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A P P L I C A T I O N A N D I N S T A L L A T I O N G U I D E
EMCP 4.1, 4.2
GENERATOR SET CONTROL
Contents
1
1.1
1.2
1.3
GENERAL INFORMATION................................................................................ 1
I
NTRODUCTION
................................................................................................................................ 1
A
PPLICATIONS
................................................................................................................................. 1
R
EFERENCES
.................................................................................................................................. 1
2
2.1
2.2
4.3
4.4
4.5
4.6
4.7
SAFETY INFORMATION ................................................................................... 2
E
LECTRICAL
S
AFETY
....................................................................................................................... 2
E
LECTROSTATIC DISCHARGE AWARENESS
........................................................................................ 2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
INSTALLATION ................................................................................................. 3
M
O
P
B
E
OUNTING
PERATING
OWER
R
ATTERY
EUI E
EQUIREMENTS
C
L
OCATION
T
EMPERATURE RANGE
HARGER
LECTRICAL
NGINES
C
...................................................................................................................... 3
.................................................................................................. 3
................................................................................................................... 3
......................................................................................................................... 4
ONNECTIONS
............................................................................................................. 5
.................................................................................................................................. 5
EMCP 4.1
AND
4.2
E
LECTRICAL
D
IAGRAMS
..................................................................................... 6
W
INDING
C
ONNECTIONS
.................................................................................................................. 8
3.9
T
RANSFORMER
C
ONNECTIONS
....................................................................................................... 10
3.10
W
IRING
R
EQUIREMENTS
................................................................................................................. 13
3.11
S
HIELDED AND
C
OMMUNICATION
W
IRING
........................................................................................ 14
4
4.1
4.2
INITIAL OPERATION AND USER ORIENTATION ......................................... 15
T
YPES OF
EMCP 4 E
VENTS
........................................................................................................... 15
U
SING THE
C
AT
S
ERVICE
T
OOL
...................................................................................................... 15
Connecting to the EMCP 4 to Configure Setpoints .....................................................................................16
V
IEWING
S
YSTEM
P
ARAMETERS
..................................................................................................... 17
Supported Parameters................................................................................................................................18
Engine Overview.........................................................................................................................................18
AC Overview ...............................................................................................................................................22
V
IEWING AND
A
DJUSTING
P
REFERENCES
........................................................................................ 23
Setting The Preferences Using The EMCP 4 Display .................................................................................24
Changing The EMCP 4 Contrast When the Display is Unreadable.............................................................26
Changing The EMCP 4 Display to Technician English ...............................................................................26
Changing The EMCP 4 Display to the Primary Language ..........................................................................27
Setting the Preferences Using the Service Tool..........................................................................................27
C
ONFIGURING
T
IME
/D
ATE
(EMCP 4.2
O
NLY
) ................................................................................. 28
Changing The Time/Date............................................................................................................................28
Changing Date Format................................................................................................................................30
A
DJUSTING
G
ENERATOR
S
ET
P
ARAMETERS
................................................................................... 31
Generator Output Voltage...........................................................................................................................31
Engine Speed .............................................................................................................................................31
Idle/Rated....................................................................................................................................................32
Engine Sensor Versus Data link .................................................................................................................33
Engine Oil Pressure ....................................................................................................................................35
Engine Coolant Temperature ......................................................................................................................38
S
TARTING AND
S
TOPPING THE
G
ENERATOR
S
ET
............................................................................. 40
Starting The Engine ....................................................................................................................................40
EMCP 4 Remote Start ................................................................................................................................41
Stopping The Engine ..................................................................................................................................41
4.9
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
6
7
7.1
7.2
7.3
8
8.1
4.8
8.2
9
9.1
9.2
9.3
Emergency Stop .........................................................................................................................................43
E
NGINE
S
ETPOINT
V
ERIFICATION
.................................................................................................... 44
Procedure For Overspeed Verification........................................................................................................45
Procedure For Low Oil Pressure Verification ..............................................................................................45
Procedure For High Coolant Temperature Verification ...............................................................................46
E
NGINE
O
PERATING
H
OURS
........................................................................................................... 47
Updating Engine Operating Hours ..............................................................................................................47
HANDLING EVENTS ....................................................................................... 49
C
ONFIGURING
E
VENT
R
ESPONSES
F
OR
EMCP 4 G
ENERATED
E
VENTS
........................................... 50
C
HANGING
A
N
E
VENT
R
ESPONSE
C
ONFIGURATION
......................................................................... 52
R
ESETTING
I
NDIVIDUAL
A
CTIVE
E
VENTS FOR THE
EMCP 4.............................................................. 55
R
ESETTING
A
LL
A
CTIVE
E
VENTS FOR A
S
INGLE
M
ODULE
................................................................ 56
R
ESETTING
A
LL
A
CTIVE
E
VENTS FOR
A
LL
M
ODULES
...................................................................... 57
R
ESETTING
E
VENTS FOR
E
NGINE
ECM
S
W
ITHOUT
P
RIMARY
C
AN
D
ATA
L
INK
S
UPPORT
................... 58
T
ROUBLESHOOTING
R
ESETTING
E
VENTS
........................................................................................ 58
Not in Auto Warning....................................................................................................................................58
Service Maintenance Interval (EMCP 4.2 Only)..........................................................................................58
SECURITY ....................................................................................................... 63
SETPOINTS ..................................................................................................... 67
C
ONFIGURING
S
ETPOINTS
.............................................................................................................. 67
S
ET
P
OINTS ON THE
EMCP 4 D
ISPLAY
............................................................................................ 69
S
ETPOINTS ON THE
C
AT
S
ERVICE
T
OOL
.......................................................................................... 69
Setpoint Categories ....................................................................................................................................70
DIGITAL INPUTS ............................................................................................. 73
P
ROGRAMMING
D
IGITAL
I
NPUTS
U
SING THE
D
ISPLAY
...................................................................... 74
Viewing the Current Digital Input Status .....................................................................................................75
Configuring Digital Inputs for Status Parameters ........................................................................................76
Digital Input Command/STatus Descriptions...............................................................................................78
Configuring Digital Inputs for System Events ..............................................................................................81
Configuring Digital Inputs for SCADA Data link...........................................................................................84
Disabling Digital Inputs ...............................................................................................................................85
P
ROGRAMMING
D
IGITAL
I
NPUTS
U
SING THE
C
AT
S
ERVICE
T
OOL
..................................................... 86
Configuring Digital Inputs for Status Parameter ..........................................................................................87
Configuring Digital Inputs for System Events ..............................................................................................88
Configuring Digital Inputs for SCADA Data link...........................................................................................92
Disabling Digital Inputs ...............................................................................................................................92
ANALOG INPUTS............................................................................................ 93
P
ROGRAMMING
A
NALOG
I
NPUTS
U
SING THE
D
ISPLAY
..................................................................... 95
Viewing the Current Analog Input Status ....................................................................................................95
Configuring Analog Inputs for Resistive Mode ............................................................................................96
Configuring Analog Inputs for Voltage Mode...............................................................................................98
Disabling Analog Inputs ............................................................................................................................100
P
ROGRAMMING
A
NALOG
I
NPUTS
U
SING THE
C
AT
S
ERVICE
T
OOL
.................................................. 101
Configuring Analog Inputs for Resistive Mode ..........................................................................................102
Configuring Analog Inputs for Voltage Mode.............................................................................................105
Disabling Analog Inputs ............................................................................................................................108
A
NALOG
I
NPUT
M
APS
.................................................................................................................. 109
Warnings and Shutdowns .........................................................................................................................119
Unsupported Analog Input Sensor Ranges...............................................................................................119
Sensor Range is Smaller than Setpoint Options .......................................................................................119
Sensor Range is Larger than Setpoint Options, But Usable Range is Not...............................................121
Sensor Range is Larger than Setpoint Options, And Usable Range is Larger Than Setpoint Options ....122
10 OUTPUTS ...................................................................................................... 123
10.1
P
ROGRAMMING
O
UTPUTS
U
SING THE
D
ISPLAY
............................................................................. 124
Viewing the Current Output Status............................................................................................................124
Configuring Outputs for Status Parameters ..............................................................................................125
Digital/relay Output Command/STatus Descriptions .................................................................................127
Configuring Outputs for System Events ....................................................................................................130
Digital/relay Output SYSTEM EVENT DESCRIPTIONS ...........................................................................134
Configuring Outputs for SCADA Data link.................................................................................................137
Disabling Outputs......................................................................................................................................138
10.2
P
ROGRAMMING
O
UTPUTS
U
SING
T
HE
C
AT
S
ERVICE
T
OOL
............................................................ 139
Configuring Outputs for Status Parameters ..............................................................................................139
Configuring Outputs for System Events ....................................................................................................141
Configuring Outputs for SCADA Data link.................................................................................................142
Disabling Outputs......................................................................................................................................143
11 MODIFIABLE TEXT STRINGS ...................................................................... 144
11.1
L
ANGUAGE
S
UPPORT
.................................................................................................................. 145
11.2
P
ROGRAMMING
M
ODIFIABLE
T
EXT
S
TRINGS USING THE
C
AT
S
ERVICE
T
OOL
.................................. 145
12 SAVING AND RESTORING SETPOINTS ..................................................... 149
12.1
SAVING EMCP 4 CONFIGURATION DATA............................................................................. 149
Fleet Configuration Option ........................................................................................................................150
ECM Replacement Option ........................................................................................................................150
12.2
L
OADING
EMCP 4 C
ONFIGURATION
D
ATA
.................................................................................... 152
13 PROGRAMMABLE CYCLE TIMER (EMCP 4.2 ONLY) ................................ 155
13.1
C
ONFIGURING THE
P
ROGRAMMABLE
C
YCLE
T
IMER
U
SING THE
D
ISPLAY
........................................ 157
13.2
C
ONFIGURING THE
P
ROGRAMMABLE
C
YCLE
T
IMER
U
SING THE
C
AT
S
ERVICE
T
OOL
....................... 159
14 REDUCED POWER MODE ........................................................................... 162
15 PROGRAMMABLE KW RELAY FUNCTION (EMCP 4.2 ONLY) ................. 164
15.1
C
ONFIGURING THE
P
ROGRAMMABLE K
W R
ELAY
F
ROM THE
D
ISPLAY
............................................. 165
15.2
C
ONFIGURING THE
P
ROGRAMMABLE K
W R
ELAYS
U
SING THE
C
AT
S
ERVICE
T
OOL
........................ 167
16 CAN DATA LINKS ......................................................................................... 170
16.1
P
RIMARY
CAN D
ATA
L
INK
(CAN 1) ............................................................................................. 170
Primary CAN Wiring..................................................................................................................................170
Network Topology .....................................................................................................................................170
16.2
A
CCESSORY
CAN D
ATA
L
INK
(CAN 2) (EMCP 4.2
O
NLY
) ........................................................... 172
Accessory CAN Wiring..............................................................................................................................172
Network Topology .....................................................................................................................................172
17 OPTIONAL MODULES .................................................................................. 174
17.1
CAN A
NNUNCIATOR
.................................................................................................................... 175
CAN Annunciator Features .......................................................................................................................176
Annunciator Specifications........................................................................................................................176
Annunciator Wiring....................................................................................................................................177
LED Colors................................................................................................................................................178
CAN Annunciator Software Configuration.................................................................................................179
Global Acknowledge .................................................................................................................................179
ECU Instance Number ..............................................................................................................................179
Configuring Annunciator LED Behavior ....................................................................................................179
Trigger Condition ......................................................................................................................................182
Severity Level ...........................................................................................................................................183
Suspect Parameter Number......................................................................................................................184
17.2
RS-485 A
NNUNCIATOR
(EMCP 4.2
O
NLY
)................................................................................... 184
Annunciator Features................................................................................................................................185
Annunciator Specifications........................................................................................................................185
RS-485 Annunciator Wiring.......................................................................................................................186
LED Colors................................................................................................................................................187
Lamp Test Function ..................................................................................................................................188
Alarm Acknowledge ..................................................................................................................................188
RS-485 ANNUNCIATOR ALARM GROUPS.............................................................................................189
Alarm Group Selection Mode (AGSM) ......................................................................................................189
Entering AGSM .........................................................................................................................................190
Re-configuring/Selecting Alarm Group Address........................................................................................190
Exiting AGSM............................................................................................................................................191
RS-485 Annunciator Custom Alarm Group Configuration.........................................................................191
CUSTOM ALARM GROUP SELECTION..................................................................................................191
Severity Level ...........................................................................................................................................192
Suspect Parameter Number......................................................................................................................192
Alarm Groups............................................................................................................................................194
Configuring Custom Alarm Groups using Cat Service Tool ......................................................................198
17.3
T
HERMOCOUPLE
M
ODULE
(EMCP 4.2
O
NLY
)............................................................................... 205
Thermocouple Features ............................................................................................................................205
Thermocouple Specifications ....................................................................................................................206
Thermocouple Wiring................................................................................................................................207
Thermocouple Physical Layout .................................................................................................................208
Thermocouple Module – Configuration .....................................................................................................208
Configuring Thermocouple Inputs .............................................................................................................210
17.4
RTD M
ODULE
(EMCP 4.2
O
NLY
) ................................................................................................ 211
RTD Features ...........................................................................................................................................211
RTD Specifications ...................................................................................................................................212
RTD Wiring ...............................................................................................................................................213
RTD Physical Layout ................................................................................................................................214
RTD Module – Configuration.....................................................................................................................214
Configuring RTD Inputs ............................................................................................................................215
17.5
D
ISCRETE
I/O M
ODULE
(EMCP 4.2
O
NLY
) ................................................................................... 216
Discrete I/O Features................................................................................................................................216
Discrete I/O Specifications ........................................................................................................................217
Discrete I/O Wiring....................................................................................................................................218
Discrete I/O Physical Layout .....................................................................................................................219
Discrete I/O Software Configuration..........................................................................................................219
Configuring Digital Inputs ..........................................................................................................................221
Configuring Relay Outputs ........................................................................................................................222
18 SCADA (MODBUS) DATA LINK (EMCP 4.2 ONLY) .................................... 223
18.1
W
IRING
....................................................................................................................................... 223
18.2
L
INE
T
ERMINATION AND POLARIZATION
......................................................................................... 225
18.3
S
OFTWARE
C
ONFIGURATION
........................................................................................................ 225
Configuring The SCADA Data Link Using The Display .............................................................................225
Configuring The SCADA Data Link Using The Cat Service Tool...................................................................227
19 INTEGRATED VOLTAGE REGULATOR ...................................................... 230
19.1
IVR F
EATURES
............................................................................................................................ 230
19.2
H
ARDWARE
I
NSTALLATION
........................................................................................................... 231
EMCP IVR Connections............................................................................................................................231
IVR Excitation Module...............................................................................................................................231
IVR Excitation Module Physical Layout.....................................................................................................232
IVR Excitation Module Connections..........................................................................................................233
IVR Excitation Module Over-Excitation Protection ....................................................................................234
IVR Excitation Module Fusing ...................................................................................................................235
19.3
IVR S
OFTWARE
C
ONFIGURATION
................................................................................................. 236
Voltage Regulator Control Source Configuration ......................................................................................237
Starting Profile ..........................................................................................................................................238
IVR PID Gain Setpoints ............................................................................................................................241
Under-Frequency Roll-Off (Loading) Profile..............................................................................................242
Voltage Regulator Load Compensation Type Configuration .....................................................................243
Line Loss (IR) Compensation....................................................................................................................243
Reactive Droop Compensation .................................................................................................................244
Voltage Regulator Lockout Configuration .................................................................................................246
Loss of Sensing Shutdown Event .............................................................................................................246
Over Excitation Shutdown Event...............................................................................................................247
19.4
IVR V
OLTAGE
A
DJUSTMENT
........................................................................................................ 247
Digital Inputs .............................................................................................................................................248
Voltage/Hz Control (EMCP Display) .........................................................................................................248
SCADA Modbus (EMCP 4.2 Only)............................................................................................................248
Analog Inputs ............................................................................................................................................249
19.5
IVR D
ISPLAY
S
CREENS
................................................................................................................ 249
20 INSTALLING & UPGRADING SOFTWARE .................................................. 252
APPENDIX A MENU STRUCTURES ......................................................................... 256
APPENDIX B EMCP 4 FRONT VIEW & NAVIGATION KEYS ................................... 258
APPENDIX C IVR EXCITATION MODULE CONNECTION DIAGRAMS................... 261
Foreword
This Application and Installation Guide describes the EMCP 4.1 and 4.2 series electric power generator set controls.
Some data used in this guide is generalized and is provided only for the purpose of comparison or illustration. Also, PC application screenshots and EMCP 4 screen images may be actual screens or simulated and are shown for illustrative purposes only. These images may not be identical to those seen by the user. Screen images of the EMCP 4 may differ from the actual screens depending on flash file language, flash file version, setpoint configuration, engine interface, or series of the EMCP (4.1 versus 4.2).
