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TOPIC: Fuel System

IDENT NO: 9-4085


DATE: June 2017

275GL* SUPERSEDES: NEW

SUBJECT: Low BTU Fuel


MODELS AFFECTED: 12/16 275GL+ Engines

The purpose of this bulletin is to announce that


new fuel system setup instructions are available
for 275GL+ engines that operate on low BTU fuel.
The new instructions require reprogramming of
the Electronic Service Program (ESP) software
and the HMI. To reprogram the ESP and HMI,
follow the attached instructions in S-09043-99.

* Trademark of INNIO Waukesha Gas Engines, Inc.


All other trademarks are the property of their respective owners.

06/22/2017
Copyright © 2017, INNIO Waukesha Gas Engines, Inc. Page 1 of 1
275GL+ Fuel System Set-up Instructions

ESP setup
Connect the ESP computer to the ECU and open the service tool

Verify the workspace opens and screens are navigable

View fault list and record any faults on ESM. If any faults are present correct the faults before going
forward.

From any screen perform Manual Actuator Calibration, observe the throttle, wastegate and bypass
actuators and verify movement. Verify ALM223 calibrate actuators fault is no longer active.

Set the following values in ESP

From any screen, start editing.

On the F3 Start Stop panel


Prelube time to 90 seconds
Purge time to 5 seconds
Post lube time to 180 seconds

On the F4 Governor panel


Enter rotating moment of inertia for coupling and driven machine.

On the F5 ignition panel


NOx setpoint to 0.16 (g/nm^3) or 0.40 (g/BHP-hr.)
WKI to the field fuel WKI value.

On the F11 Advanced panel


Set the modbus baud rate to 19200
From any panel save all changes to the ECU

NOx Control Setup (HMI)


From the top screen access the fault list by pressing any button. Icons will appear, and then press
the alarm button.
Verify no faults are active. If any faults are active, manually record the faults and correct any faults
before going forward

CLASS II (INTERNAL CRITICAL)

C.C. --- ECO 159418 Rev. No. 103


TITLE - 275GL+ Fuel System Set-up Instructions DR. DMG 10-14-16
S-
CH. DMG 10-14-16
09043-99
Form M-1880 10/15 APP. DMG 10-14-16 Page 1 of 8
Navigate through the HMI screens and view the parameters vs. ESP for inconsistencies

Press the exit button (the door)


Press the step control button

Press the edit mode button and hold for 10 seconds to


enter edit mode.

Using the up/down button navigate to the start position. Using the small (25 steps) or large
(200 steps) buttons set the start position to 800 steps

CLASS II (INTERNAL CRITICAL)

C.C. --- ECO 159418 Rev. No. 103


TITLE - 275GL+ Fuel System Set-up Instructions DR. DMG 10-14-16
S-
CH. DMG 10-14-16
09043-99
Form M-1880 10/15 APP. DMG 10-14-16 Page 2 of 8
Navigate to the high limit and set stepper high limit to
5000 steps
Navigate to the low limit and set stepper low limit to 400
steps
Press the return key to save all changed values

Navigate to SEND HOME and press the return button


Home the stepper
and listen for the stepper to go home and back to the
start position

Fault correction
Follow steps in E-help to correct any ESM related faults.
Follow steps in E-help to correct any NOx control related
faults.

A. SYSTEM DESCRIPTION &PHYSICAL REQUIREMENTS


1. The main fuel valve is to be connected to the fuel system and control system according to S-
09000-120.

2. Opening and closing of the main fuel valve and pre-chamber fuel valve (mounted) is
controlled by the ESMTM.

3. A manual shutoff valve, placed upstream of the engine main shutoff valve (high-pressure gas
line), is recommended. This valve will assist initial engine start-up and will act as a visual gas
shutoff when engine is not in operation.

4. The main gas regulator (Fisher 1098) controls the Gas/Air via the regulator actuator to 4” ±
1.4” wc, (101.6 ± 38.1 mm wc).

