Downloading Calibrations to Westport CM850 and Cummins …...2012/03/22 · Right-click on the calibration and select Transfer to ECM. CM871 ECM Calibration Authorization 28. If the

Westport HD System Downloading Calibrations to Westport CM850 and Cummins ECM

service.westport-hd.com Copyright © 2011-2012 Westport Power Inc. All rights reserved

INS NO. REV DATE PAGE

INS-10017429 02 22/03/12 1 of 13

Downloading Calibrations to Westport CM850 and Cummins ECM

Purpose:

This work instruction outlines the steps necessary to download the Westport software suite to a vehicle equipped with the Westport GX engine and LNG System. This document includes instructions for downloading software to the Cummins® engine control module (ECM), as well as the engine fuel system (EFS) and high-pressure gas system (HPGS) Westport CM850 controllers (ECU). This document supports software downloads for both the Cummins® CM871 and CM2250 model ECM. Details on the usage of INSITETM can be found in the INSITETM Help files.

Tools and Materials Required: Cummins® INLINE 5 with firmware 5.45 installed and USB cable (Cummins® P/N 4918416) Cummins® INSITETM version 7.4.2 or later Cummins® vehicle service port harness (Cummins® P/N 3165159) Westport HD WEST communication hardware (Westport P/N 10015993S) Westport HD WEST software version 4.2 or later (Westport P/N 10016158S)

Stage 1: In Preparation

1. Before beginning work, ensure the vehicle is properly parked in an outdoor shop area, or an approved natural gas vehicle shop (see local regulations), with parking brake on and engine off.

2. Ensure that the WEST software is version 4.2 or later. Visit the Westport HD Service website for more information: http://service.westport-hd.com

3. Ensure that Cummins INSITETM is version 7.4.2 or later. Visit the Cummins® INSITETM website for more information: https://insite.cummins.com/insite/index.html

4. Download the latest calibration software suite .zip file from the Westport HD Service website: http://service.westport-hd.com

NOTE

Each vehicle is equipped with one Cummins® CM871 or CM2250 ECM and two Westport CM850 controllers. The calibration download procedure must be completed once for the

EMC (Stage 2), and twice for the two Westport CM850 controllers (Stage 3).

5. Extract the calibration .zip file onto the local hard drive of the laptop. It is recommended that the user does not save the files to the computer desktop, as they may be difficult to locate when using INSITETM later on in this procedure. Figure 1 and Figure 2 show the folder structure for the CM871 and CM2250 modules respectively.

Figure 1: .zip file structure, CM871 ECM

Figure 2: .zip file structure, CM2250 ECM




INS-10017429 02 22/03/12 2 of 13

6. The CM871 or CM2250 folder contains the ECM software, and the CM850 EFS and CM850 HPGS folders contain the EFS and HPGS software respectively.

CAUTION

All three controllers must be updated with the same version of the calibration software suite downloaded from the Westport HD Service website. Failure to update all the

software on all three controllers may result in engine damage!

Stage 2: Downloading Software to the CM871 or CM2250 ECM

CAUTION

Use only calibrations provided by Westport for the CM871/CM2250. Failure to do so may result in engine damage!

Connecting to the vehicle CM871 or CM2250 ECM

7. Connect INLINE 5 to a functional USB port on the laptop.

8. Connect the vehicle service harness to the INLINE 5 and Cummins® vehicle under-dash service port (Figure 3).

Cummins Under-Dash Port

Cummins Vehicle Service Port Harness

Cummins Inline Laptop PC

Cummins INSITE

RS232 or USB Patch Cable

Figure 3: Connection from the laptop to the Cummins® under-dash service port

Prepare Calibration files

9. Navigate to the C:\Intelect folder on the laptop. Find and delete the sub-folder named esdn, if it exists (Figure 4).

Figure 4: esdn folder in C:\Intelect




INS-10017429 02 22/03/12 3 of 13

10. From the CM871 or CM2250 directory of the .zip file extracted in Step 5, copy the esdn folder to the C:\Intelect directory, as shown in Figure 5.

Figure 5: Copying esdn to the C:\Intelect folder

Setup INSITETM Connection

11. Turn the ignition key to the ON position.

12. Start INSITETM.

13. If no ECM connection is setup, follow the instructions provided in the Connecting your laptop to an ECM section of the INSITETM Help files.