In various places throughout this document, reference is made to the release date of the
EMCP 4 software. This information can be found by connecting to the subject module using the Cat Service Tool, and viewing the ECM Summary (this is the default startup screen). The release date is found in the field entitled Software Group Release Date.
See Figure 1, showing the release date for an EMCP 4.2 flash file.
Figure 1: EMCP Software Release Date
Other product specific information and data is available from a variety of sources. For more information, contact the Cat dealer or dealer TC nearest you.
The information in this document is the property of Caterpillar Inc. and/or its subsidiaries.
Any copying, distribution, transmission to others, and any use except that for which it is loaned is prohibited without written permission.
CAT, CATERPILLAR, ADEM™, their respective logos, “Caterpillar Yellow”, the “Power
Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
Application and Installation Guide
1 GENERAL INFORMATION
EMCP 4.1, 4.2 Generator Set Control
1.1 INTRODUCTION
Caterpillar has developed a product line of Generator Set Controls for use in the
Electronic Modular Control Panel 4 (EMCP 4). They are available in four versions based on Generator Set Control feature sets.
The EMCP 4 Generator Set Control, or GSC, is the primary controller within the
Generator Set Control system. The EMCP 4 line of Generator Set Controllers includes
EMCP 4.1, 4.2, 4.3, and 4.4. Appendix B shows a front view of the EMCP 4.1 and 4.2.
This Application and Installation Guide is intended to cover the EMCP 4.1 and 4.2
Generator Set Control and its application in generator set systems. It also includes information on optional add-on modules. The intended audience for this guide includes
Cat generator set system designers, Caterpillar service support personnel, Cat Dealers and Service Technicians, contractors, and customers.
1.2 APPLICATIONS
The EMCP 4 product line of generator set controllers is designed for use in a wide range of applications. They can be used on standby and prime Cat brand power generator sets. The configurability of the controllers allows them to be used, in some cases, on other applications such as Marine auxiliary generators, switchgear applications, and industrial engines and generator sets.
Most of the information in this document applies to all applications. However, the document was written with Cat brand generator sets in mind. Please contact your
Caterpillar support representative for questions regarding different applications.
1.3 REFERENCES
The System Operation Testing, Troubleshooting, and Adjusting manual (UENR 1209) is also available for EMCP 4.1 and 4.2 Generator Set Controls. The genset Operations and Maintenance manual contains details for specific products.
©2013 Caterpillar
All rights reserved. Page 1
EMCP 4.1, 4.2 Generator Set Control
2 SAFETY INFORMATION
Application and Installation Guide
DO NOT
operate or work on a generator set unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Cat dealer for replacement manuals.
Proper care is your responsibility.
EMCP 4 control contains components that are sensitive to
ELECTROSTATIC DISCHARGE
(ESD). An electrostatic charge can damage the control resulting in EMCP 4 breakdown or improper operation.
Take the following precautions while installing/removing/handling the control:
Handle equipment correctly. Use ESD protective packaging and material handling containers that are anti-static and provide discharge protection and electric field suppression.
Use protective devices: ESD-protective workstations and/or work surfaces (grounding mat, anti-static wrist strap, etc).
Keep all plastic items away from the devices. Any plastic item is a potential static generator. This includes candy wrappers, foam cups, synthetic carpet, foam cushions, etc.
The anti-static bag cannot function as a static dissipating mat.
DO NOT use an anti-static bag for any other purpose than to enclose a product.
Caution:
The 70-pin connector on the back of the control is the most vulnerable area to
ELECTROSTATIC DISCHARGE
(ESD). While handling the EMCP 4, extra attention is required to the back of the control. The control may become damaged or inoperable if extra care is not taken.
Consult the Electrostatic Discharge Association for proper procedure during particular situations: http://www.esda.org
Page 2 All rights reserved.
Application and Installation Guide
3 INSTALLATION
EMCP 4.1, 4.2 Generator Set Control
3.1 MOUNTING LOCATION
When selecting a mounting location for the EMCP 4, consider the following:
Protection from high-voltage and high-current devices.
Protection from devices which may produce electromagnetic interference.
Protection from excessive vibration. The EMCP 4 controls are designed to withstand normal generator set vibrations. They should not be mounted directly to the engine block.
Protection from direct exposure to water. Once installed with gasket, the
EMCP 4 controllers are sealed to a level of IP Level 56 for resistance to moisture.
Suitable for Flat Surface Mounting in a Type 1 Enclosure only.
3.2 OPERATING TEMPERATURE RANGE
EMCP 4 has a continuous operating temperature range of -20
C (-4F) to +70C
(158
F) ambient.
The EMCP 4.1 and 4.2 require a nominal voltage of 12 VDC or 24 VDC. If batteries are used for operating power, a charging source such as an alternator or dual-mode battery charger is necessary to maintain a stable supply voltage. The maximum power consumption of the EMCP 4.1 and 4.2 with all I/O at maximum power drain will not exceed 5A at 12VDC, or 3.5A at 24VDC.
Regional electrical codes must be followed. In the case of standby operation, follow the regional requirements for installing standby power systems. An example of this is the
National Fire Protection Association (NFPA) guidelines for emergency power systems.
When connecting the EMCP 4 to the DC power source, make sure that there is only one common connection to the negative potential of the power source. Make extra effort to avoid any ground loops in the DC electrical system. A single point common ground for sensitive electronics is recommended at the negative battery terminal or Power
Distribution Box.
Avoid daisy-chaining power supply connections from one device to another. This builds resistance from one Battery (-) point to the next, effectively building a potential difference between two different reference points. Each electronics subsystem and major engine subsystem should have its own DC network so that they do not interfere with each other
(see Figure 2).
As shown in Figure 2, all sensitive electronics are electrically isolated from higher current loads, such as the starter motor. All electronics have a
COMMON POWER BUS
and
SINGLE
POINT REFERENCE
. This point is the genset customer ground connection. The
CHASSIS
GROUND
should be bonded separately to the customer ground connection and not be used as the electronics reference.
©2013 Caterpillar
All rights reserved. Page 3
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
The sensitive electronics, such as sensors and control modules, have isolated power source paths. High current loads such as starters and solenoids can cause interference and possibly damage to low current loads, such as controllers and sensors.
Caution:
Extra effort must be made to keep the high current and low current loads electrically separated.
Figure 2: Generator Set Network Isolation
The two types of loads may share common Battery (+) and Battery (–) connections but, they should not be electrically connected at any other point. This strategy ensures maximum isolation between high current and low current loads.
The battery
DISCONNECT SWITCH
is usually located on the negative side of the battery supply.
If a battery charger is to be used, it should be connected on the battery side of the disconnect switch. Most battery chargers are not to be used as power supplies. Proper battery charger operation requires that the actual battery load be present.
If battery charger fault condition wiring is connected to the EMCP Digital Inputs and these Digital Inputs are set to D
ISABLED
, then any battery charger faults or events will not be broadcast or annunciated on the network. See Chapter 8.
Page 4 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
The EMCP 4.1 and 4.2 share the same 70-pin connector on the back of the controller
(not all of the 70 pins are used). The 70-pin connector on the EMCP 4.4 is not the same as the 70-pin connector on the EMCP 4.1 and 4.2.
Figure 3 and Figure 4 show:
What pins are used for connections
How each pin is connected for each controller version
For EUI engines, the Oil Pressure and Coolant Temperature sensors will typically be wired to the engine ECM and the EMCP 4 will get that information from the engine ECM via the Primary CAN Data Link. Ensure the EMCP 4 Oil Pressure and Coolant
Temperature setpoints are configured for Data Link.
In order for the genset to function properly in Cooldown mode, some setpoints in the
EMCP 4 must be coordinated with some engine ECM setpoints. For gensets where the engine ECM controls cooldown, the cooldown time should be set to 0 seconds in the
EMCP. For gensets where the engine ECM does not control cooldown, the cooldown time should be set to 0 seconds in the engine ECM.
©2013 Caterpillar
All rights reserved. Page 5
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
3.7 EMCP 4.1 AND 4.2 ELECTRICAL DIAGRAMS
Figure 3: EMCP 4.1 Wiring Diagram
Page 6 All rights reserved.
Application and Installation Guide
Figure 4: EMCP 4.2 Wiring Diagram
EMCP 4.1, 4.2 Generator Set Control
©2013 Caterpillar
All rights reserved. Page 7
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
The connections between the generator and the EMCP 4 depend on the winding configuration as shown in the connection diagrams below.
Figure 5: Three Phase Four Wire (Series or Parallel) Wye (Star)
Figure 6: Three Phase Four Wire Delta (L2-N-L3)
Figure 7: Three Phase Three Wire Delta
Page 8 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Figure 8: Single Phase Three Wire (L1-N-L2), Double Delta
Figure 9: Single Phase Two Wire (L1-L2), Double Delta
Figure 10: Single Phase Three Wire (L2-N-L3), Zig-
Figure 11: Single Phase Two Wire (L2-L3), Zig-Zag
©2013 Caterpillar
All rights reserved. Page 9
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Figure 12: Three Phase Four Wire Delta(B-C-N-A) FIX PICTURE
In order to monitor generator output voltages greater than 600 Volts nominal (grounded wye (star)), external potential transformers must be used.
Note
: The EMCP 4 must be programmed for the correct winding ratios when connecting external potential transformers. See Chapter 7, Setpoints for more information on how to program the winding ratios. If delta potential transformers are used on a wye (star) generator, the EMCP must be programmed for a delta generator.
Caution:
The WYE (STAR) configuration of external potential transformers is preferred for 4-wire wye (star) generators because of the greater accuracy when loads are unbalanced. With the open delta configuration, some power parameters cannot be determined. These parameters are power phase A, B, C and power factor phase A, B, C. For maximum accuracy, the open delta configuration of external potential transformers should be used only for 3-wire delta generators. See Table 1: Power Values Available by Generator
Configuration.
(PT) on the 4-Wire Wye (Star) Connected Generator
Figure 13: Wye (Star) Configuration of External Potential Transformers
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
(PT) on the 3-Wire Delta Connected Generator
Figure 14: Open Delta Configuration of External Potential Transformers
(PT) on the 4-Wire Wye (Star) Connected Generator
Figure 15: Open Delta Configuration of External Potential Transformers
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Power Values Available by Generator Configuration
I
I
I
Parameter
WYE
(STAR)
3-WIRE
DELTA
4-WIRE
DELTA
2-WIRE
1-PHASE
(L1-L2)
2-WIRE
1-PHASE
(L2-L3)
3-WIRE
1-PHASE
(L1-N-L2)
3-WIRE
1-PHASE
(L2-N-L3)
Gen Freq
Available Available Available Available Available Available Available
V
L-L AVG
Available Available Available Available Available Available Available
V
A-B
Available Available Available Available Not Available Available Not Available
V
B-C
V
C-A
V
V
V
V
L-N AVG
A
B
C
AVG
A
B
I
C
Available Available
Available Not Available
Available Not Available Not Available Not Available Not Available
Available Not Available Not Available Available
Available
Not Available
Available Not Available Available Not Available Not Available Available
Available Not Available Available Not Available Not Available Not Available
Available
Available
Available Available Available Available Available Available Available
Available Available Available Available Not Available Available Not Available
Available Available Available Available Available Available Available
Table 1: Power Values Available by Generator Configuration
Note
: Accuracy of the potential and current transformers will affect the accuracy of the voltage and current readings.
Page 12 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
3.10 WIRING REQUIREMENTS
When selecting the type of wire to use, consideration must be given to the wire voltage drop, (line loss), accuracy, communication error, and other requirements. See Table 2.
Component
Min
Wire
Size
(AWG)
Type of Wire Connections
(1)
Three-Wire
Sensors
(When applicable.
Not used on all systems)
Two-Wire
Components
(Magnetic Speed
Sensors)
CAN (J1939) Data
Link cable
Engine Solenoids
(Air Shutoff)
Power
RS-485
Annunciator
16
16 or
18
16 or
18
14
14 or
16
Or
18
Shielded twisted triad cable is recommended.
For conduits inside facilities, use Belden 8618.
For the engine harness, use the 4G-2556
Shielded Cable. The cable must be resistant to fuel and oil. The cable must have a temperature range from -40ºC (-40ºF) to plus
125ºC (257ºF).
Shielded twisted pair cable is recommended.
For conduits inside facilities, use the 123-2376
Electrical Cable or the 3E-4594 Electrical Cable.
For the engine harness, use the 6V-2744 Wire.
The cable must be resistant to fuel and oil. The cable must have a temperature range of -40ºC
(-40ºF) to plus 125ºC (257ºF).
Part number 153-2707 is available for lengths of up to 200ft. The cable has a temperature range of -40ºC (-40ºF) to plus 125ºC (257ºF).
For longer runs, select a cable that meets SAE
J1939-11 requirements.
Deutsch DT type of connectors are recommended. If
Spring Spade or
Ring Terminals are used, the connection between the terminals and the wire should be crimped and soldered.
Stranded wire normally used on engine harnesses. The cable must be resistant to fuel and oil. The cable must have a temperature range of -40ºC (-40ºF) to plus 125ºC (257ºF).
Shielded twisted triad cable is recommended.
Stranded wire normally used on engine harnesses. The cable must be resistant to fuel and oil. The cable must have a temperature range of -40ºC (-40ºF) to plus 125ºC (257ºF).
(1)
The number of connections must be kept to a minimum.
Deutsch DT type of connectors are recommended. If
Spring Spade or
Ring Terminals are used, the connection between the terminals and the wire should be crimped and soldered.
The leads of the cable should have Spring
Spade Terminals or Ring
Terminals. The
Connection between the wire and the terminal should be crimped and soldered.
Deutsch DT type of connectors are recommended.
Table 2: Wiring Requirements
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
3.11 SHIELDED AND COMMUNICATION WIRING
Shielded twisted pair cable is required for the magnetic speed sensor. CAN cable is required for Primary and Accessory CAN Data Links. This cable is used for maximum protection against inductive noise, electromagnetic interference, and radio frequency interference. The shield greatly reduces the amplitude of any unwanted voltages on the signal wire. The shields should not be connected to the sheet metal. If the shields are connected to sheet metal, the connections are susceptible to loose bolts, corrosion, etc.
The faulty connections increase the resistance of the shield. Faulty connections also reduce the effectiveness of the shield.
When the cable terminates at junction boxes, the shields must be connected to each other in order to maintain a continuous path. A continuous path must be maintained in the shield wire for sensors, whenever possible. Wire exposed beyond the shield should be as short as possible. The shield must be connected to battery negative as close to the controller as possible. Shields should be drained at one point only. When possible, this should be done at, or close to, the EMCP 4.
To avoid electromagnetic interference, do not run shielded signal wires near other wires carrying large currents. In installations with unavoidable risk of electromagnetic interference (EMI), shielded wire run in conduit, extra shielding, or other precautions may be necessary.
Page 14 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
4 INITIAL OPERATION AND USER ORIENTATION
4.1 TYPES OF EMCP 4 EVENTS
The EMCP 4 has two lamps to annunciate events. The amber lamp indicates warningtype events, while the red lamp indicates shutdown-type events. The amber lamp also lights if a “Protect” lamp is being sent by a different module. ET2013B and later can be used to help identify what modules are sending different lamp statuses. The lamps flash when new events arrive, and remain flashing (often accompanied by an audible horn) until acknowledged by pressing the acknowledge button locally or remotely. Shutdowntype events do not clear until the user fixes the condition(s) that caused the shut down and “resets” the events. The EMCP 4 supports a very large number of events, and most events generated by the EMCP can be configured based on application needs. For information on viewing, resetting, and configuring events, see Chapter 5.
Note
: The EMCP 4 will annunciate and display events from other modules, even if these events are not generated by the EMCP 4. These events are not logged in the
EMCP itself, but are viewable from the individual module log located in the EMCP 4.
4.2 USING THE CAT SERVICE TOOL
Many of the features of the EMCP 4 system can be accessed via the Cat Service Tool.
These features include viewing status data, monitoring optional modules, viewing and resetting events, and configuring setpoints.
Note
: A minimum of the Cat ET Service Tool version 2010C is required to communicate properly with the EMCP 4. If an earlier version is used, the EMCP 4 will be grayed out. In order to have access to the latest setpoints, the latest version of the Cat ET service tool should always be used.
Throughout this document, instructions for accessing a feature both via the EMCP 4 display and via the Cat Service Tool will be given. However, the Cat Service Tool also offers other unique features that are useful for site commissioning, ECM retrofitting, or troubleshooting, such as the ability to log data to a file or graph data in real-time. Such features are not in the scope of this document. For more information on the Cat Service
Tool, refer to the Cat Service Tool documentation and training.
Figure 16 outlines the available EMCP 4 features that are available within the Electronic
Technician software.