CLASS II (INTERNAL CRITICAL)

C.C. --- ECO 159418 Rev. No. 103


TITLE - 275GL+ Fuel System Set-up Instructions DR. DMG 10-14-16
S-
CH. DMG 10-14-16
09043-99
Form M-1880 10/15 APP. DMG 10-14-16 Page 3 of 8
5. The 3” Main Adjusting Screw (MAS) is between the fuel regulator and the carburetor in the
Vee of the engine. The MAS valve is used to adjust fuel flow at rated speed and load, with
the NOx control functioning in Automatic, until the regulator actuator is at the proper steps.

6. The venturi carburetor housing for the 275GL+ takes inserts with various size holes. The
natural gas insert has 36 metering holes (24 in the cross member and 12 in the perimeter of
the Venturi, 0.236” (6 mm) diameter each).

7. The 1098 regulator has a sensing port labeled “vent” on the pilot actuator. This sensing port
is connected to the venturi carburetor housing through a 3/8” tube. Disconnect this tube at
the regulator end and confirm the regulator opening is drilled or orificed to 0.104” (#36 drill,
2.6 mm). It cannot be a larger or smaller opening.

B. FUEL SYSTEM ADJUSTMENT PRIOR TO ENGINE START-UP


1. Using the Human Machine Interface Panel (HMI) set the regulator actuator to 800 steps start
position.

2. On the HMI Navigate to the Stepper Control screen,


depress the ‘EDIT MODE’ button down for 10 seconds
until EDIT MODE is displayed on the top of the screen.
Move the selection arrow to Start Position and adjust the
steps to 800 and depress the enter/return arrow. The
Current position should match the start position and the
stepper should now be at 800 steps.

3. Initially adjust the MAS according to the charts below:

CLASS II (INTERNAL CRITICAL)

C.C. --- ECO 159418 Rev. No. 103


TITLE - 275GL+ Fuel System Set-up Instructions DR. DMG 10-14-16
S-
CH. DMG 10-14-16
09043-99
Form M-1880 10/15 APP. DMG 10-14-16 Page 4 of 8
4. Adjust pre-chamber gas over intake manifold pressure to 2” Hg. For initial adjustment, turn
pre-chamber regulator adjusting screw completely in and then back out 8 turns. Note: Low
BTU fuels may need higher pre-chamber gas over intake manifold pressure. See chart in
Section C, Step 7.

5. With manual fuel shut-off valve closed, crank engine for 15 seconds to verify adequate
purging.

C. ENGINE START-UP AND PRELIMINARY SETTINGS


1. Complete all pre-start activities and checks including checking oil and coolant levels,
adjusting valves (if needed), alignment and crankshaft deflection, rocker arm oiling, piping
tests, etc.…

2. Confirm engine coolant and lube oil are at least 60°F for reliable starting.

3. Open manual gas shut-off valve.

4. Prelube engine for 90 seconds.

5. Set operating speed to 750 RPM.

6. Crank engine for 15 seconds maximum. Engine should start in the first 7 to 8 seconds of
cranking cycle. (A 5 second delay from crank initiation to fuel valve opening is programmed
into ESM to purge unburned fuel from previous start attempts from the engine and fuel
system)

7. Adjust pre-chamber regulator according to the chart below:

CLASS II (INTERNAL CRITICAL)

C.C. --- ECO 159418 Rev. No. 103


TITLE - 275GL+ Fuel System Set-up Instructions DR. DMG 10-14-16
S-
CH. DMG 10-14-16
09043-99
Form M-1880 10/15 APP. DMG 10-14-16 Page 5 of 8
8. If engine fails to start, confirm fuel is reaching engine,
ignition is firing. Reduce regulator steps in 200 step
increments and re-try. Raise regulator steps in 200 step
increments and re-try. Repeated start attempt failures
may cause moisture to build on spark plugs. Crank
several times with fuel off to “dry” the spark plugs, and
repeat start attempts. To adjust steps, navigate to the
Stepper Control screen and depress the ‘EDIT MODE’
button for 10 seconds until EDIT MODE is shown on
the top of the screen. Move the selection arrow to
‘START POSITION’ and adjust the steps as desired
and then commit the entry by depressing the
enter/return arrow.

