Instruction

Title: ESM tuning and calibrating instruction Doc ID: DAAB038320

Project: - Revision: b
Authors: J. Böling Status: Finalized
Engine Division Date: 10.09.2004 / 11.11.2005 Pages: 1/9

Tuning and calibrating instructions for ESM-10

Table of content:

1 ESM-10 tuning instructions.........................................................................................................2

1.1 Tools needed for ESM tuning.................................................................................................2
1.2 How to do the tuning...............................................................................................................2
2 ESM-10 calibrating instructions..................................................................................................3
2.1 Tools needed for complete ESM calibration...........................................................................3
2.2 PT-100 inputs for HT water temperature measuring..............................................................3
2.3 4-20mA input for lubricating oil pressure measuring.............................................................4
2.4 Engine speed frequency inputs................................................................................................4
2.4.1 Calibration of f/U conversion for speed sensor 1 input..................................................4
2.4.2 Calibration of f/U conversion for speed sensor 2 input..................................................4
2.5 Engine speed analogue outputs...............................................................................................5
2.6 Turbo charger speed analogue outputs....................................................................................5
3 Test connectors in ESM................................................................................................................6
4 ESM setting table, DAAB038630 rev. a......................................................................................7

Revision b: Corrections to turbo charger speed analogue output calibration procedure

 Doc ID: DAAB038320 Revision: a 2/9

1 ESM-10 tuning instructions

1.1 Tools needed for ESM tuning

Always use calibrated instruments when tuning the ESM
 24VDC power supply
 Multimeter or instrument for voltage measurement
 Frequency generator
 ESM test adapter, PAAE004087
 Small screw driver (0.30 x 1.5)
 2,5mm hexagon key for hexagon socket screws

1.2 How to do the tuning

1. Fill out the ESM-10 settings table, DAAB038630, described in figure 1and 2 in chapter
4. You will automatically get the positions and values needed to trim the module.
2. Power OFF the ESM
3. Remove the cover of the ESM by un-screwing the 7 hexagon socket screws. Pay
attention so the lightbars in the cover don’t get damaged.
4. Locate the configuration switches with the help of the layout picture, figure 3 in chapter
3 in this document.
5. Set the switches in the correct positions according to the output table from the
configuration sheet.
6. Connect the test adapter to test connector XP3, PAAE004087.
7. Before powering on the ESM be sure that there is nothing laying on the PCB that can
cause any short circuits.
8. Power ON the ESM.
9. Use a calibrated multimeter to measure the limits for the speed switches and speed
windows. Measurement points in table 1 and also in the PCB layout picture.
Table 1, test connector XP3 in ESM

10. Adjust the speed switch and speed window limits to the correct values according to the
output table on the configuration sheet.
11. Connect a frequency generator to the engine speed sensor 1 input, (X13-2, X13-3)
Adjust the frequency to the same as the frequency from the engine speed sensors at
nominal engine speed. The speed signal high level has to be min.15 V.
 Doc ID: DAAB038320 Revision: a 3/9

12. Measure Vmax, XP3-12, it should now be 1,000V. If not, check the input frequency and
the actual speed settings, S701-705 and S711-715. If still not Ok, see calibrating
instructions for ESM-10, chapter 2.
13. Measure Vdisplay, XP3-14 and adjust the Vdisplay voltage to the correct value according to
the output table from the configuration sheet. This is to be done while the input
frequency is equal to the frequency from speed sensors at nominal engine speed, 100%.
14. Power OFF the ESM and disconnect the test adapter and the frequency generator
15. Put back the module cover and tighten the screws holding it.
16. The ESM is now ready to be installed.
17. After tuning an ESM-10 make sure that the “as tuned” setting values are stored
properly for later use.

2 ESM-10 calibrating instructions

The ESM is calibrated at the module manufacturer. Normally the ESM doesn’t need to
be re-calibrated only configured to fulfil the requirements of the installation where it is
going to be used.
If for some reason it is necessary to re-calibrate the ESM, please follow the following
instructions.