Figure 16: Electronic Technician EMCP 4 Features
1. Status Tool
2. Active Diagnostic Codes
3. Logged Diagnostic Codes
4. Active Event Codes
5. Logged Event Codes
6. ECM Summary
7. Configuration Tool
8. Connect/Disconnect
9. Winflash
©2013 Caterpillar
All rights reserved. Page 15
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
When in the Status tool, buttons to Active Codes and Events are provided at the bottom of the screen.
CONNECTING TO THE EMCP 4 TO CONFIGURE SETPOINTS
In order to use the Cat Service Tool with the EMCP and configure setpoints, do the following:
1. Connect the Service Tool to the PC and configure the port settings as appropriate.
2. Ensure the Service Tool is connected to the Primary Data Link (CAN 1).
3. Start the Electronic Technician software.
4. The software will search the data links.
5. When the software finds the EMCP and connects to it, The ECM Summary screen will appear. If multiple devices are detected, always select the EMCP before continuing to be able to access special EMCP features with ET such as annunciator configuration and device lamp status.
Page 16 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
6. To view configurable parameters within the EMCP 4, press the Configuration button.
7. The parameter groups will appear.
8. Selecting a group in the left pane will show all the parameters within that group in the right pane.
Many generator and engine parameters are viewable in real time from both the Cat
Service Tool, and the EMCP 4 display.
F
ROM THE
C
AT
S
ERVICE
T
OOL
Parameters are accessed by selecting Information > Status from the menu, or by clicking on the S
TATUS
T
OOL
icon in the toolbar. Refer to the Cat Service Tool help from the
Help > Contents menu for more information on the Status Tool.
F
ROM THE
EMCP 4 D
ISPLAY
Parameters are accessed (irrespective of the current screen position) by pressing the AC
O
VERVIEW ,
E
NGINE
O
VERVIEW , or
Main Menu
buttons located below the screen. Detailed screens provide even more information by pressing the S
CROLL
D
OWN
button from each of the overview screens. For a description of the front view and navigation keys, refer to Appendix B.
The EMCP 4 parameters are organized with different levels of users in mind. These levels are as follows: View, Control, and Configure. Some of the parameters are accessible from multiple paths. For a complete menu structure, refer to Appendix A.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
SUPPORTED PARAMETERS
Different versions of the EMCP 4 support different numbers of parameters. EMCP 4.2 supports multiple parameters not supported on the EMCP 4.1. Some parameters are only available in certain configurations, for example, electronic engine ECMs provide more engine data than what is available from mechanical engines. The sections below list all of the parameters available, and on which level of EMCP 4 they may be available.
Parameters are displayed with units, some of which are configurable. For changing units or setting other user preferences see Chapter 4.4, Viewing and Adjusting Preferences.
Parameters that are not available to the EMCP 4 are shown as (four asterisks).
This may indicate an incorrect software configuration, a wiring problem, or a problem with the sensor.
ENGINE OVERVIEW
The Engine Overview screens display various engine parameters. The following parameters are displayed on the Engine Overview screens:
E
NGINE
O
VERVIEW
S
CREEN
Engine Oil Pressure
Engine Coolant Temperature
Battery Voltage, as measured at the connector entering the EMCP 4
Engine Operating Hours
Engine Operating State (Initialization,
Pre-Crank, Starting, Running, Pre-
Cooldown, Cooldown, Stopping,
Stopped, Idling; many states are transient and only briefly active, and some states may not occur in some configurations)
E
NGINE
S
CREEN
1
Engine Oil Pressure
Engine Coolant Temperature
E
NGINE
S
CREEN
2
Battery Voltage, as measured at the connector entering the EMCP 4
Engine Fuel Level or Engine Oil
Temperature via Analog input #3
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Application and Installation Guide
E
NGINE
S
CREEN
3 (EMCP 4.2
O
NLY
)
Engine Hours remaining until Service
Maintenance Interval expires, or
Calendar Days remaining until Service
Maintenance Interval expires
E
NGINE
S
CREEN
4
Total engine Cranks since last reset
(a crank is defined as the number of times the starter motor switches on)
Total engine Starts since last reset
(a start is defined as the number of times the engine transitions from below the Crank Terminate speed setpoint to above it)
E
NGINE
S
CREEN
5 (EMCP 4.2
O
NLY
)
Cylinder
(if temperature module is installed)
Press the D
OWN
arrow to view the remaining cylinder temperatures.
E
NGINE
S
CREEN
6 (EMCP 4.2
O
NLY
)
(if temperature module is installed)
Temperature
Left Exhaust Manifold
Right Exhaust Manifold
Intake
Exhaust
Turbo 1 Compressor Inlet
Turbo 2 Compressor Inlet
Turbo 3 Compressor Inlet
Turbo 4 Compressor Inlet
Turbine 1 Inlet
Turbine 1 Outlet
Turbine 2 Inlet
Turbine 2 Outlet
Turbine 3 Inlet
Turbine 3 Outlet
Turbine 4 Inlet
Turbine 4 Outlet
Press the D
OWN
remaining temperatures.
arrow to view the
EMCP 4.1, 4.2 Generator Set Control
©2013 Caterpillar
All rights reserved. Page 19
EMCP 4.1, 4.2 Generator Set Control
E
NGINE
S
CREEN
7 (EMCP 4.2
O
NLY
)
(if supported by Engine ECM)
Engine Oil Temperature
Engine Fuel Temperature
E
NGINE
S
CREEN
8 (EMCP 4.2
O
NLY
)
(if supported by Engine ECM)
Engine Fuel Pressure
Engine Crankcase Pressure
E
NGINE
S
CREEN
9 (EMCP 4.2
O
NLY
)
(if supported by Engine ECM)
Oil Filter Differential Pressure
Fuel Filter Differential Pressure
E
NGINE
S
CREEN
10 (EMCP 4.2
O
NLY
)
(if supported by Engine ECM)
Air Filter Differential Pressure
E
NGINE
S
CREEN
11 (EMCP 4.2
O
NLY
)
(if supported by Engine ECM)
Total Fuel Consumption
Instantaneous Fuel Consumption Rate
E
NGINE
S
CREEN
12
(if supported by SCR or Engine ECM)
SCR Tank Level Status
E
NGINE
S
CREEN
13
(if supported by SCR or Engine ECM)
SCR Tank Temperature
E
NGINE
S
CREEN
14
(if supported by SCR or Engine ECM)
SCR Air Assist Pressure
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Application and Installation Guide
All rights reserved.
Application and Installation Guide
E
NGINE
S
CREEN
15
(if supported by SCR or Engine ECM)
E
NGINE
S
CREEN
16
(if supported by SCR or Engine ECM)
SCR Exhaust Gas Differential
Pressure
E
NGINE
S
CREEN
17
(if supported by SCR or Engine
ECM)SCR System Status
Engine Screen 18
(if supported by SCR or Engine ECM)
Diesel Exhaust Fluid Dosing
Temperature
E
NGINE
S
CREEN
19
(if supported by SCR or Engine
ECM)Total Diesel Exhaust Fluid Used
E
NGINE
S
CREEN
20
(if supported by SCR or Engine ECM)
Time Since Last Inducement
E
NGINE
S
CREEN
21
(if supported by SCR or Engine ECM)
Time Remaining Until Inducement
EMCP 4.1, 4.2 Generator Set Control
©2013 Caterpillar
All rights reserved. Page 21
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
AC OVERVIEW
The AC Overview screens display various generator parameters. The following parameters are displayed on the AC Overview screens:
AC O
VERVIEW
S
CREEN
Average Line-Line AC Voltage
Power Factor (EMCP 4.2 Only)
Power Factor Lead/Lag status
(EMCP 4.2 Only)
Total Generator Real Power – kW
(EMCP 4.2 Only)
Percent Real Power as a percentage of
Generator Rated Power (EMCP 4.2 Only)
G
ENERATOR
S
CREEN
1
G
ENERATOR
S
CREEN
2
Voltages: A-N, B-N, C-N
G
ENERATOR
S
CREEN
3 (EMCP 4.2
O
NLY
)
Phase Generator Real Power – kW
Phase Generator Apparent Power – kVA
Phase Generator Reactive Power – kVAr
G
ENERATOR
S
CREEN
4 (EMCP 4.2
O
NLY
)
Phase Generator Real Power – kW
Phase Generator Apparent Power – kVA
G
ENERATOR
S
CREEN
5 (EMCP 4.2
O
NLY
)
Total Generator Real Power – kW
Total Generator Apparent Power – kVA
Total Generator Reactive Power – kVAr
G
ENERATOR
S
CREEN
6 (EMCP 4.2
O
NLY
)
Generator Real Energy produced since last meter reset
Generator Reactive Energy produced since last meter reset
Page 22 All rights reserved.
Application and Installation Guide
G
ENERATOR
S
CREEN
7
Average Line-Line AC Voltage
Average Line-Neutral AC Voltage
Power Factor (EMCP 4.2 Only)
Power Factor Lead/Lag status
(EMCP 4.2 Only)
G
ENERATOR
S
CREEN
8 (EMCP 4.2
O
NLY
)
Rear Bearing Temperature
(if temperature module is installed)
Front Bearing Temperature
(if temperature module is installed)
G
ENERATOR
S
CREEN
9 (EMCP 4.2
O
NLY
)
Generator Phase A Winding Temperature
(if temperature module is installed)
Generator Phase B Winding Temperature
(if temperature module is installed)
Generator Phase C Winding Temperature
(if temperature module is installed)
G
ENERATOR
S
CREEN
10 (EMCP 4.2
WITH
CDVR O
NLY
)
Generator Excitation Field Voltage
Generator Excitation Field Current
EMCP 4.1, 4.2 Generator Set Control
4.4 VIEWING AND ADJUSTING PREFERENCES
The EMCP 4 display can be used for monitoring the generator status, viewing and resetting events, and configuring setpoints. There are several preferences to alter how you view the data on the display. These include: display contrast, units used to display pressure, units used to display temperature, units used to display volume (EMCP 4.2 only), and displayed language (to select between the customer language and Technician
English).
Note
: These preferences do not affect operation of the EMCP 4, the values in the
SCADA Communications (Modbus) or the data as viewed in the Cat Service Tool. They only affect how the text and data is converted and displayed on the EMCP 4 display.
©2013 Caterpillar
All rights reserved. Page 23
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
SETTING THE PREFERENCES USING THE EMCP 4 DISPLAY
On the EMCP 4 display, the Preferences menu is located at the bottom of the Main Menu.
Scroll D
OWN
to the desired Preference.
Press the OK
K
EY
Use the Arrow keys to adjust the Preference as described below.
.
For any preference, press the OK
K
EY
to accept the change (or E
SCAPE
K
EY
to reject the change) and return to the Preferences menu.
Page 24 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
PREFERENCES
C
V
ONTRAST
OLUME
(EMCP 4.2 only)
This determines the darkness of the pixels on the display. A minimum contrast setting (reached by pressing and holding the down or left arrow) effectively blanks the screen, and a maximum contrast setting (reached by pressing and holding the up or right arrow) effectively darkens the entire screen. To change the contrast if the screen is unreadable due to a misconfiguration or ambient conditions, see
C
HANGING THE
EMCP 4
C
ONTRAST
W
HEN THE
D
ISPLAY IS
U
NREADABLE
.
P
RESSURE
This allows pressure parameters (such as Engine Oil Pressure) and setpoints
(such as Low Engine Oil Pressure Event Threshold) to be shown in either kPa, psi, or bar. Select the desired unit with the up or down arrows, or the Function keys.
T
EMPERATURE
This allows temperature parameters (such as Engine Coolant Temperature) and setpoints (such High Engine Coolant Temperature Event Threshold) to be shown in either Celsius (Centigrade) or degrees Fahrenheit. Select the desired unit with the up or down arrows.
This allows volume parameters (such as Fuel Volume) to be shown in Liters,
Imperial Gallons, or US Gallons. Select the desired unit with the up or down arrows.
L
AMP
T
EST
L
ANGUAGE
When this selection is highlighted, pressing and holding the OK
K
EY
will darken all pixels on the screen and illuminate all LED’s on the face of the controller.
This allows the display to be switched between Technician English (always listed first) and the customer language (always listed second, and written in the font of the customer language). Select the desired language with the up or down arrows. To change the language to Technician English, regardless of the current screen, and without needing to read the text, see C
HANGING
THE
EMCP 4 D
ISPLAY TO
T
ECHNICIAN
E
NGLISH
.
The
LANGUAGE
setting has been conveniently located at the bottom of the Preferences menu, which is at the bottom of the Main Menu.
©2013 Caterpillar
All rights reserved. Page 25
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CHANGING THE EMCP 4 CONTRAST WHEN THE DISPLAY IS UNREADABLE
1. Press the M
AIN
M
ENU
2. Scroll
D
OWN
key
until scrolling stops
3. Press the OK
K
EY
4. Press the OK
K
EY
(this will take you into the Preferences Menu)
again (this will take you into the Contrast selection)
5. Press and hold either
LEFT ARROW
or
RIGHT ARROW
and graphics become visible
until the text
6. Press the OK
K
EY
to accept the adjustment
CHANGING THE EMCP 4 DISPLAY TO TECHNICIAN ENGLISH
1. Press the M
AIN
M
ENU
2. Scroll
D
OWN
key
until the scrolling stops
3. Press the OK
K
EY
(this will take you into the Preferences Menu)
4. Press the D
OWN
A
RROW
key until scrolling stops
5. Press the OK
K
EY
6. Press the U
P
A
RROW
(this will take you into the Language selection)
key until the scrolling stops
7. Press the OK
K
EY
to select T
ECHNICIAN
E
NGLISH
The EMCP 4 language setting is changed back to T
ECHNICIAN
E
NGLISH
.
Page 26 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Similar steps can be followed by a customer who is unfamiliar with English, to change the language setting back to their primary language:
CHANGING THE EMCP 4 DISPLAY TO THE PRIMARY LANGUAGE
1. Press the M
AIN
M
ENU
2. Scroll
D
OWN
key
until the scrolling stops
3. Press the OK
K
EY
(this will take you into the Preferences Menu)
4. Press the D
OWN
A
RROW
until the scrolling stops
5. Press the OK
K
EY
6. Press the
D
OWN
(this will take you into the language selection)
arrow to select the customer language
7. Press the OK
K
EY
to change to the customer language
The EMCP 4 language setting is changed back to the customer language.
SETTING THE PREFERENCES USING THE SERVICE TOOL
Only the preferences for units can be configured using the Cat Service Tool. They are located in the Configuration Tool. Select Display Preferences from the left panel.
Figure 17: Display Preferences
©2013 Caterpillar
All rights reserved. Page 27
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
The display units can be changed the same way other setpoints are changed with the
Service Tool.
P
RESSURE
This allows pressure parameters (such as Engine Oil Pressure) and some setpoints (such as Low Engine Oil Pressure Event Threshold via
Datalink) to be shown in either kPa, psi, or bar.
T
EMPERATURE
This allows temperature parameters (such as Engine Coolant
Temperature) and setpoints (such High Engine Coolant Temperature
Event Threshold) to be shown in either Celsius (Centigrade) or degrees
Fahrenheit.
V
OLUME
(EMCP 4.2
ONLY
)
This allows volume parameters (such as Fuel Volume) to be shown in
Liters, Imperial Gallons, or US Gallons.
The EMCP 4.2 has an internal Real Time clock that is used for time-stamping events and Programmable Cycle Timer (Chapter 13). The timestamps for the last date and time an event has occurred and the first date and time the event has occurred are viewed by selecting a module in the Event Log and pressing the OK key, followed by the D
OWN
A
RROW
key. See Figure 18.
Figure 18: Event Details Screens
CHANGING THE TIME/DATE
The EMCP 4.2 clock allows the time/date to be modified. Changing the time/date will change the timestamp on all future events, but not for existing events. (For example, an event that has occurred previously will still show the same FIRST time/date, but if it occurs again after the time/date has been adjusted, the LAST time/date will reflect the change.)
This procedure must be performed on the EMCP 4 display; it cannot be done using the
Cat Service Tool. In order to update time/date, L
EVEL
1
ACCESS
is required. Refer to
Chapter 6.
Security for information on obtaining L
EVEL
1
ACCESS
.
Page 28 All rights reserved.
Application and Installation Guide
To change the time/date, do the following:
At
MAIN MENU
scroll
D
OWN
to
CONFIGURE
.
Press the
OK K
EY
.
EMCP 4.1, 4.2 Generator Set Control
Scroll
D
OWN
to
TIME
/
DATE
.
Press the OK
K
EY
.
To begin editing the time, press the
OK
KEY
while the current time is selected.
Press the
OK
KEY
again to enter the editor.
Select a digit using the
LEFT ARROW
or
RIGHT ARROW
To change the selected digit use the
To accept changes, press the OK
K
UP ARROW
EY
or
.
DOWN ARROW
.
. To reject changes, press the
ESCAPE KEY
.