14. Connect to the ECM by clicking the Connect to ECM button on the left sidebar menu.

15. A Connect pop-up window will appear (Figure 6). Ensure that the Security Type: is set to None. Click Connect.

Figure 6: INSITETM Connect pop-up window

16. Once the connection is made, create a New Work Order.




INS-10017429 02 22/03/12 4 of 13

17. In the New Work Order window, fill in the following information: Customer Name VIN Mileage ESN In the Technician’s Note field, enter the engine hours as displayed on the vehicle

dash, a description of the work to be performed on the vehicle, and the part and version numbers of the software suite which is being downloaded.

NOTE

Be sure to note the new Work Order number, as it will be used again later in this procedure

18. Once the new work order is complete, an image of the truck data in its present state must be exported and kept on record. Select the applicable work order image number and export it to an external file. Instructions on exporting an image to an external file can be found in the image section of the INSITETM Help files.

19. Save the image as a .csv file on the local hard drive of the laptop.

20. Check and record all Cummins® fault codes present on the vehicle. It is recommended to resolve any issues related to these fault codes prior to continuing the download process.

Download Calibration to the CM871 or CM2250 ECM

21. Click on the Calibration Selection button on the left sidebar menu of INSITETM.

22. In the pane that opens, navigate to the Westport GX15 CM871 or Westport GX15 CM2250 calibration file by selecting "system (C:\)" and expanding it to show the seven-digit calibration file (Figure 7, Figure 8).

Figure 7: Calibration file structure, CM871 ECM

Figure 8: Calibration file structure, CM2250 ECM




INS-10017429 02 22/03/12 5 of 13

23. If the message "INSITE could not detect calibration(s) for the selected ECM part number" appears, complete steps 23-26. Otherwise skip to step 27.

24. In the right pane, right-click on the calibration file number and select Certification Codes (Figure 9).

Figure 9: Certification Codes selection

25. In the “Certification Code Selection” window that opens, click on the ->> button (Figure 10).

Figure 10: Certification Code Selection window

26. Click the OK button when all the certifications have been moved to the right column (Figure 11).

Figure 11: Certification Code Selection window (all codes selected)




INS-10017429 02 22/03/12 6 of 13

27. A calibration should appear in the right pane. Right-click on the calibration and select Transfer to ECM.

CM871 ECM Calibration Authorization

28. If the controller being calibrated is a CM2250, the following Steps 29-30 do not apply. Skip to Step 31.

29. If it is the first time INSITETM is being used to download a calibration to a CM871 ECM, a “Calibration Authorization” screen may appear. If this screen appears, a “Calibration Authorization Password” will be required. Contact a local Cummins®

parts dealer and request a “Calibration Authorization” password.

The dealer will require the version of INSITETM being used and the PC ID number. The PC ID number can be found on the “Calibration Authorization” screen (Figure 12).

A fee may be required in order purchase the “Calibration Authorization Password”. This fee may be charged to Westport HD Service, if the vehicle is still under warranty.

Figure 12: ECM calibration download wizard

30. Entering the password and click Next >.




INS-10017429 02 22/03/12 7 of 13

31. On the following screen, ensure that the “Save / Restore Adjustable Parameters" checkbox is checked (Figure 13). Click Next >.

Figure 13: Save / Restore Adjustable Parameters checkbox

NOTE

If the Save/Restore Adjustable Parameter check box is grayed out, adjustable parameters will need to be manually restored. Ensure an image of the truck data in its present state has been saved on the local hard drive of the laptop before proceeding.

32. Follow the prompts displayed to complete the calibration transfer.

NOTE

Ensure that all items in the “Calibration Transfer Results” window are “Successful”.

33. If the truck’s adjustable parameters need to be restored, proceed to Step 34. Otherwise, skip to Step 52.

Restoring Adjustable Parameters to the ECM

34. Open the .csv image file saved from Step 19 using Notepad.

35. Access the Features and Parameters menu and manually input each adjustable parameter from the Notepad file to their corresponding fields.

36. Send the updated adjustable parameters to the ECM and follow the prompts displayed to complete the update.

37. If more than one vehicle in a fleet needs its adjustable parameters replaced, a template can be created and overlaid onto the subsequent vehicles as outlined in Step 38. Details on creating and overlaying templates could be found in the template section of the INSITETM Help files. Otherwise, skip to Step 52.