2.1 Tools needed for complete ESM calibration

Always use calibrated instruments when performing calibration to the ESM!
 24VDC power supply
 Multimeter
 Frequency generator
 PT-100 calibrator / simulator
 4-20mA calibrator
 ESM test adapter, PAAE004087
 Small screw driver (0.30 x 1.5)
 2,5mm hexagon key for hexagon socket screws

2.2 PT-100 inputs for HT water temperature measuring

1. Power OFF the ESM and remove the module cover
2. Connect the test adapter, PAAE004087, to test connector XP2.
3. Connect a PT-100 simulator, (3-wire), to the input for HT water temp. A, X13-4, 5, 6
4. Power ON the ESM
5. Set the input temperature to 0°C, (= 100,000Ω)
6. Measure the voltage in point XP2-1 and adjust it to 0,000V by turning trimmer P300
7. Set the input temperature to 100°C, (=138,506Ω)
8. Measure the voltage in point XP2-3 and adjust it to 0,625V by turning trimmer P301
9. Repeat points 5-8 until the values are OK
10. Make sure that switch S402 is in the OFF position, (enable HT water temp. B input)
11. Connect the PT-100 simulator to the input for HT water temp. B, X14-4, 5, 6
12. Set the temperature to 0°C, (=100,000Ω)
13. Measure the voltage in point XP2-2 and adjust it to 0,000V by turning trimmer P302
14. Set the temperature to 100°C, (=138,506Ω)
15. Measure the voltage in point XP2-4 and adjust it to 0,625V by turning trimmer P303
16. Repeat points 12-15 until the values are OK
17. Calibration of the PT-100 inputs for HT water temp. is now ready
18. Power OFF the ESM and mount the module cover
 Doc ID: DAAB038320 Revision: a 4/9

2.3 4-20mA input for lubricating oil pressure measuring

1. Power OFF the ESM and remove the module cover
2. Connect the test adapter, PAAE004087, to test connector XP2
3. Connect a 4-20mA signal calibrator to the input for L.O. pressure sensor, X14-7, 8
4. Make sure that the 4-20mA signal calibrator is not in source mode
5. Power ON the ESM
6. Set the mA signal to 4,000mA
7. Measure the voltage in point XP2-5 and adjust it to 0,000V by turning trimmer P400
8. Set the mA signal to 20,00mA
9. Measure the voltage in point XP2-6 and adjust it to 1,000V by turning trimmer P401
10. Repeat points 6-9 until the values are OK
11. Calibration of the 4-20mA input for L.O.pressure sensor is now ready
12. Power OFF the ESM and mount the module cover

2.4 Engine speed frequency inputs

The input frequency from the speed sensor is converted into a voltage in the ESM. This
conversion is done by a micro controller, one controller per frequency input. The f/U
conversion is calibrated in the software of these micro controllers. In order to make this
calibration, please follow the following instructions.

2.4.1 Calibration of f/U conversion for speed sensor 1 input

1. Power OFF the ESM and remove the module cover
2. Connect the test adapter, PAAE004087, to test connector XP3
3. Connect a multimeter to test point XP3-13, (V1)
4. Press switch S700 and keep it pressed while powering ON the ESM
5. Release the button and watch the reading from the multimeter it should now display a
negative voltage
6. Press the S700 button with short pushes until the reading on the multimeter is 0.000V.
The reading on the multimeter will increase for each push and the CPU1 LED will also
blink
7. When 0.000V is reached press the S700 for a longer time until CPU1 LED goes dark,
(>3s)
8. Now the multimeter reading should be slightly below 1 V
9. Press the S700 button with short pushes until the reading on the multimeter is 1.000V.
The reading on the multimeter will increase for each push and the CPU1 LED will also
blink
10. When 1.000V is reached press the S700 button for a longer time until CPU1 LED goes
dark, (>3s)
11. In order to exit the calibration mode press the S700 button again until CPU1 LED goes
dark, (> 3s). NOTE! If not exiting the calibration mode the calibration data will not be
stored properly. (This point only apply to ESM-10 rev.3 and upwards)
12. The calibration of the f/U conversion for speed sensor 1 input is now ready
13. Perform the calibration for f/U conversion for speed sensor 2 input if needed
14. Check the tuning of the module
15. Power OFF the ESM and mount the module cover

2.4.2 Calibration of f/U conversion for speed sensor 2 input

1. Follow the same procedures as described in point 2.4.1, (f/U calibration of speed sensor
1 input), but with the following deviations
2. Connect the multimeter to test point XP3-15, (V2)
 Doc ID: DAAB038320 Revision: a 5/9

3. Use switch S710 instead of S700

4. Related LED indication is CPU2 LED
5. Check the tuning of the module
6. Power OFF the ESM and mount the module cover

If you by accident press the switch used for f/U calibration to many times so that the
value goes greater that 0.000V or 1.000V you have to start the calibration from the
beginning.