©2013 Caterpillar
All rights reserved. Page 29
EMCP 4.1, 4.2 Generator Set Control
T
O
C
HANGE THE
D
ATE
F
ROM
T
HIS
P
OINT
Press the
ESCAPE KEY
SET TIME
/
DATE
screen.
again to return to the
Application and Installation Guide
Press the
RIGHT ARROW
around the date.
key to put the box
Press the OK
KEY
again to enter the editor.
Select a digit using the
LEFT ARROW
or
RIGHT ARROW
To change the selected digit use the
UP ARROW
.
or
DOWN ARROW
To accept changes, press the OK
K
EY
.
. To reject changes, press the
ESCAPE KEY
.
CHANGING DATE FORMAT
The data format can be set to either display in the form Month/Day/Year or the form
Day/Month/Year. This procedure must be performed on the EMCP 4.2 display; it cannot be done using the Cat Service Tool.
Note
: This preference does not affect operation of the EMCP 4 or the data as viewed in the Cat Service Tool. It only affects how the date is displayed on the EMCP 4 display and the format of the event time stamps.
Page 30 All rights reserved.
Application and Installation Guide
To change the date format, do the following:
At
MAIN MENU
scroll
D
OWN
to
CONFIGURE
.
Press the
OK K
EY
.
EMCP 4.1, 4.2 Generator Set Control
S
CROLL
D
OWN
to
TIME
/
DATE
.
Press the
OK K
EY
.
To begin editing the date, press the OK
KEY
while the current date is selected.
Select the format using the
LEFT ARROW
the OK
K
EY
or
RIGHT ARROW
, then press
to accept, or the
ESCAPE KEY
to reject, the change.
4.6 ADJUSTING GENERATOR SET PARAMETERS
On many gensets, the engine speed, generator output voltage, and idle/rated status can be adjusted from the display of the EMCP 4. This ability is dependent upon the engine interface strategy and input/output configuration.
GENERATOR OUTPUT VOLTAGE
If the genset is equipped with a Cat Digital Voltage Regulator (Cat DVR) or the
Integrated Voltage Regulator (IVR), then the generator output voltage setpoint can be adjusted from the display of the EMCP 4. When using the CDVR, the CDVR must be programmed to allow this control. In order for the
VOLTAGE ADJUST
to work via CAN, the
AVR V
OLTAGE
C
ONTROL
D
ESIRED
I
NPUT
C
ONFIGURATION
setpoint in the CDVR must be programmed for CAN
I
NPUT
. If that setpoint is set to S
WITCH
, the
VOLTAGE CONTROL
from the EMCP 4 will
NOT WORK
.
ENGINE SPEED
If the genset is equipped with an ADEM A3 or A4 governor, then the engine speed setpoint can be adjusted from the display of the EMCP 4, provided the A3 or A4 is programmed to allow this control. In order for the S
PEED ADJUST
to work via CAN, the
DESIRED THROTTLE
I
NPUT
C
ONFIGURATION
setpoint in the A3 or A4 must be programmed for CAN
I
NPUT
. If that setpoint is set to
PWM
, the
SPEED CONTROL
from the EMCP 4 will
NOT WORK
.
©2013 Caterpillar
All rights reserved. Page 31
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
P
ROGRAMMING THE
G
ENERATOR
O
UTPUT
V
OLTAGE AND
E
NGINE
S
PEED
From the
MAIN MENU
select
CONTROL
.
Press the OK
K
EY
.
From the C
ONTROL MENU
, select V
OLT
/H
Z
C
ONTROL
.
Press the OK
K
EY
.
The speed and voltage adjust screen will be displayed.
To adjust the generator voltage from this screen:
Press the
D
OWN
A
RROW
K
EY
to
DECREASE
the generator voltage.
Press the
U
P
A
RROW
K
EY
to
INCREASE
the generator voltage.
To adjust the engine speed from this screen:
Press the
L
EFT
A
RROW
K
EY
to
DECREASE
the engine speed.
Press the
R
IGHT
A
RROW
K
EY
to
INCREASE
the engine speed.
The EMCP 4 will broadcast a desired engine speed bias based on the adjustment that is made. When the engine speed is adjusted, then that value will remain until either it is adjusted again or until the control is power-cycled.
Unlike the setpoints or preferences
(i.e. contrast), any changes to this screen take effect immediately. The
OK K
EY
and E
SCAPE
K
EY
do not serve to accept or cancel changes.
IDLE/RATED
The EMCP 4.1 and EMCP 4.2 both have the ability to be placed into Idle mode via the display, a Discrete Input, or through the SCADA Data Link. With some genset systems, the engine ECM may also send the EMCP into Idle mode when the engine ECM is operating in Idle mode. Idle mode will disable Under Speed, Under Voltage, and Under
Frequency protections in the EMCP 4. It will also use a different set of oil pressure thresholds.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Note
: The Engine Forced Idle Feature Enable Status parameter must be set to
“Enabled” within Cat ET prior to seeing this menu option on the display. This setpoint is under the Automatic Start/Stop submenu in Cat ET.
When the EMCP 4 is placed in Idle mode, a programmable output may be programmed and wired to signal that it is operating in Idle. In some wiring configurations, the EMCP will also send a signal via the Primary CAN Data Link to the ADEM.
The engine speed can be toggled between L
OW
I
DLE
and R
ATED
S
PEED
from the display of the control as follows:
From the
MAIN MENU
select
CONTROL
.
.
Press the OK
K
EY
From the C
ONTROL MENU
select I
DLE
/R
ATED
.
Press the OK
K
EY
.
The IDLE/RATED screen will be displayed and the current state will be shown.
Press the OK
K
EY
.
Press the
UP ARROW
to change the state.
or
DOWN ARROW
Press the OK
K
EY
.
ENGINE SENSOR VERSUS DATA LINK
The Engine Oil Pressure and Engine Coolant Temperature setpoints need special care when programming. These can be configured as either SENSOR or DATA LINK.
When SENSOR is configured, the physical sensor is connected directly to the EMCP 4.
In this configuration, Analog Inputs are configured with the desired setpoints for the rated speed warnings and shutdowns. The idle setpoints are still configured under the Engine
Oil Pressure Monitor.
When DATA LINK is configured, the physical sensors are connected to the engine ECM.
The engine ECM is configured with setpoints to protect the engine. Sensor values may also be communicated to the EMCP over the data link. The EMCP allows for redundant setpoints to be assigned based on this information seen from the engine.
©2013 Caterpillar
All rights reserved. Page 33
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
T
O CONFIGURE THE CONTROLLER AS
SENSOR
OR
DATA LINK
USING THE DISPLAY
:
At
MAIN MENU
scroll
D
OWN
to
CONFIGURE
.
Press the
OK K
EY
.
S
CROLL
D
OWN
to ALL
S
ETPOINTS
.
Press the
OK K
EY
S
CROLL
D
OWN
to ENG
MONITOR/PROTECT.
Press the
OK K
EY
S
CROLL
D
OWN
to ENG
COOL TEMP MON
OR
ENG OIL PRES MON.
.
Press the
OK K
EY
Note
: Level 3 password is required.
.
.
Press the
OK K
EY
To change the selection use the
UP ARROW
or
DOWN ARROW
.
Press the
OK K
EY
.
T
O CONFIGURE THE CONTROLLER AS
SENSOR
OR
DATA LINK
USING
C
AT
ET:
1.
Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2.
Select Automatic Start/Stop on the left.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
3.
Double click the Engine Coolant Temperature Sensor Configuration setpoint to change this value from the drop down menu. Click the OK button to program.
4.
Double click the Engine Oil Pressure Sensor Configuration setpoint to change this value from the drop down menu. Click the OK button to program.
ENGINE OIL PRESSURE
The Engine Oil Pressure setpoints need special care when programming. The first step is to set the configuration as either SENSOR or DATA LINK.
When SENSOR is configured, the physical sensor is connected directly to the EMCP 4.
In this configuration, Analog Input #1 (normally used for Oil Pressure Sensor) is configured with the desired setpoints for the rated speed Oil Pressure warnings and shutdowns. The idle speed step and idle oil pressure setpoints are still configured under the Engine Oil Pressure Monitor.
When DATA LINK is configured, the physical sensor is connected to the engine ECM.
The engine ECM is configured with setpoints to protect the engine. Sensor values may also be communicated to the EMCP over the data link. The EMCP allows for redundant setpoints to be assigned based on this information seen from the engine.
©2013 Caterpillar
All rights reserved. Page 35
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
S
ENSOR
C
ONFIGURATION
In SENSOR configuration, Analog Input #1 contains the parameters for warnings and shutdowns for High and Low OIL PRESSURE. Security Level 3 is required to program
Analog Input #1.
T
O CONFIGURE
A
NALOG
I
NPUT
#1
FOR
E
NGINE
O
IL
P
RESSURE
:
A
T THE MAIN MENU
,
scroll down to
CONFIGURE
.
SCROLL DOWN
Press the OK
K
EY
to I
NPUTS
& O
UTPUTS
.
Press the OK
K
EY
.
.
SCROLL DOWN
to A
NALOG
I
NPUTS
.
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Select the A
NALOG
I
NPUT
#1.
Press the OK
K
EY
.
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, R
ESISTIVE
,
OR
V
OLTAGE
)
.
Scroll
DOWN
to R
ESISTIVE
.
Press the OK
K
EY
.
Scroll
DOWN
to D
ATA
I
DENTIFICATION
Press the OK
K
EY
to change the current D
ATA
I
DENTIFICATION
.
Select the D
ATA
I
DENTIFICATION
to ENG OIL PRES.
Press the OK
K
EY
.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Scroll
DOWN
to configure the remaining setpoints for Analog Input #1:
Map Selection Number
Low Warning Threshold
Low Warning Delay
Low Warning Event Response
Low S/D Threshold
Low S/D Delay
Low S/D Event Response
Shared Supply Voltage
In addition to the setpoints for high and low Oil Pressure available in Analog Input #1, setpoints for LOW IDLE LOW OIL PRESSURE and STEP SPEED are also available in the ENG MONITOR/PROTECT menu.
T
O CONFIGURE THESE SETPOINTS
:
At
MAIN MENU
scroll
D
OWN
to
CONFIGURE
.
Press the
OK K
EY
to ALL
S
ETPOINTS
.
.
S
CROLL
D
OWN
S
CROLL
D
OWN
Press the
OK K
EY
.
to ENG
MONITOR/PROTECT.
Press the
OK K
EY
.
S
CROLL
D
OWN
to ENG
OIL PRES MON.
Press the
OK K
EY
Note
: Level 3 password is required.
.
Scroll
DOWN
to configure the remaining setpoints for Engine Oil Pressure Monitor:
Low Eng Oil Pressure Warning Threshold
Low Idle Low Eng Oil Pres Warn Threshold
Low Eng Oil Pressure Warning Delay Time
Low Eng Oil Pressure Shutdown Threshold
Low Idle Low Eng Oil Pres S/D Threshold
Low Eng Oil Pressure Shutdown Delay Time
Low Engine Oil Pressure Step Speed
©2013 Caterpillar
All rights reserved. Page 37
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Note
: All DATA LINK OIL PRESSURE setpoints in this menu are inactive when in
SENSOR configuration. The Low Idle setpoints are still active regardless of SENSOR or DATA LINK. Setpoints labeled as DATA LINK to refer to the fact they are only active when the DATA LINK configuration is chosen.
D
ATA LINK
The OIL PRESSURE setpoints when in the DATA LINK configuration are redundant to the primary protection provided by the engine ECM. If these protections are not programmed to match those in the ADEM and an event occurs, check the Event Logs to determine which module generated the event.
ENGINE COOLANT TEMPERATURE
The Engine Coolant Temperature setpoints need special care when programming.
The first step is to set the configuration as either SENSOR or DATA LINK.
When SENSOR is configured, the physical sensor is connected directly to the EMCP.
In this configuration, Analog Input #2 (normally used for Coolant Temperature) is configured with the desired setpoints for Coolant Temperature warnings and shutdowns.
When DATA LINK is configured, the physical sensor is connected to the engine ECM.
The engine ECM is configured with setpoints to protect the engine. Sensor values may also be communicated to the EMCP over the data link. The EMCP allows for redundant setpoints to be assigned based on this information seen from the engine.
S
ENSOR
C
ONFIGURATION
In SENSOR configuration, Analog Input #2 contains the configurations for alarms and shutdowns for High and Low COOLANT TEMPERATURE. Security Level 3 is required to program Analog Input #2.
T
O CONFIGURE
A
NALOG
I
NPUT
#2
FOR
E
NGINE
C
OOLANT
T
EMPERATURE
:
A
T THE MAIN MENU
,
scroll down to
CONFIGURE
SCROLL DOWN
Press the OK
K
EY
to I
NPUTS
& O
UTPUTS
Press the OK
K
EY
.
.
SCROLL DOWN
to A
NALOG
I
NPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Select the A
NALOG
I
NPUT
#2
Press the OK
K
EY
.
.
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Application and Installation Guide
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, R
ESISTIVE
,
OR
V
OLTAGE
)
.
Scroll
DOWN
sensor
to select the appropriate
Scroll
DOWN
to D
Press the OK
K
EY
ATA
I
DENTIFICATION
.
Press the OK
K
EY
to change the current
D
ATA
I
DENTIFICATION
.
Select the ENG COOLANT TEMP
Press the OK
K
EY
.
EMCP 4.1, 4.2 Generator Set Control
Scroll
DOWN
to configure the remaining setpoints for Analog Input #2:
Map Selection Number
High Warning Threshold
High Warning Delay
High Warning Event Response
High Warning Threshold
Low Warning Delay
Low Warning Event Response
High S/D Threshold
High S/D Delay
High S/D Event Response
Shared Supply Voltage
Note
: All COOLANT TEMP setpoints in the ENG MONITOR/PROTECT menu are inactive when in SENSOR configuration. They are labeled as DATA LINK to refer to the fact they are only active when the DATA LINK configuration is chosen.
D
ATA LINK
The COOLANT TEMPERATURE setpoints when in the DATA LINK configuration are redundant to the primary protection provided by the engine ECM. If these protections are not programmed to match those in the ADEM and an event occurs, check the Event
Logs to determine which module generated the event.
©2013 Caterpillar
All rights reserved. Page 39
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
4.7 STARTING AND STOPPING THE GENERATOR SET
STARTING THE ENGINE
Once the control is configured correctly, the control panel is powered up, and the generator set is ready to be operated, the generator set can be started. Refer to Figure
19, Stopping The Engine. There are several ways the generator set can be started from the control panel.
To S
TART
the engine:
MANUAL OPERATION
, press the RUN
K
EY
or
2. Activate a Digital Input programmed for ECS in Run or
3. Place the control in A
UTO
mode then,
4. The engine can be started THREE
DIFFERENT
WAYS
:
REMOTE
S
TART INPUT
b: Activate a R
EMOTE
I
NITIATE
over the MODBUS data link (EMCP 4.2 only) a
ROGRAMMABLE
C
YCLE
T
IMER
(EMCP 4.2 only). See Chapter 13.
When the control panel initiates a start command on an engine, the EMCP checks to make sure there are no
SHUTDOWN EVENTS
present (labeled PRESENT) or that there are no latched
SHUTDOWN EVENTS
(labeled ACTIVE).
If there are no shutdown events that are active or present, and after any pre-crank or start-aid activities have completed, the starter motor and fuel control will be activated.
The EMCP 4 will activate the Relay Output programmed to activate the starter motor magnetic switch, and the Relay Output programmed to activate the fuel enable circuit.
On electronic engines with ADEM
A3 or newer engine ECMs using Common Engine
Interface, the start command and fuel enable signals may be sent from the EMCP 4 to the engine ECM via the PRIMARY CAN data link. After receiving the signals, the engine
ECM will operate the fuel control relay and starter motor magnetic switch. Relay Outputs
#1 and #2 are not needed on those engines and can be configured for other uses.
The Starter Motor Relay will remain active until the programmed
ENGINE CRANK TIME
has been reached, or until the engine speed has reached the programmed C
RANK
T
ERMINATE
S
PEED
setpoint value.
Note
: The EMCP 4 Crank setpoints number of cranks, crank duration, and crank terminate speed are not used on engines with the Common Engine Interface option or newer engine ECM. These values must be adjusted in the engine ECM.
Caution:
To determine the exact starting sequence for your engine, consult your engine’s Operation and Maintenance Manual.
Page 40 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Note
: If a Digital Input is programmed for ECS in Auto, or Run, or Stop, and a maintained switch latches that input to make it active, the front panel buttons will not have any effect.
EMCP 4 REMOTE START
The EMCP 4 has the ability to accept a remote start signal. If this signal is activated, the EMCP will send an Engine Start request to the engine controller. If the Remote Start signal is removed, the EMCP will send a Stop request signal to the engine controller.
A momentary signal will not keep the engine running.
This signal should be wired into pin 55. This input will be logically active when pulled down to battery negative.
