GE Power SERVICE BULLETIN

TOPIC: Electronic Controls

Waukesha* gas engines IDENT NO: 17-41038
DATE: January 2019
SUPERSEDES: 17-4103A

SUBJECT: Start Improvement Software

MODELS AFFECTED: 12V275GL+ and 16V275GL+ Engines

The purpose of this bulletin is to inform the field that If the fuel system has not been set up previously or
updated NOx Control Module (NCM) software with needs adjustment:
added starting functionality is available to address
1. Follow the instructions in the "Fuel System
difficult starting of a 12V275GL+ or a 16V275GL+
Adjustment" (page 3.00-4) and the "Initial Start-Up
engine. If starting a 275G L+ engine requires manual
Procedure" (page 3.00-5 - 3.00-8) sections of
adjustment of the stepper motor position, new NCM
Form 6354-2, 275GL+ with ESM Operation and
software with enhance:d air/fuel ratio control
Maintenance Manual.
functionality to reduce or eliminate manual intervention
is available from GE Waukesha. Please contact Brad 2. Before initial start of the engine, set stepper
Schieble at: [email protected]. This update offer START position to 0 steps. If the purge time
expires one year from the date this bulletin is programmed in ESP is greater than the default
published (August 2019). value of 2 seconds, a higher stepper position may
be required (see Tip #3 below).
What's new:
3. If engine does not start, increase START position
• NCM programmed with enhanced air/fuel ratio
to 500 steps.
control functionality.
4. After adjusting the MAS valve at full speed and
• Determines the correct stepper position for starting
load , shut down engine.
the engine and ramping up to idle speed.
5. Reset the START position to approximately 50% of
• Adds fuel as necessary before NOx sensor is
the actual value required to start the engine.
activated.
Restart engine to confirm fuel system setup is
• Calibration improvements for transition to closed- correct.
loop air/fuel ratio control.
Tips for setup:
SETUP GUIDE TIP 1: The starting strategy consists of a series of up
to three stepper position sweeps. Please see
If the fuel system has been set up previously: Figure 1 far example of the start assist
1. Before removing or programming original NCM , sequence.
note current or typical stepper start position,
stepper fence positions and NOx setpoint.
2. Replace or program original NCM.
3. Once the NCM with updated software is powered
on, program the stepper START position to 50% of
the original value. Program the original stepper
fence positions and NOx setpoint.
4. Start engine.

* Trodemork of General Electric Company

All other trademarks are the property of their respective owners .

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Copyright© 2019, Generol Electric Co. Page 1of3
 Service Bulletin No. 17-41036

Start Assist Example

1500
1400
1300
1200
1100
1000
900
800
1100 RPM I ------------
,... --------- ... _ -------
, .," --
;
700
600 ,,,
500 I500 RPM I,,/
I
400 ,,I

I
300 I
" I
200 I 1so RPM J/ '"

100 ,
I

, ,---------" --- Engine Speed -Stepper Position

0 ·-----" -
0 10 20 30 40 so 60 70
Time (Seconds)

I Figure 1: Start Assist Example

1. The first sweep occurs while cranking, during Parameters available to adjust for setting up the
which time the stepper motor will adjust by starting strategy:
increasing steps at a rate of 100 steps/s beginning
1. Stepper Start Position (set in HMI) - Stepper
3 seconds after the main fuel valve opens and
position at which the initial sweep will begin (see
continuing until the engine speed surpasses 150
Tips 3, 4, 5 and 6).
RPM , crank timeout (20 seconds) occurs, a 2000-
step limit is reached, or the user-adjustable 2. Stepper High Limit (set in HMI) - Maximum
maximum stepper position (High Limit) is reached. stepper position limit (see Tip 6).
2. A second stepper position sweep will only occur if 3. Purge Time (set in ESP) - Delay time after first
the engine speed does not reach 500 RPM within engine rotation before the Main Fuel Valve and
3 seconds. This sweep will run at a rate of 50 ignition are turned on (see Tips 4 and 5).
steps/s and will stop once 500 RPM is reached, a
4. Main Fuel On RPM Adjust (set in ESP) - Adjusts
2000-step limit is reached, or the user-adjustable
maximum stepper position (High Limit) is reached. the RPM threshold at which the Main Fuel Valve
opens.
3. A third stepper position sweep will only occur if the
engine speed does not reach 700 RPM within 5
seconds of reaching 500 RPM.