Creating a Template

38. Navigate to the current work order and create a New ECM Image.

39. Convert the new image to a template and fill in the Comments field so that it can be identified later.




INS-10017429 02 22/03/12 8 of 13

40. Export it to the laptop and proceed to Step 52 to complete the software download.

CAUTION

Do not modify the name of the template as that could cause an error to occur.

Downloading the Template to Trucks of the Same Fleet

Steps 41 to 51 outline the procedure for downloading a template to a vehicle. This procedure should be used when multiple vehicles in a fleet that requires a manual restore of the adjustable parameters.

41. Follow Steps 7 to 20 to connect to the vehicle through INSITETM, save an image of the ECM, and review the fault codes present.

42. Prior to downloading the new template onto the vehicle, take note of the vehicle’s Customer name, Customer Unit Number, VIN, Mileage and Engine Build Date and Engine Serial Number. This information may need to be manually filled in after the template has been downloaded.

43. Import the template from Step 40 and send it to the ECM.

44. Follow the prompts displayed to apply the template.

45. Once the template has been applied, a Calibration Conflict Warning window may pop up (Figure 14). Make note of the conflicts listed and click OK to continue.

Figure 14: Calibration conflicts after template application

46. Follow the prompts displayed to complete the download.

47. Verify that the template values have been correctly flashed to the controller by comparing the adjustable parameter values with the values in the “_afterflash.csv” file saved for the first truck of the fleet. If conflicts were recorded in step 45, manually update the applicable parameters with the values found in the “_afterflash.csv” file.

48. Fill in the vehicle’s Customer name, Customer Unit Number, VIN, Mileage and Engine Build Date and Engine Serial Number if necessary.

49. Send adjustable parameters that were updated to the ECM.

50. Confirm that the update was successful by following the prompts displayed.




INS-10017429 02 22/03/12 9 of 13

51. Verify that the vehicle’s Customer name, Customer Unit Number, VIN, Mileage and Engine Build Date and Engine Serial Number have been updated.

Completion

52. It is recommended to repeat Steps 18 to 19 to download the updated vehicle image of each truck to the laptop. Add the words “_afterflash” to the end of the filename.

53. If a calibration download fails and communication with the ECM cannot be established, a special procedure is required in order to fix the ECM controller. Please contact Westport HD Service at 1-888-978-4734 or [email protected].

54. The calibration download to the CM871 or CM2250 ECM is now complete.

55. For all subsequent vehicles of the same fleet, repeat Step 41 to Step 54 to perform the calibration download.

Stage 3: Downloading Software to the Westport CM850 Controllers (ECU)

Stage 3 will outline the steps to download the operating system, software code, and the calibration data from the laptop to the two Westport CM850 controllers.

CAUTION

Use only calibrations provided by Westport for the CM871/CM2250 and CM850 controllers. Failure to do so may result in engine damage!

CAUTION

Each truck is equipped with two CM850 controllers (HPGS and EFS) for the Westport LNG System. Stage 3 must be completed twice, once for the HPGS controller, and once

for the EFS controller. Note that the software downloaded to the EFS controller is different from the software downloaded to the HPGS controller.

Connecting to the Controller

56. Connect the truck to the laptop PC using the WEST communication cable and the Westport connection port, as shown in Figure 15.

Figure 15: Connection from the laptop to the vehicle

57. Launch WEST by double clicking on the WEST icon (Figure 16).

Figure 16: WEST desktop icon




INS-10017429 02 22/03/12 10 of 13

58. Once the program has started, the “Configuration and Communication SetUp” window will appear. Select the Communication tab (Figure 17).

Figure 17: Configuration and Communication SetUp screen, Configuration tab

59. Select the Port Name: (USB or COM), and choose the ECU ID to select the desired controller for the download (EFS or HPGS). Click the Check Communication button (Figure 18).

Figure 18: Configuration and Communication SetUp screen, Communication tab

60. Verify connection to the correct controller by checking the header information in WEST. In the top-left corner of the screen, the first field should read the connected controller (either EFS or HPGS) (Figure 19).

Figure 19: Verifying that you are connected to the correct controller (HPGS controller shown)

61. Throughout this procedure verify that the light bulb, located near the bottom left of the screen on the information bar, is blinking (Figure 20). This indicates correct communication with the selected controller.