STOPPING THE ENGINE
Once the engine is started, the engine can be stopped by pressing the STOP
K
EY
on the control panel, or activating a Digital Input programmed for ECS in Stop. If the control is in AUTO, the engine can also be stopped by
DEACTIVATING
all of the remote initiate commands. There are three possible sources for this command:
S
TART INPUT
over the Modbus data link (EMCP 4.2 only).
3. The P
ROGRAMMABLE
C
YCLE
T
IMER
(EMCP 4.2 only). See Chapter 13
Once the STOP command is issued, the control will go into
COOLDOWN MODE
. Cooldown mode will run for the duration of time that it is programmed in the C
OOLDOWN DURATION
setpoint. If the cooldown time is set for zero minutes, the engine will stop immediately.
On engines with ADEM
A4 or newer engine ECMs using Common Engine
Interface(CEI), the cooldown timer in the EMCP 4 should be set to 0 (Zero) minutes because the cooldown time is controlled from the engine ECM (if this is not done, both cooldown timers will run in sequence). Also, the E
NGINE
O
PERATING
S
TATE
I
NPUT
C
ONFIGURATION
parameter must be set to CAN
I
NPUT
.
The cooldown timer on the EMCP can be overridden by pressing and holding the STOP
K
EY
for approximately 5 seconds. The display will show a splash screen that will ask if you want to B
YPASS
C
OOLDOWN
? or continue with the cooldown cycle.
If the OK
K
bypassed.
EY
is pressed from the splash screen, the cooldown timer will be
If the E
SCAPE
K
EY
is pressed from the splash screen, the cooldown cycle will continue until the programmed cooldown time has elapsed.
©2013 Caterpillar
All rights reserved. Page 41
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
When the cooldown timer has elapsed or has been bypassed, the Discrete or Relay
Output programmed for fuel injection will be deactivated (by default, Relay Output #2 will deactivate, but this may be programmed differently). The
STOP
command will also be sent over the PRIMARY CAN data link for those engines that require it. The engine will come to a stop.
Any time, while the engine is
RUNNING
:
If the EMCP 4 detects a condition where an engine or generator parameter exceeds programmed event thresholds for a programmed amount of time, or another
SHUTDOWN EVENT
occurs, then the EMCP 4 will attempt to shut the engine down.
Note
: Event behavior is determined by setpoints called EVENT RESPONSE
CONFIGURATIONS. If a shutdown-type event’s EVENT RESPONSE
CONFIGURATION is disabled or not set to shutdown, it may not shut the engine down.
Appropriate default values are pre-configured in the factory. Modify EVENT RESPONSE
CONFIGURATIONS at your own risk! See Chapter 5.
Note
: If a Digital Input is programmed for ECS in Auto, or Run, or Stop, and a maintaining switch latches that input to make it active, the front panel buttons will not have any effect.
Depending on how a specific EVENT RESPONSE CONFIGURATION is programmed, the EMCP 4 will either put the engine in
COOLDOWN
,
followed by a shutdown (
SOFT
SHUTDOWN
) or shut the engine down immediately (
HARD SHUTDOWN
). See Figure 19.
Figure 19: Stopping the Engine
Page 42 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
EMERGENCY STOP
The EMCP 4 Emergency Stop input is configurable as Active High, or Active Low. The active state may be configured within the EMCP 4 display or within Cat ET.
T
O CONFIGURE THE
E-S
TOP
A
CTIVE
S
TATE
C
ONFIGURATION FROM THE DISPLAY
,
DO THE
FOLLOWING
:
At
MAIN MENU
scroll
D
OWN
to
CONFIGURE
.
Press the
OK K
EY
.
S
CROLL
D
OWN
to ALL
S
ETPOINTS
.
Press the
OK K
EY
.
S
CROLL
D
OWN
to C
ONTROL
.
Press the
OK K
EY
.
S
CROLL
D
OWN
to A
UTO
S
TART
/S
TOP
.
Press the
OK K
EY
S
CROLL
D
OWN
to E
MERGENCY
S
TOP
I
NPUT
A
CTIVE
S
TATE
C
ONFIG
.
.
©2013 Caterpillar
All rights reserved. Page 43
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
T
O CHANGE THE
E-S
TOP
A
CTIVE
S
TATE
C
ONFIGURATION WITH ET
,
DO THE FOLLOWING
:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select Automatic Start/Stop on the left.
3. Double click Emergency Stop Switch Input Configuration on the right to select a new value.
4.8 ENGINE SETPOINT VERIFICATION
The engine setpoint verification procedure verifies that the EMCP 4 operates correctly when a L
OW
O
IL
P
RESSURE
or H
IGH
C
OOLANT
T
EMPERATURE
event occurs. The engine setpoint verification procedure also verifies that the EMCP 4 operates correctly when an
ENGINE OVERSPEED
event occurs.
On an E
NGINE
O
VERSPEED
event, the EMCP 4 will shut the engine down.
L
OW
O
IL
P
RESSURE
and H
IGH
C
OOLANT
T
EMPERATURE
each have two events,
WARNING
and
SHUTDOWN
.
The EMCP 4 will issue a
WARNING
whenever the warning threshold is reached and a
SHUTDOWN
whenever the shutdown threshold is reached. This verification procedure will modify configuration setpoints used in normal operation. The steps below outline how to perform the LOW OIL PRESSURE SHUTDOWN and HIGH COOLANT
TEMPERATURE SHUTDOWN PROCEDURE. A similar process can be used for LOW
OIL PRESSURE WARNING and HIGH COOLANT TEMPERATURE WARNING, along with LOW IDLE LOW OIL PRESSURE.
Page 44 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
During this procedure
Each configuration setpoint should be recorded prior to adjustment.
Returned back to the original setting after the setpoint has been verified.
The following conditions are required before the
ENGINE SETPOINTS
are verified:
R
EQUIRED
C
ONDITIONS
The setpoints must be correct for the engine application.
No shutdown events should be present. If necessary, troubleshoot, correct, and reset any and all shutdown events.
PROCEDURE FOR OVERSPEED VERIFICATION
Note
: Adjustment of E
NGINE
O
VER
S
PEED
S
HUTDOWN
T
HRESHOLD
setpoint from the display requires a level 3 password. For details on changing security levels refer to Chapter 6.
The Security Level only affects changing parameters from the EMCP 4. Changing parameters with the Cat Service Tool does not require passwords.
1. Start the engine and run the engine at rated speed.
2. Adjust the setpoint value for Engine Over Speed Shutdown Threshold to a value that is below the speed that the engine is running at. An Engine Overspeed
Shutdown event will occur immediately after the setpoint is changed, and the engine will shut down.
3. View the event by going to the Genset Control event log. Reset the event.
For more information about how to view and reset the event, refer to Chapter 5,
Handling Events.
4. Return the setpoint value for Engine Over Speed Shutdown Threshold to the original value.
PROCEDURE FOR LOW OIL PRESSURE VERIFICATION
Note
: Low Oil Pressure Shutdown is disabled during start-up and while the engine is not running by the Fault Protection Timer (FPT). The fault protection timer starts timing when crank terminate rpm is reached during the starting sequence. The fault protection timer will then run for a programmed time which is determined by the Engine Start Fault
Protection Activation Delay Time setpoint. Make sure the fault protection timer has elapsed before starting the Low Oil Pressure Verification.
1. Start the engine and run the engine at rated speed.
2. Determine whether the controller is set for SENSOR or DATA LINK, refer to
Chapter 4.6.
If SENSOR is selected, perform steps 3-5 in the CONFIGUREINPUTS &
OUTPUTSANALOG INPUTS configuration for ANALOG INPUT#1 setpoints.
If DATA LINK is selected, perform steps 3-5 in the CONFIGUREALL
SETPOINTSENG MONITOR/PROTECTENG OIL PRES MON setpoints.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
3. Adjust the setpoint value for Low Engine Oil Pressure Shutdown Event Threshold to a value that is above the oil pressure that the engine is operating at. The shutdown event will occur after the programmable time delay (the Low Engine
Oil Pressure Shutdown Delay Time setpoint).
4. View the event by going to the Genset Control event log. Reset the event. For more information about how to view and reset the event, refer to Chapter 5,
Handling Events.
5. Return setpoint value for Low Engine Oil Pressure Shutdown Event Threshold to the original value.
PROCEDURE FOR HIGH COOLANT TEMPERATURE VERIFICATION
Note
: High Coolant Temperature shutdown is disabled during start-up and while the engine is not running by the Fault Protection Timer (FPT). The fault protection timer starts timing when the crank terminate rpm is reached during the starting sequence. The fault protection timer will then run for a programmed time (the Engine Start Fault
Protection Activation Delay Time setpoint). Make sure the fault protection timer has elapsed before starting the High Coolant Temperature Verification.
1. Start the engine and run the engine at rated speed.
2. Determine whether the controller is set for SENSOR or DATA LINK, refer to
Chapter 4.6.
If SENSOR is selected, perform steps 3-5 in the CONFIGUREINPUTS &
OUTPUTSANALOG INPUTS configuration for ANALOG INPUT#2 setpoints.
If DATA LINK is selected, perform steps 3-5 in the CONFIGUREALL
SETPOINTSENG MONITOR/PROTECTENG COOL TEMP MON setpoints.
3. Adjust setpoint value for High Engine Coolant Temperature Shutdown Event
Threshold to a value that is below the engine coolant temperature that the engine is operating at. The minimum value for this setpoint is 49ºC (120ºF), so you may have to run the engine for a few minutes to get the temperature above the minimum value. The shutdown event will occur after the programmable time delay (the High
Engine Coolant Temperature Shutdown Event Notification Delay Time setpoint).
4. View the event by going to the Genset Control event log.
5. Reset the event. Refer to Handling Events for more information about how to view and reset the event.
6. Return setpoint value for High Engine Coolant Temperature Shutdown Event
Threshold to the original value.
Page 46 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
4.9 ENGINE OPERATING HOURS
One of the features of the EMCP 4 is the ability to maintain the E
NGINE
O
PERATING
H
OURS
, which is the cumulative amount of time that the engine has run above the Crank Terminate speed. This time is displayed on the Engine Overview screen, just below Battery Voltage.
UPDATING ENGINE OPERATING HOURS
For applications where a new EMCP 4 is fitted to a generator set that was previously in operation, the EMCP 4 allows the user to increment the engine hours to match the engine.
Note
: Engine Hours can only be increased. They cannot be decreased.
This procedure must be performed on the EMCP 4 display; it cannot be done using the
Cat Service Tool. In order to update engine hours, L
EVEL
3
ACCESS
is required. Refer to
Chapter 6, Security.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
U
PDATING
E
NGINE
H
OURS
At
MAIN MENU SCROLL
S
CROLL
D
OWN
to C
ONFIGURE
Press the OK
K
EY
.
Scroll
D
OWN
to E
NGINE
O
PERATING
H
OURS
Press OK
K
EY
(if pressing OK has no effect, then Level 3 access has not been obtained)
Current E
NGINE
H
OURS
are displayed.
.
Press the OK
K
EY
to change the hours.
To edit the E
NGINE
H
OURS
, Select a digit using the
Application and Installation Guide
LEFT ARROW
or
RIGHT ARROW
To change the selected digit use the
UP ARROW
or
DOWN ARROW
.
To accept changes, press the OK
K
EY
. To reject changes, press the
ESCAPE KEY
.
Again, press the OK
K
EY
ESCAPE KEY
to confirm, or the
to reject the changes.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
5 HANDLING EVENTS
The EMCP 4 shows previous and current events from both the EMCP and external modules. These events are organized into logs for each physical module the EMCP 4 is receiving EVENT messages from.
The logs include:
GENSET CONTROL Events for the EMCP 4 GSC
ENGINE CONTROL Events for a Primary CAN Data Link-compatible engine ECM
DIGITAL AVR Events for the Cat Digital Voltage Regulator (Cat DVR)
THERMOCOUPLE Events for the Thermocouple Module
EXTERNAL I/O
RTD MODULE
SCR MODULE
Events for the Discrete Input/Output (DIO) module
Events for the Resistive Temperature Device (RTD) module
Events for Engine Aftertreatment systems
The Genset Control Log stores events generated by the EMCP 4. Any other event is stored within the module that generated the event. Even if the EMCP annunciates an event, it does not mean that the EMCP logs that event. It may be within another module’s log.
Each log is visible only if the module is connected to the appropriate data link, either the
Primary data link or the Accessory data link, and is communicating with the EMCP 4.
The list of Event Logs can be viewed by pressing the Event Log hotkey or via the
View Submenu. Select the log you wish to view and press OK to view the events.
The EMCP 4 supports more than one instance of some of the above modules. (See
Chapter 17, for the number of modules supported by each of the EMCP models). Those modules are uniquely identified with a number at the end of the log name.
The module number is software-configured, and is called the module’s ECU
I
NSTANCE
N
UMBER
. The ECU Instance Number can be viewed and modified by the Cat Service
Tool. See the appropriate sub section of Chapter 17, for the expansion module in question, to see how to program the Instance Number.
An event in the EMCP 4 Genset Control Log can be in one of three states; PRESENT,
ACTIVE
, or INACTIVE.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
PRESENT
ACTIVE
INACTIVE
Application and Installation Guide
This state is only applicable to the Genset Control Log. PRESENT means that the condition that caused the event is still present. The condition needs to be addressed before the event can be reset.
Note
: This state only applies to Genset Control events. Other modules will not have Present in logs.
The event was previously in a “Present” state, but it is no longer present. It has been latched by the event system and needs to be reset before the engine can be restarted.
Within the Genset Control Log, the condition that caused the event is still affecting the system, but may be reset. (See Chapter 5.3 through
5.6 on how to Reset Events). Warning type events automatically reset when the condition that caused the event is resolved and will never be
Active.
Within any log other than the Genset Control Log, the condition that caused the event is affecting the system. The event may, or may not, be resettable. If the Reset All command fails to reset the event, then this event is still occurring and must be resolved before the event can be reset.
Note
: Many events go from Present to Active when the engine is shutdown and may reoccur once the engine starts running again.
Further action may be required to resolve the issue.
The event has happened at some time in the past but is no longer affecting the system. Inactive events are stored for historical purposes only.
5.1 CONFIGURING EVENT RESPONSES FOR EMCP 4 GENERATED
EVENTS
The category of event, as well as other behavior when an event occurs, can be configured via a group of EMCP 4 setpoints called E
VENT
R
ESPONSE
C
ONFIGURATIONS
.
An example of an event response configuration is L
OW
E
NGINE
L
OW
O
IL
P
RESSURE
W
ARNING
E
VENT
R
ESPONSE
C
ONFIGURATION
. This setpoint determines what actions the
EMCP 4 takes when it receives an event.
Note
: Event Response Configuration is only valid for the EMCP 4, not any other modules.
Each E
VENT
R
ESPONSE
C
ONFIGURATION
type setpoint can either be viewed or edited. By default, VIEW is highlighted. These setpoints can only be edited when the ECS (Engine
Control Switch) is in the Stop mode.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
The following is a list of all the possible options for an event response configuration:
W
ARNING
Creates a Warning event in the event log and lights the amber LED.
The engine will not shut down. A Warning event will reset by itself
(i.e. it will go from the “Present” state to the “Inactive” state) as soon as the condition that caused it goes away.
A
UDIBLE
A
LERT
Determines whether this event will also trigger an audible horn. If so, the event activates any relays that are programmed for Horn Control
(see Chapter 10 Relay Outputs or Chapter 10 Digital Outputs). If no relay is programmed for Horn Control, no action will be taken; the
EMCP 4 does not have an internal horn. Audible Alert can only be programmed if either a Warning or Shutdown is also programmed.
S
OFT
S
HUTDOWN
Creates a Shutdown event in the event log, lights the red LED, and shuts the engine down after the cooldown period has expired (see
Chapter 4.5, Starting and Stopping the Engine).
H
ARD
S
HUTDOWN
Creates a Shutdown event in the event log, shuts the engine down immediately and lights the red LED.
B
REAKER
#1 T
RIP
Activates a Breaker #1 Trip, which can be programmed for a Relay
Output or Digital Output for external use. Breaker #1 usually refers to the Generator circuit breaker.
B
REAKER
#2 T
RIP
Activates a Breaker #2 Trip, which can be programmed for a Digital
Output or Relay Output for external use. Breaker #2 may refer to a second circuit breaker.
F
AULT
P
ROTECTION
Suppresses the event unless the engine is running and the Fault
T
IMER
E
NABLED
Protection Timer has expired (this prevents nuisance events during startup, or ones that are not relevant when the engine is stopped).
A
CTIVE
O
NLY
Creates an Active Only event in the event log. Active Only events are for informational purposes only. They typically do not light the
Amber LED or behave like a Warning (although many events can be configured to do so). When the condition goes away, the event disappears from the event log.
Note:
Not all options are available for all setpoints. For example, the Engine Low
Oil Pressure Warning event cannot be configured as a shutdown, because there is a separate event (Engine Low Oil Pressure Shutdown) dedicated for that purpose.