2.5 Engine speed analogue outputs

The analogue outputs for engine speed are individually calibrated.

1. Power OFF the ESM and remove the module cover

2. Connect the test adapter, PAAE004087, to test connector XP3
3. Connect a frequency generator to speed sensor 1 input, X13-2 and X13-3
4. Power ON the ESM
5. Adjust the frequency to the same as the frequency from the engine speed sensors at
nominal engine speed, (this is depending on how the actual module is tuned)
6. Set Vdisplay = Vmax , (XP3-14 = XP3-12) by trimming P1200
7. Switch OFF the frequency generator
8. Measure the speed 1 analogue output, X27-7, 8
9. If the value is not 4.000mA adjust the offset with trimmer P1204 until you get
4.000mA, (or 0.000V if the module has analogue voltage output)
10. Measure the speed 2 analogue output, X28-7, 8
11. If the value is not 4.000mA adjust the offset with trimmer P1202 until you get 4.000mA
12. Switch on the frequency generator and set the frequency so you get Vdisplay = 1.000V,
XP3-14
13. Measure the speed 1 analogue output, X27-7, 8
14. If the value is not 20.00mA adjust the gain with trimmer P1203 until you get 20.00mA,
(or 10.00V if the module has analogue voltage output)
15. Measure the speed 2 analogue output, X28-7, 8
16. If the value is not 20.00mA adjust the gain with trimmer P1201 until you get 20.00mA,
(or 10.00V if the module has analogue voltage output)
17. Repeat the trimming procedure point 6-16 until the settings are correct
18. Calibration completed, perform the module tuning before module is taken in use

2.6 Turbo charger speed analogue outputs

1. Power OFF the ESM and remove the module cover
2. Set switch S721 to 0 position
3. Press switch S720 and keep it pressed while powering ON the ESM
4. Release the button
5. Measure the output current, (or voltage if the module has analogue voltage outputs), for
the TCA 1 output, X27-3, 4
6. The reading should be a negative voltage
7. Press the S720 button with short pushes until the reading on the multimeter is 4,000mA,
(or 0,000V). The reading on the multimeter will increase for each push and the CPU3
LED will also blink
8. When 4,000mA, (or 0,000V), is reached press S720 for a longer time until CPU3 LED
goes dark, (>3s)
9. Now the multimeter reading should be slightly below 20mA
 Doc ID: DAAB038320 Revision: a 6/9

10. Press the S720 button with short pushes until the reading on the multimeter is 20,00mA.
The reading on the multimeter will increase for each push and the CPU3 LED will also
blink
11. When 20,00mA, (or 10,00V), is reached press S720 for a longer time until CPU3 LED
goes dark, (>3s)
12. Measure the output current for the TCA 2 output, X28-3, 4
13. Repeat points 5-10
14. Measure the output current, (or voltage), for TCB 1 output, X27-5, 6
15. Repeat points 5-10
16. Measure the output current for TCB 2 output, X28-5, 6
17. Repeat points 5-10
18. For exiting the calibration mode press the S720 button again until CPU3 LED goes dark,
(> 3s). NOTE! If not exiting the calibration mode the calibration data will not be stored
properly. (This point only apply to ESM-10 rev.3 and upwards)
19. Set switch S721 back to the correct position according to ESM setting table related to
the installation in question
20. Now the calibration for the turbo charger analogue conversion is ready
21. Power OFF the ESM and mount the module cover

3 Test connectors in ESM

 Doc ID: DAAB038320 Revision: a 7/9

4 ESM setting table, DAAB038630 rev. a

Name of the switch on Postition / value the

ESM-10 corresponding switch / voltage
Name of the function Input column for level should have in
to the setting
affected by the setting setting values ESM-10

Fill in the This column is

wanted values automatically
in this column giving the swith
settings based on
the input data
Figure 1, input table for ESM-10 configuration
 Doc ID: DAAB038320 Revision: a 8/9

Function description for

Pull-down menu containing the selected configuration
allowed setting values

Figure 2, Pull-down menus and function description in ESM setting table

 Doc ID: DAAB038320 Revision: a 9/9

Figure 3, ESM PCB layout with switches, trimmers and test connectors