Waukesha Gas Engines: Warning

GE Power & Water
Distributed Power
Waukesha* gas engines TOPIC:

IDENT NO:
Electronic Controls
17-3048A
DATE: December 2014
ESM *
SUBJECT: PDB Reset and Water Integrity Guidelines
SUPERSEDES: 17-3048
MODELS AFFECTED: All Waukesha gas engines with ESM
The purpose of this bulletin is to inform the field of the

steps necessary to reset the Power Distribution NOTICE
Junction Box (PDB) and to provide and maintain the
The electrical interference from solenoids and other
proper water integrity of the PDB.
electrical switches will not be cyclic and can be as
high as several hundred volts. This could cause
! WARNING faults within the ESM system that may or may not be
indicated with diagnostics. Waukesha requires a
Do not install, set up, maintain or
freewheeling diode (1N4002 or equivalent rated for
operate any electrical components
100V and 1A) be added across the coils of relays
unless you are a technically
and solenoids to suppress high induced voltages
qualified individual who is familiar
that may occur when equipment is turned off. Failure
with the electrical elements
to comply will void product warranty.
involved. Electrical shock can
cause severe injury or death. For engines equipped with electric starters, diode
P/N 740051 is required to be installed on each
All outputs on these power distribution junction boxes starter (see Figure 1). This will further protect the
have been designed to protect against short circuits, power distribution junction box from voltage spikes.
current overloads and spikes. If one of these incidents
occurs, the power distribution junction box will disable
power to the affected output to prevent damage to the
power distribution junction box and the device being
powered.
Proper installation and maintenance will minimize
short circuits, current overloads and spikes. Reference
the appropriate ESM manual for the engine being
serviced for details.
All non-GE trademarks, service marks, logos, slogans, and trade names
are the properties of their respective owners.
* Trademark of General Electric Company
12/19/2014
Copyright © 2014, General Electric Co. Page 1 of 3
Service Bulletin No. 17-3048A
1
3 1
S BAT
G
2
MTR
Figure 1: Installing Diode P/N 740051
1 - Starter 3 - Red End

2 - Diode 4 - Starter Solenoid
Attach the red end of the diode to the S terminal of the
solenoid and attach the other end of the diode to the
G terminal.
RESETTING THE POWER DISTRIBUTION
NOTICE
De-energize any source of inputs (customer PLC,
etc.) to the ECU prior to cycling the power or
pressing the reset switch on the PDB. Failure to do Figure 2: Power Distribution Box (P/N 309204C)
so may produce a voltage or current into the ECU
that is out of range, causing the circuit to disable. To 1 - Reset Switch 2 - Internal Fault LED
de-energize the inputs to the ECU, disconnect the
customer interface cable at the ECU. NOTE: After completing the PDB reset procedure, if
the problem is not corrected, contact your local
Waukesha Distributor for technical support.
RESETTING POWER DISTRIBUTION BOX
P/N 309204B (NO RESET BUTTON) ESTABLISHING AND MAINTAINING
1. Stop the engine. WATER INTEGRITY
2. Disconnect the power source to the power The PDB has been factory-tested and proven to be
distribution junction box. watertight under reasonable conditions. For proper
3. Reconnect the power source. engine operation and to maintain the factory warranty,
it is imperative to preserve the watertight integrity of
RESETTING THE POWER DISTRIBUTION BOX the PDB.
P/N 309204C (WITH RESET BUTTON)
As shipped from the factory, the PDB has several
1. Stop the engine. openings meant for unused electrical options and/or
2. Press and hold the reset switch about 3 seconds customer connections. These openings are factory-
until all LEDs turn off. sealed with either a push-in, self-centering, rubber
plug (1-1/2 in.) or a steel with rubber gasket plug that
3. Release the switch. must be manually centered and tightened with an
internal wing nut (3/4 in.).
NOTE: Only the B version has the metal plug.
12/19/2014
Service Bulletin No. 17-3048A
These plugs must remain firmly in place at all times INSTALLING PDB COVER
unless the opening is used for wiring.
Be sure to properly reinstall the PDB cover any time
ADDING CUSTOMER-SUPPLIED WIRING that it has been removed (see Figure 4) for wiring or
TO PDB troubleshooting using the internal LEDs. DO NOT
leave the cover off when work is not actively being
When adding customer-supplied wiring to the PDB, all done. This includes indoors or overnight. When
connectors, fittings and grommets used must have a reinstalling the cover, all six latches must properly
rating equivalent to NEMA 4 or CSA type 4. Using engage the cover and the latch screws must be tight.
connectors, fittings or grommets that do not meet this
standard could allow water to enter the PDB, causing
problems up to and including failure of the PDB. See
Figure 3 for examples of both good and bad practice.
1 Figure 4: Cover Latch and Screw
The PDB is watertight under reasonable conditions

when:
• The cover is properly installed
• Plugs are properly in place
Figure 3
• Connectors equivalent to NEMA 4 or CSA type 4,
1 - Proper NEMA 4 or 3 - Factory-Supplied, fittings and grommets are used for wiring
CSA Type 4 Style Self-Centering
Connector 1-1/2 in. Plug NOTICE
2 - Non-Approved
Connector Without Use caution when pressure-washing the engine. Do
Grommet (allows not spray the high-pressure water stream directly at
water entry) the cover gasket, at any plug or wiring connector on
the PDB or at any engine-mounted electronics, as
water entry may occur and component damage may
result.
12/19/2014

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GE Power & Water

Waukesha* gas engines TOPIC:

MODELS AFFECTED: All Waukesha gas engines with ESM

The purpose of this bulletin is to inform the field of the

Figure 1: Installing Diode P/N 740051

1 - Starter 3 - Red End

RESETTING THE POWER DISTRIBUTION

1 Figure 4: Cover Latch and Screw

The PDB is watertight under reasonable conditions

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