Likewise, events cannot be generated for any and all conditions. For example, a Low
Engine Coolant Temperature Shutdown is meaningless and cannot be generated.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
5.2 CHANGING AN EVENT RESPONSE CONFIGURATION
To change an event response configuration, the control must be in STOP mode.
Here are the steps to access event response configurations on the EMCP 4 display.
At
MAIN MENU
,
scroll
D
OWN
to C
ONFIGURE
Press the OK
K
EY
.
Scroll D
OWN
to
ALL SETPOINTS
.
Scroll D
OWN
Press the OK
K
EY
to
EVENTS
Press the OK
K
EY
to
EVENT RESPONSE CFG
Scroll D
OWN
Press the OK
K
EY
Scroll D
OWN
event to configure.
to choose the group for the
.
Press the OK
K
EY
.
.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
The group name should help find the setpoint. However, a list of setpoints in each group, or submenu is given in Table 3.
Diagnostics
Config
Accessory
Data Link*
Link
Link*
Battery
Charger Fail
*EMCP 4.2 only
Engine Protection
Config
Pressures
Temperatures
Exhaust
Eng Cont Not
Responding
Levels
RS485-
Annunciator
Data Link*
Inputs
Fuel
Ext Fuel Tank
Others
Air
Closed
Unexpected
Engine
Shutdown
Overspeed
Underspeed
Emergency
Stop
Generator
Protection
Config
Generator
Rear Bearing
Temperature
Generator
Overcurrent
Generator
Over
Frequency
Generator
Under
Frequency
Reverse
Power
Generator
Over Voltage
Generator
Under
Voltage
Generator
Winding
Temperature
#1
Generator
High Power
Reverse
Reactive
Power
Custom
Event
Config
Other System
Config
Digital
Input
Custom
Events
Analog
Input
Custom
Events
Battery
Charging
System Voltage
Generator
Breaker Open
Generator
Breaker Closed
Event
Inputs
Aux
Event
Inputs
Engine
Cooldown
Speed-
Frequency
Mismatch
Not in Auto
EPS
Load
Battery
Cranking
Voltage
Event System
Engine
Lamp
Conditions*
Trip #1
kW
Trip # 2
Service
Maintenance
Interval
Manifold
Charge
Combustion
Table 3: Event Response Configuration Setpoints
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
E
XAMPLE
:
Select
ENGINE
P
ROTECTION CONFIG
Press the OK
K
EY
Application and Installation Guide
.
In this group of event response configurations, there are four types of events, grouped by the type of data:
Pressures, Temperatures, Levels, and Others (such as status).
Select
P
RESSURES
Press the OK
K
EY
.
To edit a setpoint, press the
RIGHT ARROW
key to highlight EDIT.
This brings up a list of event response configuration setpoints. Use the Up or Down arrows to scroll though the list.
Note
: This will only work if the control is in
STOP
mode. Some setpoints cannot be configured, or require a minimum security level. Those setpoints will display a lock icon to the right of the EDIT text.
Then, press the
OK K
EY
to edit the setpoint.
Here you can edit individual responses, as described above.
Use the
LEFT ARROW
and
RIGHT ARROW
to toggle between checked and unchecked, and use the
UP ARROW
and
DOWN ARROW
move between the responses.
to
Some responses are fixed and cannot be disabled. For those responses, a lock will be displayed instead of a checkbox.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
5.3 RESETTING INDIVIDUAL ACTIVE EVENTS FOR THE EMCP 4
There are three ways to reset events. One way, described in this chapter, which applies to the EMCP 4 GSC only (the “Genset Control” log), is to reset individual Active events by navigating to the desired event in the event log, described below.
The second way, which applies to all modules other than the EMCP 4, is to reset all
Active events in that module’s event log by navigating to one of the Active events in that event log (see Chapter 5.4).
The third way is an approach that resets all Active events for all modules (see Chapter 5.5).
With any of these methods, you must be in STOP mode.
To reset individual events on the EMCP 4, start by navigating to the event log:
At
MAIN MENU
Select V
IEW
by pressing the
OK K
EY
.
Alternately, press the E
VENT
L
OG BUTTON
to access the
E
VENT
L
OG
.
Select
EVENT LOGS
by pressing the OK
K
EY
.
Scroll up or down the G
ENSET
C
ONTROL
L
OG
to select
Press the
OK K
EY
Scroll up or down through the list of events and find the ACTIVE event that requires resetting.
Generally, events are ordered by the status of the event; P
RESENT
events are listed first, followed by ACTIVE events, and finally the
INACTIVE
events. Within each status, the events are listed with the most recent first.
.
In this example image, there is one
PRESENT
or
ACTIVE
event under Genset Control #1.
Press the
OK K
EY
feature.
to enable the reset
Press the
OK K
EY
to reset the event.
Notice that the event changes from Active to
Inactive.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
5.4 RESETTING ALL ACTIVE EVENTS FOR A SINGLE MODULE
The second way to reset events, described in this chapter, which applies to all modules other than the EMCP 4, is to reset all of the module’s Active events by navigating to one of the Active events in the event log. This method doesn’t apply to the EMCP 4 GENSET
CONTROL log. For information on resetting events on the EMCP 4, see chapters 5.3 or 5.5.
With any method, you must be in STOP mode. A key difference between the EMCP 4 and all other modules is that the other modules don’t display a PRESENT status for events.
Events are shown as ACTIVE if they are currently affecting the system, or as INACTIVE if they are not.
To reset all of a modules Active events on any individual module except the EMCP 4
(listed as GENSET
CONTROL
in the event log), start by navigating to the event log.
At
MAIN MENU
scroll
D
OWN
to V
IEW
by pressing the OK
K
EY
.
Select
EVENT LOGS
by pressing the OK
K
EY
.
Scroll
UP
or
DOWN
the desired log and
Press
OK
details.
K
EY
to select
Press
OK K
EY
to view the first event
.
Pressing the OK
K
EY
will allow an option to
RESET
all events in the selected module.
Pressing the OK key will reset all of the
ACTIVE
events in that module’s event log that can be reset.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Note
: Modules other than the EMCP 4 cannot display events as PRESENT.
If pressing OK
K
EY
at RESET
ALL
doesn’t reset all of the events, the condition causing the event being viewed may still be present. For example, if the engine shut down on high coolant temperature, then the events will not reset until the coolant temperature drops below the shutdown threshold.
5.5 RESETTING ALL ACTIVE EVENTS FOR ALL MODULES
The third way to reset events, described in this chapter, is a shortcut that resets all
Active events for all modules. With any method, you must be in STOP mode.
Once all of the condition(s) that are causing the events have been corrected, all Active events (those for which the condition is not present) on all modules can be reset using the
RESET ALL EVENTS
feature.
In order to do this, the control must be in
STOP
mode and engine speed should be zero.
F
ROM ANY SCREEN
:
Press the RESET
K
EY
.
A confirmation prompt will appear.
Pressing the OK
K
EY
will continue and
RESET
all events on all modules.
Pressing the
ESCAPE KEY
will
CANCEL
the reset operation.
The controller will display which events were reset, and which ones were not.
Note
: Reset All Events will not reset Present events! For example, if the E-Stop switch is pressed and an EMERGENCY
STOP SHUTDOWN
is present, it cannot be reset until the E-Stop is pulled out and the event status changes from PRESENT to ACTIVE.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
5.6 RESETTING EVENTS FOR ENGINE ECMS WITHOUT PRIMARY CAN
DATA LINK SUPPORT
The EMCP 4 has the ability to reset all events for electronic engines with no PRIMARY
CAN support by means of a Relay Output. A number of conditions must be satisfied in order for this to work.
F
IRST
:
S
ECOND
:
One of the Outputs must be configured as a Command/Status for ECU
F
AULT
R
ESET
. See Chapter 10.
The corresponding output must be wired to a corresponding Fault Reset I/O pin on the engine ECM or it must be setup to power cycle the ECM.
T
HIRD
:
Pressing the RESET
ALL KEY
with this option selected will activate the
ECU F
AULT
R
ESET
, which will activate the corresponding Relay Output and trigger the engine ECU to reset its faults or will power cycle the ECU. This will only active the ECU FAULT RESET OUTPUT if the EMCP has a warning or fault. This warning or fault can be triggered by using a custom event on a digital input that is wired to the fault alarm of the ECU.
5.7 TROUBLESHOOTING RESETTING EVENTS
There are common reasons for the EMCP 4 not allowing events to be reset. First of all, in order to reset any event, the EMCP 4 must be in STOP mode. In order to reset engine
ECM events, the engine speed must also be zero.
SERVICE MAINTENANCE INTERVAL WARNING
and NOT
IN AUTO WARNING
are explained more fully below.
NOT IN AUTO WARNING
This event is Present whenever the control is in either RUN or STOP. As a result, it cannot be reset in STOP (since the event is present). The event will reset when the control is returned to A
UTO
. This event can be disabled by modifying the
GENERATOR CONTROL NOT IN AUTOMATIC WARNING EVENT RESPONSE
CONFIGURATION setpoint. See Chapter 7 for instructions on editing that setpoint.
SERVICE MAINTENANCE INTERVAL (EMCP 4.2 ONLY)
If a SERVICE
MAINTENANCE INTERVAL WARNING
is PRESENT, it cannot be reset.
The warning is PRESENT because one of the countdown timers has reached zero. To clear the warning, the timer must be reset, rather than the event. When the timer is reset, it returns to the programmed interval (typical is 180 calendar days and 500 engine hours).
This timer must be reset from the display; it cannot be reset by using the Service Tool alone. This warning can only be disabled by using the Event Response Configuration. See
Chapter 5.2.
Note
: This warning does not appear on the face of the EMCP 4 as a flashing LED unless configured to do so within Cat ET under Event Response Configuration – Engine
Protection Events.
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Application and Installation Guide
T
O VIEW THE TIMER SETTINGS ON THE DISPLAY
:
At
MAIN MENU
scroll
D
OWN
to C
ONFIGURE
Press the OK
K
EY
.
EMCP 4.1, 4.2 Generator Set Control
Scroll
DOWN
to R
ESET
C
OUNTER
Press the OK
K
EY
.
Scroll
DOWN
until you reach
SERVICE MAINTENANCE INTERVAL
Press the OK
K
EY
The
SERVICE MAINTENANCE INTERVAL
H
OURS
is displayed.
.
Scroll
DOWN
to view the
SERVICE MAINTENANCE INTERVAL
D
AYS
Press the OK
K
EY
Scroll
DOWN
to view the
P
ASSWORD
R
EQUIRED TO
R
ESET THE SERVICE
MAINTENANCE INTERVAL
.
The security level required to reset the service maintenance level is shown as a level 2, but the security level required to change the level is level
3. The required security level can be changed by using the Service Tool.
.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
T
O RESET THE TIMER ON THE DISPLAY
:
At
MAIN MENU
scroll
D
OWN
to C
ONFIGURE
Press the OK
K
EY
.
Scroll
DOWN
to R
ESET
C
OUNTERS
Press the OK
K
EY
to S
ERV
M
AINT
I
NTERVAL
Scroll
DOWN
Press the OK
K
EY
RESET SERV INTVL?
is highlighted. To
RESET
the service interval press the OK
K
EY
.
A confirmation prompt will appear. Pressing the
OK K
EY
will continue and
RESET
the service maintenance interval. Pressing the
ESCAPE KEY
will
CANCEL
the reset operation.
The new Service intervals will be displayed.
.
.
Application and Installation Guide
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
T
O ADJUST THE TIMER SETTINGS FROM
C
AT
ET,
DO THE FOLLOWING
:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select Service Maintenance Interval on the left.
3. Double click Maintenance Level 1 Cycle Interval Hours on the right to enter a new interval.
4. Double click Maintenance Level 1 Cycle Interval Days on the right to enter a new interval.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
5. Double click Customer Password Security Level to Reset Service Maintenance
Interval on the right to enter a new security level.
Caution:
Be sure to change the password level back to L
EVEL
3
after the reset, to prevent inadvertently resetting the timer at other times!
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
6 SECURITY
There are five levels of security access on EMCP 4: L
EVEL
0
, L
EVEL
1
, L
EVEL
2
, L
EVEL
3
, and S
ERVICE
T
OOL
. Any configurable parameter or function that is set to Level 0 can be accessed by anyone at any time, and there will never be any security information on the display screen.
L
EVEL
1
ACCESS
and L
EVEL
2
ACCESS
represent increasing levels of access to the setpoints and functions of the controller. Both levels 1 and 2 can be password protected with separate user-defined passwords.
Note
: These are optional levels of security; by default these passwords are disabled, and the default access level is LEVEL 2 from Parts Service.
L
EVEL
3
ACCESS
is password protected at the factory, and requires contacting the Cat
D
EALER
TC
to obtain a password.
If the present security level of the controller is below the level needed to perform a desired function, a padlock and a number will be displayed at the bottom right hand corner of the display. The number represents the level of security that is required in order to perform the desired function; 1, 2, or 3.
If there is a padlock but no number, then the Cat Service Tool is required in order to perform the desired function; or the setpoint may be read only and cannot be changed.
All of the adjustable parameters are associated with a specific level of security required to make an adjustment to the parameter. Certain functions, such as resetting the number of crank attempts, are also associated with a specific level of security. The passwords only affect actions taken at the EMCP 4. Access of the EMCP 4 remotely via the Cat
Service Tool or via the SCADA data link is not affected by the security level on the
EMCP 4 display.
Changing parameters with the Cat Service Tool does not require passwords, since the
Service Tool already has the highest level of access.
When connecting via the SCADA
DATA LINK
, passwords can also be used. The levels of access granted via SCADA are identical to the levels of access granted at the EMCP 4.
However, the passwords themselves may differ. Furthermore, the EMCP 4 and the
SCADA data link may be at different levels of access at any given time. For more information about SCADA security see Chapter 18.
Level 1 and Level 2 passwords are usually
DISABLED
when shipped from the factory.
Level 1 and Level 2 passwords can be user defined if desired. If the Level 1 and Level 2 passwords are not user defined, the Level 2 will be the
MINIMUM LEVEL
. All parameters that require Level 0, Level 1, or Level 2 security will be able to be changed by anyone at any time.
Note
: The EMCP 4 will always move up in security level to the highest level of access that is not password protected when a certain level of access is requested. For example, if a Level 1 password has been defined, but a Level 2 password has not, the EMCP 4 will start at Level 0 on power up. When the Level 1 password is entered, the EMCP 4 will move up to Level 2 access. If neither a level 1, nor a level 2 password has been defined, the EMCP 4 will always be at least at a Level 2 access.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
T
HE
S
ECURITY
M
ENU
To get to the security menu:
At
MAIN MENU
scroll
DOWN
to Configure
Press the OK
K
EY
.
Application and Installation Guide
At
SECURITY
,
press the OK
K
EY
.
The S
ECURITY
M
ENU
will show the current level of security at the top of the screen.
There are six options on the security menu:
DROP TO MIN LEVEL CHANGE LVL 1 PSWD
ENTER LEVEL 1 or 2 CHANGE LVL 2 PSWD
ENTER LEVEL 3 CHANGE SCADA PSWD
Selecting DROP
TO MIN LEVEL
will make the control go to the minimum level of security. As previously discussed, if the level 1 and level 2 passwords are not defined by the user, the minimum level of security will be level 2. If a level 2 password is defined by the user, but not a level 1 password, then the minimum level of security will be level 1.
In contrast, if a level 1 password is defined by the user, but not a level 2 password, then the minimum level of security will be level 0.
Page 64 All rights reserved.
Application and Installation Guide
Selecting ENTER
LEVEL 1
OR
2
will open up a password entry screen.
EMCP 4.1, 4.2 Generator Set Control
The password entry screen will have 4 spaces. In each space a numbers from 0 through 9 can be entered. The password can be from 1 to 4 digits and is entirely user defined. Enter the password for either level 1 or level 2 if either of those passwords have been defined. Use the
UP
ARROW
or
DOWN ARROW
to change the value of any highlighted digit. Use the
LEFT ARROW
or
RIGHT ARROW
to navigate between digits.
Selecting ENTER
LEVEL 3
will cause the display to say “
PHONE IN WITH
”
and a 16 digit number will be displayed. Under that,
ENTER RESPONSE
will be highlighted. Record the 16 digit number and call the
Cat Dealer TC with this number. The TC will reply with another 16 digit number. Note: Level 3 seed key and response will change based on various pieces of information. It is valid only when generated, and will be different in the future for that specific controller.
Press the OK
K
EY
from the
PHONE IN WITH
screen, and a password entry screen will be displayed. Enter the password that was supplied by the TC in the same manner as the other types of passwords.
Press the OK
K
EY
to confirm, or
ESCAPE KEY
to reject the change. Pressing the OK
K
EY
after entering the number will set the current level to 3. The control will remain in level 3 security level until no key presses have been made for 10 minutes. After 10 minutes of inactivity the control will revert back to the minimum level of security.