Figure 20: Verifying communications

62. If communication is lost, the source of the fault can be identified by referring to the information bar at the bottom of the WEST screen (Figure 21). The source of the fault can be identified as follows: Computer Communication Port [COMM], Westport Service Tool [CAN], or Westport Controller [ECU].

Figure 21: Isolating connectivity issues




INS-10017429 02 22/03/12 11 of 13

Downloading Software Scal to the Controller

63. Navigate to the Software menu and select Download Software Scal (Figure 22).

Figure 22: Software Download

64. Acknowledge the warning, and click Yes to proceed (Figure 23).

Figure 23: Download All software warning

65. Find and select the software .scal file in the local directory for the respective controller, then click Open (Figure 24). The “CM850 EFS” or “EFS 850” directory contains the .scal file for the EFS controller, while the “CM850 HPGS” or “HPGS 850” directory contains the .scal file for the HPGS controller.

Figure 24: Browse for the correct Scal file

66. The download process will begin, and may take up to 20 minutes per controllers. During this process, the message shown in Figure 25 will be displayed on the screen.

Figure 25: Download in progress message

67. The download progress will be shown in the bottom left corner of the screen.

Figure 26: Scal download progress bar




INS-10017429 02 22/03/12 12 of 13

68. Once downloading is complete, the message indicated in Figure 27 will be displayed on the very bottom of the WEST screen.

Figure 27: Download complete message

69. A prompt will appear to select a new .a2w configuration file. It is not necessary to use an .a2w file. Select No (Figure 28).

Figure 28: Reload A2W file

70. To complete the download, turn the ignition key to OFF and wait for 30 seconds until the controller has powered down.

71. Turn the ignition key to ON and press the RESET button located in the lower right corner of the WEST screen to re-established communication with the controller (Figure 29).

Figure 29: Reset button

72. Repeat Steps 58 to 71 to complete the Scal installation for the second controller.

73. The download to the two ECUs is now complete. Verify that the correct software and calibrations have been successfully downloaded to the controllers. From left to right, the header contains the following information, where the last three fields are related to the software and calibration just downloaded (Figure 30): [Specific ECU PIN ID] [ECU firmware APP ID] [Project ID] [Project Revision] Displays the Scal version downloaded [Calibration Name] Displays the last six digits of the WPT software part number [Calibration Revision] Displays the calibration revision

Figure 30: Header information

74. At this point all fault codes that may have appeared on the CM850 must be cleared. To do this, navigate to the Service menu and select Clear Fault Codes (Figure 31).

Figure 31: Clearing fault codes




INS-10017429 02 22/03/12 13 of 13

75. If a calibration download fails and communication with the ECUs cannot be established, a special procedure is required to fix the controllers. Please contact Westport HD Service at 1-888-978-4734 or [email protected].

Stage 4: Clearing the ECM Fault Codes

Stage 4 should only be performed after the entire software suite has been downloaded to the CM871 or CM2250, as well as both CM850 controllers. This step ensures that no fault codes are present on the CM871 or CM2250 controller.

NOTE

Fault codes present on the CM871 or the CM2250 ECM should have been resolved or noted prior to downloading the new software. Any new fault codes are likely due to the

software download procedure and should be cleared.

Connect to the Vehicle CM871 Controller

76. Connect the Cummins® INLINE 5 to a USB port on the laptop.

77. Connect the vehicle service harness to the Cummins® INLINE 5 and vehicle service port under the dashboard.

78. Turn the ignition key to ON.

79. Load the INSITETM software and connect to the ECM.

Clearing the Fault Codes Caused by the Download

80. Using INSITETM, access the Fault Codes menu.

81. Clear the fault codes by right clicking in the fault code window and selecting Reset Inactive Faults > All (Figure 32).

Figure 32: Reset inactive faults

82. Disconnect from the under-dash port, ensure the truck starts and there are no “Check ECU Next Stop” messages on the Westport driver display.

Revision Date (DD/MM/YY) Description 00 14/03/11 Initial Release 01 09/19/11 Minor Update 02 22/03/12 Reduced document through referencing INSITETM

Help files

Documents

Downloading Calibrations to Westport CM850 and Cummins …...2012/03/22 · Right-click on the calibration and select Transfer to ECM. CM871 ECM Calibration Authorization 28. If the