9. Once started, using HMI put NOx control in “Automatic”


and load engine to 75 psi BMEP. Allow engine to reach
operating temperature and control to start functioning.
The control is functioning when the actuator steps move.
To put the HMI in Auto mode, navigate to the Stepper
Control screen, depress the ‘EDIT MODE’ button for 10
seconds until EDIT MODE is shown on the top of the
screen. Move the selection arrow to the ‘AUTO/MANUAL’
mode selection and change to AUTO.
NOTE: The NOx Control initializes 1 minute after
reaching above 750 RPM and 105kPa (31” Hg) of IMAP
pressure. After that time is achieved then the system will
heat up and then go into automatic control within
approximately another minute if ‘AUTO’ is turned on.

CLASS II (INTERNAL CRITICAL)

C.C. --- ECO 159418 Rev. No. 103


TITLE - 275GL+ Fuel System Set-up Instructions DR. DMG 10-14-16
S-
CH. DMG 10-14-16
09043-99
Form M-1880 10/15 APP. DMG 10-14-16 Page 6 of 8
10. Slowly raise engine speed and load. While increasing load and speed observe the “reserve”
on the Engine Service Program (ESP). If reserve exceeds 14” HG, or falls below 10” HG,
hold load and speed steady until the reserve gets closer to 12” HG. This is a “learning”
process that the wastegate control goes through.

11. Continue to raise speed and load until reaching 1000


RPM and 100% torque.

12. Slowly adjust the MAS valve until actuator steps are 1200
±200. This can be viewed on the HMI Stepper Control
Screen listed as ‘CURRENT POSITION’.

13. If equipped with external NOx measurement instruments,


confirm engine operates at 0.35 to 0.45 g/bhp-hr NOx
(45-60 ppmv @ 11.5% O2)

14. Adjust NOx setpoint in ESM as required to meet above NOx setting. To do this, In the ESP
program navigate to the F5 Ignition screen and enter a value between 0.30 to 0.45 g/bhp-hr
NOx in the NOx setpoint window. NOTE: up to 1-minute delay time may be seen until the
NOx control updates the entered value. This is an ESM
program delay. Once changed the HMI should show the
newly entered setpoint and if In AUTO mode the control
will automatically change the AFR to achieve this value.

CLASS II (INTERNAL CRITICAL)

C.C. --- ECO 159418 Rev. No. 103


TITLE - 275GL+ Fuel System Set-up Instructions DR. DMG 10-14-16
S-
CH. DMG 10-14-16
09043-99
Form M-1880 10/15 APP. DMG 10-14-16 Page 7 of 8
15. Once finished with testing, the engine can be unloaded and reduced in speed as necessary.
The control will continue to control the AFR until the RPM
dips below 750RPM and/or the IMAP drops below
105kPA (31” Hg) at which time the stepper will lock steps.
If desired, the control can be put into manual and steps
can be adjusted as necessary. (To do this, navigate to the
Stepper Control screen, put the HMI into ‘EDIT MODE’
adjust the AUTO/MANUAL selection to ‘MANUAL’ and
then adjust the ‘CURRENT POSITION’ to the desired
steps and commit the entry using the enter/return arrow.

159418 10-16 ADDED FUEL RANGE DOWN TO 550 BTU/SCF. UPDATE FORM FORMAT

CLASS II (INTERNAL CRITICAL)

C.C. --- ECO 159418 Rev. No. 103


TITLE - 275GL+ Fuel System Set-up Instructions DR. DMG 10-14-16
S-
CH. DMG 10-14-16
09043-99
Form M-1880 10/15 APP. DMG 10-14-16 Page 8 of 8