Note
: To change a level 3 parameter requires either a level 3 password from the TC or a
PC connection using a Service Tool. Therefore, if you have a Service Tool, try to change the parameter using the Service Tool rather than calling the TC.
Selecting CHANGE
LVL 1 PSWD
will allow for the level 1 password to be changed. The control must be at level 1 security in order to select
CHANGE LVL
1
PSWD
. The
CHANGE
LVL
1
PSWD
screen looks just like the password entry screen. It has 4 blank spaces that can each be set to a number from 0 to 9. The password can use as few as one digit and can use as many as 4 digits. It is entirely up to the user. If a password has been set but, it is now desired to not have level 1 password protection, the level 1 password can be disabled by setting the password to be a single 0.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Once the desired password is entered, press the OK
K
EY
and the control will go back to the security screen and the level 1 password will be set.
Selecting CHANGE
LVL 2 PSWD
will allow for the level 2 password to be changed.
The control must be at level 2 security in order to select
CHANGE LVL
2
PSWD
. The
CHANGE LVL
2
PSWD
screen looks just like the password entry screen. It has 4 blank spaces that can each be set to a number from 0 to 9. Selecting a password is entirely up to the user and can use as few as one digit or as many as 4 digits.
The level 2 password can be disabled by setting the password to be a single 0.
Once the desired password is entered, press the OK
K
EY
and the control will go back to the
SECURITY SCREEN
and the level 2 password will be set.
Selecting CHANGE
SCADA PSWD
will allow for the SCADA password to be changed.
This password, if
ENABLED
, will require a SCADA system to first enter the password into the W
RITE
A
CCESS
P
ASSWORD
register prior to conducting any other reads and writes.
The control must be at level 2 security in order to select
CHANGE SCADA PSWD
. The
CHANGE SCADA PSWD
screen looks just like the password entry screen. It has 8 blank spaces that can each be set to a number from 0 to 9. The password can use as few as one digit and can use as many as 8 digits.
Just as with level 1 and level 2 passwords, entering a single 0 will
DISABLE
the SCADA password.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
7 SETPOINTS
The EMCP 4.1 and 4.2 have a variety of setpoints that can be programmed or adjusted.
These setpoints can be adjusted via the display, or via the Cat Service Tool. In order to program the setpoints via the display, go through the following menu options:
At
MAIN MENU
scroll
D
OWN
to C
ONFIGURE
Press the OK
K
EY
.
Scroll D
OWN
to
ALL SETPOINTS
Press the OK
K
EY
.
All of the setpoints on EMCP 4 can be accessed through this menu. However, setpoints related to input and output configuration can also be accessed through the INPUTS
AND
OUTPUTS
menu under CONFIGURE. It is recommended to use the latter to configure inputs and outputs. For more information on configuring inputs and outputs, see
Chapter 8 through 10.
Setpoints can be one of four different types: N
UMERICAL
E
NTRY
, S
ELECTION
, S
USPECT
P
ARAMETER
N
UMBER
,
or E
VENT
R
ESPONSE
.
Each type is configured differently. For configuring any setpoint via the display, the user must first have the proper security access. See Chapter 6 for more information on security.
N
UMERICAL
E
NTRY
setpoints are parameters like time delays, thresholds, etc. For these setpoints the display will show the current value.
To change the value of a N
UMERICAL
E
NTRY
type setpoint:
1. Press the OK
K
EY
when the setpoint is highlighted. The current value of the setpoint will be shown with the rightmost digit highlighted.
and
DOWN
arrow keys to adjust that digit to the desired value. Digits will wrap around. Therefore, pressing up when 9 is shown will change it to 0, or pressing down when 0 is shown will change it to 9.
3. Once that digit is set to the desired value, use the
LEFT
arrow key to move the cursor to the next digit.
4. Then use the
UP
desired value.
and
DOWN
arrow keys to adjust that digit to the
5. Continue this process until the desired value for the setpoint is set.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
6. Then press the OK
K
EY
to save the value.
Tip: You can quickly select the largest possible value for the setpoint by pressing the
LEFT
arrow key until the leftmost digit is shown, and then pressing the
UP
arrow key until the value stops changing. Similarly you can select the smallest possible value by pressing the
LEFT
arrow key until the leftmost digit is shown, and then pressing and holding
DOWN
arrow key until the value stops changing.
S
ELECTION
type setpoints, such as Generator Configuration, or Active State, have options that are not numerical. For these setpoints, the display will show the current setting.
To change the value of a S
ELECTION
type setpoint:
1. Press the
OK K
EY
setpoint will be shown.
when the setpoint is highlighted. The current setting of the
2. Use the or
DOWN
arrow keys to scroll through the options that are available for that setpoint. Scroll quickly by holding the key.
3. When the desired option is displayed, press the OK
K
EY
to save the setting.
S
USPECT
P
ARAMETER
N
UMBER
type setpoints are similar to S
ELECTION
type setpoints, but the selections are grouped into four groups:
1. Pressures
2. Temperatures
3. Levels
4. Others
Any selection with units that are not pressure, temperature, or percent will be in the
“Others” group. This group also contains Custom Parameters and Custom Events.
Suspect parameter numbers indicating status (like Gen Breaker Open) will also be here.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
To change the value of a S
USPECT
P
ARAMETER
N
UMBER
type setpoint:
1. Press the
OK K
EY
when the setpoint is highlighted. Notice here that the setpoint value is not shown. Instead, the first group name, PRESSURE, is shown.
or
DOWN
arrow keys to scroll through the four groups:
PRESSURE, TEMPERATURE, LEVEL, OTHERS.
3. When the desired option is displayed, press the OK
K
EY
parameter numbers (by name) in that group.
to see the suspect
or
DOWN
arrow keys to scroll through the suspect parameter numbers (by name) until the desired one is selected.
5. Press the OK
K
EY
to save the setting. Alternately, press the BACK key to return to the group selection: PRESSURE, TEMPERATURE, LEVEL, OTHERS.
E
VENT
R
ESPONSE
C
ONFIGURATION
type setpoints are a little different from the previously discussed setpoints. Each setpoint configures one or more actions that occur when the event occurs. See Chapter 5.1 for more information.
7.2 SETPOINTS ON THE EMCP 4 DISPLAY
The setpoints in the EMCP 4 are organized into multiple submenus. See Appendix A and the appropriate sections of this document for more information.
7.3 SETPOINTS ON THE CAT SERVICE TOOL
EMCP 4 setpoints can be configured using the Cat Service Tool (ET). To access setpoints, see Chapter 4.2.
If a value is changed from the EMCP display, Cat ET will not refresh the setpoint automatically. Press the “Config Tool” icon to refresh the list.
Categories of setpoints are listed along the left pane, and clicking on one of them will bring up that list in the right pane.
The EMCP 4.1 and 4.2 have different numbers of setpoints. The categories shown here match those in ET version 2013B. Older versions may have less, and newer versions may have more.
Note
: Any setpoint with a value given as Unavailable is not applicable to that level of
EMCP 4.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
SETPOINT CATEGORIES
Here are the categories of setpoints as found in the left pane of the ET Configuration Tool:
A
NALOG
I
NPUTS
Setpoints related to Analog Inputs. See Chapter 9.
A
UTOMATIC
S
TART
/S
TOP
Setpoints related to starting and stopping the generator set, as well as engine configuration.
B
ATTERY
V
OLTAGE
M
ONITOR
Setpoints related to monitoring battery voltage from the battery power input to the EMCP 4.
C
RANK
A
TTEMPT
/S
UCCESSFUL
S
TART
C
OUNTER
Setpoint related to crank/start counters.
DATA LINK
: RS-485
SCADA (EMCP 4.2
ONLY
)
Setpoints related to SCADA (Modbus) data link communications. See Chapter 18.
D
IGITAL
I
NPUTS
Setpoints related to Digital Inputs. See Chapter 8.
D
IGITAL
O
UTPUTS
Setpoints related to the polarity of Digital Outputs. See Chapter 10.
E
NGINE
C
OOLANT
T
EMPERATURE
M
ONITOR
Setpoints related to monitoring engine coolant temperature.
E
NGINE
O
IL
P
RESSURE
M
ONITOR
Setpoints related to monitoring engine oil pressure.
E
NGINE
S
PEED
M
ONITOR
Setpoints related to monitoring engine speed using the Magnetic Pick-Up (MPU) input.
E
NHANCED
E
NGINE
M
ONITOR
Setpoints related engine cylinder temperature monitoring via the optional Thermocouple module. Applies to EMCP 4.2 only.
E
NHANCED
G
ENERATOR
M
ONITOR
Setpoints related to generator bearing and winding temperature monitoring via the optional
RTD module. Applies to EMCP 4.2 only.
E
VENT
R
ESPONSE
C
ONFIGURATION
D
IAGNOSTIC
E
VENTS
Setpoints used to configure the EMCP 4 response to diagnostic events. See Chapter 5.7.
E
VENT
R
ESPONSE
C
ONFIGURATION
E
NGINE
P
ROTECTION
E
VENTS
Setpoints used to configure the EMCP 4 response to engine protection events.
See Chapter 5.
E
VENT
R
ESPONSE
C
ONFIGURATION
G
ENERATOR
P
ROTECTION
E
VENTS
Setpoints used to configure the EMCP 4 response to generator protection events.
See Chapter 5.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
E
VENT
R
ESPONSE
C
ONFIGURATION
O
THER
S
YSTEM
E
VENTS
Setpoints used to configure the EMCP 4 response to events that do not fit into the category of diagnostics, engine protection, or generator protection. See Chapter 5.
E
VENT
R
ESPONSE
C
ONFIGURATION
– C
USTOM
E
VENTS
Setpoints used to configure the EMCP 4 response to custom events. See Chapter 5.
E
VENT
S
YSTEM
(EMCP 4.2
ONLY
)
Setpoints used to configure the Engine Running Conditions for the Engine Run Lamp on the
RS-485 Annunciator. See Chapter 17.
F
UEL
T
RANSFER
Setpoints related to fuel transfer feature.
G
ENERATOR
AC M
ONITOR
Setpoints related to generator configuration (for EMCP 4 calculation and reporting).
G
ENERATOR
AC P
OWER
M
ONITOR
(EMCP 4.2
O
NLY
)
Setpoints related to generator power monitoring.
G
ENERATOR
C
URRENT
M
ONITORING
(EMCP 4.2
O
NLY
)
Setpoints related to generator AC overcurrent monitoring.
G
ENERATOR
O
VER
/U
NDER
F
REQUENCY
Setpoints related to generator overfrequency and underfrequency monitoring.
G
ENERATOR
O
VER
/U
NDER
V
OLTAGE
Setpoints related to generator AC overvoltage and undervoltage monitoring.
G
ENERATOR
R
EVERSE
P
OWER
(EMCP 4.2
O
NLY
)
Setpoints related to generator AC reverse power monitoring.
I
NTEGRATED
V
OLTAGE
R
EGULATOR
Setpoints related to configuring the Integrated Voltage Regulator (if installed). See Chapter 19.
P
ROGRAMMABLE
C
YCLE
T
IMER
(EMCP 4.2
O
NLY
)
Setpoints related to configuring Programmable Cycle Timers. See Chapter 13.
E
LECTRONIC
C
ONTROL
M
ODULE
R
EDUCED
P
OWER
M
ODE
Setpoints related to a power-saving mode of the EMCP 4 called Reduced Power Mode.
See Chapter 14.
R
ELAY
O
UTPUTS
Setpoints related to Relay Outputs. See Chapter 10.
S
ERVICE
M
AINTENANCE
I
NTERVAL
Setpoints related to configuring and resetting the timers used to indicate a service needed warning. See Chapter 5.7.
K
W R
ELAY
S
ETPOINTS
Setpoints related to configuring the behavior of the Trip Point function, which is used to indicate that the generator is approaching overload.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
C
ONFIGURATION
D
ATA
Contains the Engine Serial Number setpoint, which is read-only.
D
ISPLAY
P
REFERENCES
Setpoints determining the units used on the EMCP 4 display. Note that this does not affect the data as viewed on the Cat Service Tool. See Chapter 4.4.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
8 DIGITAL INPUTS
The EMCP 4.1 and 4.2 have six user-programmable Digital Inputs. The user programmable Digital Inputs are referenced to Battery (-) and will see a change in state at ~3VDC with a 1VDC hysteresis. The Digital Inputs seen on the display that are labeled “A” and “B” are reserved for E-Stop and Remote Start.
The programming of the Digital Inputs starts by selecting a “Usage Type“. The rest of the programming is dependent upon what Usage Type is selected. Programming Digital
Inputs from the EMCP display requires Level 2 security access. Figure 20 summarizes the paths possible for Programming a Digital Input.
Disabled
Command/Status
System Event
SCADA Data Link
Status Parameter
Active State
List of Choices
Event Parameter
Failure Type
Event Delay
Active State
List of Choices
List of Choices
Figure 20: Digital Input Programming Paths
The Usage Type of D
ISABLED
is used to completely disable the input. No status will be shown, and no action will be taken by the EMCP 4.
The Usage Type of C
OMMAND
/S
TATUS
is used to make certain system conditions be known by the EMCP 4; an example of a Command/Status parameter is the Idle Mode command.
The Usage Type of S
YSTEM
E
VENT
is used to inform the EMCP 4 of system conditions that require the EMCP 4 to trigger an event.
The Usage Type of SCADA
D
ATA
L
INK
is used to bring in digital input to the EMCP 4 specifically for use by the SCADA data link. EMCP 4 will not take any action or trigger any events on such an input.
The Digital Inputs of the EMCP 4 are tied to an internal pull-up resistor inside the controller. Therefore, if a Digital Input is
UNCONNECTED
, the Digital Input will sit at a
PHYSICAL HIGH
state. See Figure 21. Note that a Digital Input wired to battery positive will always remain Active if programmed for Active High, and will always remain Inactive if programmed for Active Low.
A battery negative input should be switched to each EMCP 4 Digital Input for proper operation.
If an A
CTIVE
H
IGH
configuration is desired, the battery negative input should be wired through a normally-closed switch.
If an A
CTIVE
L
OW
configuration is desired, the battery negative input should be wired through a normally-open switch.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Figure 20: Valid States of Digital Input Wiring and Configuration
Note
: Improper configuration of these inputs can cause a false event to be triggered, or cause an event to not be triggered when desired.
Note
: If more than one Digital Input is configured for the same physical quantity
(i.e. the setpoint Digital Input Data Identification matches between two Digital Inputs), then the higher numbered Digital Input value will be have priority. For example, if both
Digital Input #4 and Digital Input #5 are configured for ECS in Run but Digital Input #4 is activated with Digital Input #5 left inactive, then Digital Input #4 will be ignored.
8.1 PROGRAMMING DIGITAL INPUTS USING THE DISPLAY
The steps to configure the Digital Inputs for each of the Usage Types are described below.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
VIEWING THE CURRENT DIGITAL INPUT STATUS
To view the current status of a Digital Input, go through the following menu options:
A
T THE MAIN MENU
,
scroll
DOWN TO
V
IEW
Scroll
DOWN
Press the OK
K
EY
Press the OK
K
EY
to I/O
S
TATUS
Press the OK
K
EY
to access
D
IGITAL
I
NPUTS
.
.
.
The status of all Digital Inputs is shown.
A dash under an input number (or letter) indicates an input that is programmed, but inactive. A large
“X” under an input number (or letter) indicates an input that is disabled. A number (or letter) under an input number (or letter) indicates an input that is programmed and active.
With the
LEFT ARROW
or
RIGHT ARROW
, select the D
IGITAL
I
NPUT
that you want to view, then press the OK
K
EY
.
The programmed Usage Type of the selected Digital
Input is shown.
Scroll
DOWN
to view the remaining parameters for this input:
Delay Time (System Event only)
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CONFIGURING DIGITAL INPUTS FOR STATUS PARAMETERS
Command or Status parameters are used to control specific functions within the control system or to make certain conditions within the system be known. To configure a Digital
Input as a Command or Status Parameter, go through the following menu options:
A
T THE MAIN MENU
,
scroll
DOWN
CONFIGURE
TO
Scroll
DOWN
Press the OK
K
EY
to I
NPUTS
& O
UTPUTS
Press the OK
K
EY
Alternately, access to the
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Press the OK
K
EY
to access
D
IGITAL
I
NPUTS
.
.
.
Select the D
IGITAL
I
NPUT
that you want to program
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, C
OMMAND
/S
TATUS
,
S
YSTEM
E
VENT
,
OR
SCADA)
.
Scroll
DOWN
to S
TATUS
Press the OK
K
EY
.
Scroll
DOWN
to S
TATUS
P
ARAMETER
Press the OK
K
EY
to highlight the current
S
TATUS
P
ARAMETER
.
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Application and Installation Guide
Select the S
TATUS
P
ARAMETER
that you want to program
Press the OK
K
EY
Scroll
DOWN
to A
CTIVE
S
TATE
Press the OK
K
EY
to highlight the current
A
CTIVE
S
TATE
.