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Copyright © 2019, General Electric Co. Page 2 of 3
 Service Bulletin No. 17-41038

TIP 2: The stepper START position must always be set • Stepper Position Adjustment - In general, the Start
lower than the actual stepper position required Improvement Software automatically adjusts t~e
to start the engine. stepper position as necessary to start the engine,
TIP 3: A purge time programmed in ESP will shorten thereby reducing or eliminating the need for manual
the amount of time the stepper will adjust by the stepper adjustment while starting. Therefore, the
calibrated purge time value. The longer the fuel system must be in proper working order and
calibrated purge time, the shorter the amount of adjusted correctly for successful start attempts. The
adjustment time the stepper will have. Start Improvement Software cannot overcome .
Increasing the purge time may require setting mechanical issues in the fuel system such as failed
the stepper START position closer to (but still admission valves, a misadjusted MAS valve, etc.
less than) the required position to start the Additionally, fluctuating or inconsistent fuel
engine. pressure, temperature and WKI may require
readjustment of the fuel system settings for
TIP 4: If a customer fuel shutoff valve is located successful starts.
upstream of the ESM controlled main fuel valve,
and the two valves are opened simultaneously • Loading the Engine - The Start Improvement
when starting the engine, there may be a Software can assist in loading the engine before the
transient delay for fuel to reach the main fuel NOx control is activated. If load is applied before the
regulator on the engine. This may also be the NOx control is activated and the engine speed
case with a "double block and bleed" fuel shutoff drops more than 25 RPM from the speed setpoint
valve system, If this delay is significant, the for more than 2 seconds, the stepper position will
stepper motor position sweep during cranking increase by 50 steps/s. The stepper position will
increase until the engine speed reaches the speed
may end up at a position that is too rich at i?le
for stable operation or even to start the engine. setpoint, a 500-step offset from the stepper position
If this is an issue, account for this delay by when the sweep began is reached, or a 2000-step
limit is reached.
increasing the purge time or reducing the
stepper START position. If this does not • Idling the Engine - It is not recommended to idle the
address the issue, the customer fuel valve may engine for an extended amount of time. However, if
need to open several seconds before the ESM an engine is idled for at least 5 minutes below an
main fuel valve. intake manifold pressure of 90 kPa (26.6 in-Hg), the
TIP 5: Stepper position limits: The Low Limit is now Start Improvement Software will reduce the stepper
only in effect when the NOx control is in closed- position by 15% at a rate of 10 steps/s. The engine
loop mode to not interfere with the starting can be loaded during this sweep as the stepper
routine. There is no change to the High Limit. It position can increase to help accept load as
described above.
is always in effect and can be set to limit the
maximum stepper position at any time. • NOx Sensor and Control - Once the NOx sensor
TIP 6: If a start attempt fai ls, the stepper position will activates and NOx control enters closed-loop, all
remain at the last position of the sweep. When starVload assist and lean-out features of the start
the next start attempt is initiated, the stepper improvement software are disabled and will activate
again during the next start attempt.
position will change back to the START p~~ition.
There is no need to manually set the pos1t1on • Closed-Loop NOx Control - To improve engine
back to the START position. performance during the transition to closed-loop
TIP 7: When "Manual" control is selected, the stepper NOx control, the time until this transition takes place
position will be fixed when starting the engine has been increased by 15 seconds on the
and the start routine will not occur. Set to "Auto" 16V275GL+ and by 45 seconds on the 12V275GL+.
to enable the start routine.
NOTES:
• Stepper Motor Reset - The stepper motor
automatically resets to the HOME position upon
shutdown and automatically goes to the START
position at start-up. For more information on the
stepper motor function, please consult the
appropriate Operation & Maintenance Manual.

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