,
INNIO pushes beyond the possible and looks
boldly toward tomorrow. Our diverse portfolio of
reliable, economical and sustainable industrial gas
engines generates 200 kW to 10 MW of power for
numerous industries globally. We can provide life
cycle support to the more than 48,000 delivered
gas engines worldwide. And, backed by our service
network in more than 100 countries, INNIO connects
with you locally for rapid response to your service
needs. Headquartered in Jenbach, Austria, the
IWK-319020-EN
business also has primary operations in Welland,
Ontario, Canada, and Waukesha, Wisconsin, US.
*Indicates a trademark
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