Select the A
CTIVE
S
TATE
that you want to program and
.
EMCP 4.1, 4.2 Generator Set Control
Press the OK
K
EY
.
Any Digital Input can be configured for any one of the Command/Status parameters in
Table 4:
ECS in Run*
ECS in Auto*
ECS in Stop*
Idle Mode Command
Nominal Voltage Selection is Low***
Auto Load Fuel
Auto Unload Fuel***
Start Aid Timer Bypass
Inhibit Cooldown
Raise Voltage
Lower Voltage
Raise Speed
Lower Speed
Nominal Frequency Selection is Low***
Fuel Priming Command
Inhibit Reactive Droop Compensation**
Inhibit Line Drop Compensation**
Enable Power Factor Control Command**
Disable Generator Excitation**
*
If a Digital Input is programmed for ECS in Auto, or Run, or Stop, and a maintained switch latches that input to make it active, the front panel buttons will not have any effect.
** Only available with Integrated Voltage Regulator
*** Not available with Standard software
Table 4: Digital Input Command/Status Options
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
DIGITAL INPUT COMMAND/STATUS DESCRIPTIONS
Below is a brief description of the purpose of each command/status digital input option:
ECS IN RUN
When activated, has the same effect as pressing the “Run” button (puts the EMCP in RUN mode and runs the generator at rated voltage and speed). While this input is Logically Active, the ECS can’t be changed from RUN.
ECS IN AUTO
When activated, has the same effect as pressing the “Auto” button (puts the EMCP in AUTO mode). While this input is Logically Active, the ECS can’t be changed from AUTO.
ECS IN STOP
When activated, has the same effect as pressing the “Stop” button (puts the EMCP in STOP mode). While this input is Logically Active, the ECS can’t be changed from STOP.
IDLE MODE COMMAND
When activated, attempts to force the engine to run at idle speed when the engine is running. This action will also disable various protective functions including functions such as underspeed, undervoltage and under-frequency
INHIBIT COOLDOWN
While activated, prevents the engine from entering cooldown and keeps the EMCP in pre-cooldown state. Must be de-activated before the engine will completely stop. A hard shutdown will still stop the engine even if Inhibit Cooldown is in place.
RAISE VOLTAGE
When activated, raises generator voltage level by 0.5% of rated. If the input is maintained, after 0.5 seconds generator voltage level increases by 0.5% every 400ms (approximate). Typically used for external voltage biasing and/or external paralleling control.
LOWER VOLTAGE
When activated, lowers generator voltage level by 0.5% of rated. If the input is maintained, after 0.5 seconds generator voltage level decreases by 0.5% every 400ms (approximate). Typically used for external voltage biasing and/or external paralleling control.
RAISE SPEED
When activated, raises engine speed by 0.5% of rated. If the input is maintained, after 0.5 seconds engine speed increases by 0.5% every
400ms (approximate). Typically used for external speed biasing and/or external paralleling control.
LOWER SPEED
When activated, lowers engine speed by 0.5% of rated. If the input is maintained, after 0.5 seconds engine speed decreases by 0.5% every
400ms (approximate). Typically used for external speed biasing and/or external paralleling control.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
NOMINAL FREQUENCY SELECTION IS LOW
When activated, selects low frequency ratings group #3 or #4. If an input is not mapped to a digital input, it is assumed to be a logical “0”. When used in conjunction with Nominal Voltage Selection is Low the following ratings groups can be selected:
Programmable Digital Input
“Nominal Frequency is Low”
Logical Status
0 (high frequency)
0 (high frequency)
1 (low frequency)
1 (low frequency)
Programmable Digital Input
“Nominal Voltage is Low”
Logical Status
0 (high voltage)
1 (low voltage)
0 (high voltage)
1 (low voltage)
Ratings Group
Selected
Group #1
Group #2
Group #3
Group #4
(Not available on standard software)
NOMINAL VOLTAGE SELECTION IS LOW
When activated, selects low voltage ratings group #2 or #4. If an input is not mapped to a digital input, it is assumed to be a logical “0”. When used in conjunction with Nominal Frequency Selection is Low the following ratings groups can be selected:
Programmable Digital Input
“Nominal Frequency is Low”
Logical Status
0 (high frequency)
0 (high frequency)
1 (low frequency)
1 (low frequency)
Programmable Digital Input
“Nominal Voltage is Low”
Logical Status
0 (high voltage)
1 (low voltage)
0 (high voltage)
1 (low voltage)
(Not available on standard software)
Ratings
Group
Selected
Group #1
Group #2
Group #3
Group #4
AUTO LOAD FUEL
When activated, initiates the automatic fuel transfer in feature (if enabled). Typically used in conjunction with programmable digital outputs and analog input to control loading fuel.
AUTO UNLOAD FUEL
When activated, initiates the automatic fuel transfer out feature (if enabled). Typically used in conjunction with programmable digital outputs and analog input to control unloading fuel. (Not available on standard software)
START AID TIMER BYPASS
When activated, bypasses any remaining Start Aid Activation time and allows the set to proceed directly to cranking.
FUEL PRIMING COMMAND
When activated, initiates fuel priming pump (if enabled). If Engine
Operating State is configured for Hardwired, EMCP controls the fuel priming pump using fuel control relay output. If Engine Operating State is configured for CAN Input, EMCP communicates fuel priming command to engine ECM.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
INHIBIT REACTIVE DROOP COMPENSATION
When activated, reactive droop compensation bias (if configured) is removed from generator voltage output. (Only available with Integrated
Voltage Regulator).
INHIBIT LINE DROP COMPENSATION
When activated, line drop compensation bias (if configured) is removed from generator voltage output. (Only available with Integrated Voltage
Regulator).
ENABLE POWER FACTOR CONTROL COMMAND
When activated, voltage regulator control is performed in order to control power factor to a desired level. (Only available with Integrated Voltage
Regulator).
DISABLE GENERATOR EXCITATION COMMAND
When activated, generator excitation command is forced to zero and generator voltage output will only consist of residual voltage. (Only available with Integrated Voltage Regulator).
Page 80 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
CONFIGURING DIGITAL INPUTS FOR SYSTEM EVENTS
System Events are used to know when specific conditions are reached and to alert the control system of warning or shutdown conditions. To configure a Digital Input as a
System Event, go through the following menu options:
A
T THE MAIN MENU
,
scroll down to
CONFIGURE
SCROLL DOWN
Press the OK
K
EY
to I
NPUTS
& O
UTPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Press the OK
K
EY
to access
D
IGITAL
I
NPUTS
.
.
.
Select the D
IGITAL
I
NPUT
that you want to program and
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, S
TATUS
, S
YSTEM
E
VENT
,
OR
SCADA)
.
Scroll
DOWN
to S
YSTEM
E
VENT
Press the OK
K
EY
.
Scroll
DOWN
to E
VENT
P
ARAMETER
Press the OK
K
EY
to edit the current S
TATUS
P
ARAMETER
.
Select the type of E
VENT
P
ARAMETER
that you want to program (Pressures, Temperatures, Levels, or Others)
Press the OK
K
EY
.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
Select the E
VENT
P
ARAMETER
that you want to program
Press the OK
K
EY
to F
AILURE
T
YPE
.
Scroll
DOWN
Press the OK
K
EY
to edit the current F
AILURE
T
YPE
.
Select the F
AILURE
T
YPE
that you want to program
Press the OK
K
EY
.
Application and Installation Guide
Scroll
DOWN
to E
VENT
D
ELAY
Press the OK
K
EY
E
VENT
D
ELAY
.
to highlight the current
Select the E
VENT
D
ELAY
that you want
Scroll
DOWN
Press the OK
K
EY
to A
CTIVE
S
TATE
.
Press the OK
K
EY
to highlight the current
A
CTIVE
S
TATE
.
Select the A
CTIVE
S
TATE
that you want to program and
Press the OK
K
EY
.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Any Digital Input can be configured for any one of the System Event parameters in Table 5:
Pressures Others
Engine Oil Pressure
Custom Event*
Gas Pressure Air Damper Closed
Temperatures
Engine Coolant Temperature
Engine Oil Temperature
Battery Charger Failure
Fuel Leak
Earth Fault
Exhaust Temp Earth Leakage
Generator Rear Bearing Temperature Battery Charging System Voltage
Generator Winding #1 Temperature Generator Breaker Closed
Levels
Engine Coolant Level
Engine Oil Level
Fuel Level
External Tank Fuel Level
Generator Breaker Open
Generator Current
Generator Real Power
Inlet Manifold Charge Combustion
EPS Supply Load (EMCP 4.2 only)
Emergency Stop Switch (Remote)
Table 5: Digital Input System Events
*Note
: Digital Input s configured for Custom Event SPNs (701-718) are shared between the EMCP and DIO Modules. Therefore ONLY one Custom Event SPN-FMI can be used between the two modules. SPN701 (Digital Input #1 Custom Event) may also be used in the Configuration of “Engine Running”.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CONFIGURING DIGITAL INPUTS FOR SCADA DATA LINK
When a Digital Input is configured for SCADA Data Link, the state of the input will be placed into the appropriate MODBUS register only. No alarms or warnings will be generated by the EMCP.
To configure a Digital Input for SCADA Data Link, go through the following menu options:
A
T THE MAIN MENU
,
scroll down
TO CONFIGURE
SCROLL DOWN
Press OK
K
EY
to inputs & outputs
Press OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Press OK
K
EY
to access
D
IGITAL
I
NPUTS
Select the D
IGITAL
I
NPUT
that you want to program
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, S
TATUS
, S
YSTEM
E
VENT
,
OR
SCADA)
.
Scroll
DOWN
to SCADA
D
ATA
L
INK
Press the OK
K
EY
.
Scroll
DOWN
to A
CTIVE
S
TATE
Press the OK
K
EY
to highlight the current
A
CTIVE
S
TATE
.
Select the A
CTIVE
S
TATE
that you want to program
Press the OK
K
EY
.
For information on reading the status of Digital Inputs via MODBUS, please refer to the
SCADA documentation.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
DISABLING DIGITAL INPUTS
To disable a Digital Input, go through the following menu options:
A
T THE MAIN MENU
,
scroll down
CONFIGURE
TO
SCROLL DOWN
Press the OK
K
EY
to I
NPUTS
&
OUTPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Press the OK
K
EY
to access
D
IGITAL
I
NPUTS
Select the D
IGITAL
I
NPUT
that you want to program
.
.
.
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, S
TATUS
, S
YSTEM
E
VENT
,
OR
SCADA)
.
Scroll
DOWN
to D
ISABLED
Press the OK
K
EY
.
Note
: If a Digital Input is set to Disabled, then any faults or events on that input will not be broadcast or annunciated on the network.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
8.2 PROGRAMMING DIGITAL INPUTS USING THE CAT SERVICE TOOL
The EMCP 4 Digital Inputs can be configured using the Cat Service Tool. The key to programming them is to program the setpoints related to each input in order from top to bottom. To program an input, do the following steps:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select Digital Inputs on the left.
3. Determine which input is to be configured. For example, all of the setpoints for
Digital Input #1 have the text “#1” in their name.
4. Next follow the steps below according to which Usage Type is desired.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
CONFIGURING DIGITAL INPUTS FOR STATUS PARAMETER
1. Double click the Digital Input #N Usage type to change this value to Command/
Status Parameter from the drop down menu. Click the OK button to program.
2. The Digital Input #N Command/Status Parameter Data Identification and Active
State Configuration parameters will now be visible in the right pane.
3. Configure the Active State Configuration setpoint according to your wiring – either active High or active Low. Click the OK button to program.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
4. Double click the Configure the Command/Status Parameter Data Identification setpoint to change this value from the drop down menu. Click the OK button to program.
See Table 4 in Chapter 8.1 for a complete list of possible Status Parameter Data
Identifications.
CONFIGURING DIGITAL INPUTS FOR SYSTEM EVENTS
1. Double click the Digital Input #N Usage type to change this value to System
Event from the drop down menu. Click the OK button to program.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
2. The Event Input Function #N Event Notification Delay Time, Suspect Parameter
Number (SPN), Failure Mode Identifier (FMI) and Active State Configuration parameters will now be visible in the right pane.
3. Double click the Event Input Function #N Event Notification Delay Time setpoint to change this value. Click the OK button to program.
4. Double click the Event Input Function #N Suspect Parameter Number (SPN) setpoint to change this value from the drop down menu. Click the OK button to program.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
5. Double click the Event Input Function #N Failure Mode Identifier (FMI) setpoint to change this value from the drop down menu. Click the OK button to program.
6. Configure the Active State Configuration setpoint according to your wiring – either active High or active Low. Click the OK button to program.
7. Once the input is set with an SPN and FMI, the Event Response Configuration may have to be checked. For information on Event Response Configurations and how to program them, see Chapter 5.2.
Not all SPN and FMI combinations are valid. Table 6 indicates which FMIs are valid for which SPNs. If a combination other than one indicated with a “y” in the table above is configured, the event will not trigger any response by the EMCP 4. The EMCP 4 may not give the option of an invalid FMI for a given SPN. In Cat ET, there is no restriction on the
SPN/FMI combination. An invalid combination in Cat ET will result in an “Out of Range” error.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Category
Pressures
Temperatures
Levels
Others
Suspect Parameter Number
Engine Oil Pressure
Gas Pressure
Engine Coolant Temperature
Engine Oil Temperature
Exhaust Temperature
Generator Rear Bearing
Temperature
Generator Winding #1
Temperature
Engine Coolant Level
Engine Oil Level
Fuel Level
External Tank Fuel Level
Air Damper Closed
Battery Charging System Voltage
Battery Charger Failure
Custom Event (see note below)
Earth Fault
Earth Leakage
Emergency Stop Switch
EPS Supply Load
Fuel Leak
Gen Breaker Closed
Gen Breaker Open
Generator Current
Generator Real Power
Inlet Manifold Charge
Combustion
Table 6: Event Input Function SPN and FMI Options
Failure Mode Identifier Valid Options
High
Shutdown
Low
Shutdown
High
Warning
y
Low
Warning Status
y y y y y y y** y y y y y
*This status is FMI 14 (Special Instruction), not FMI 31 (Condition Exists).
** This status is FMI 14(Special Instruction), not FMI 31 (Condition Exists). This gives a means to differentiate between a Remote Emergency Stop and Emergency Stop.
Note
: For Custom Events, each input can only trigger the custom event number that matches the Digital Input number (Digital Input #1 can only activate Custom Event #1, etc).
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CONFIGURING DIGITAL INPUTS FOR SCADA DATA LINK
1. Double click the Digital Input #N Usage type to change this value to Data Link from the drop down menu. Click the OK button to program.
DISABLING DIGITAL INPUTS
1. Double click the Digital Input #N Usage type to change this value to Disabled from the drop down menu. Click the OK button to program.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
9 ANALOG INPUTS
The EMCP 4.1 and 4.2 support three 2-wire (plus shield) Analog Inputs. None of these inputs are dedicated to specific functions. These are individually selectable as either
Voltage or Resistive Sender inputs for interface to senders, customer signals, etc. The modes of operation are described below: mode: 0-5 Volts with software-selectable sub-ranges (see Table 9 in
Chapter 9.3). The input impedance is a minimum of 10k Ohms and a maximum of 1M Ohms. The Analog Input return signals must be tied to battery negative external to the controller.
Resistive Sender (VDO typemtr) Mode: 5-2000 Ohms with software-selectable nonlinear maps. Accuracy is 1% or 0.5 Ohms accuracy, whichever is worse. The
Analog Input return signals must be tied to battery negative external to the controller.
The Analog Inputs have a 5V common non-isolated power supply capable of supplying up to 100mA of current, and has overload protection. This supply is to be used to provide power to sensors if required by the source power pin and Analog Input returns.
The negative side of this supply is battery negative.
See Electrical Connections Chapter 3.5 for illustrations on how to connect the sensors to the control.
Analog Inputs programmed to monitor pressures should be wired to sensors that read gauge, not absolute pressure, unless absolute pressure is desired.
For Analog Inputs, the data range can be positive or negative, but Event thresholds are only positive. Therefore, to prevent nuisance alarms for low warnings, disable the Event
Response Configuration if data is acceptable to be negative (see Chapter 5.2).
The first and second Analog Inputs are configured by default for non-electronic engines to monitor engine oil pressure and engine coolant temperature, respectively, and are protected by Level 3 security. The third Analog Input is protected at Level 2 security. For help on programming the Level 3 password prior to running this procedure, see Chapter 6, Security.
Alternately, the Cat Service Tool can be used to program these setpoints.
Note
: If the Analog Inputs are set to D
ISABLED
, then any sensor faults or events will not be broadcast or annunciated on the network.
Note
: If more than one Analog Input is configured for the same physical quantity (i.e. the setpoint Analog Input Data Identification matches between two Analog Inputs), then the higher numbered Analog Input value will be displayed on the Engine Overview screen.
For example, if both Analog Input #2 and Analog Input #3 are configured for oil temperature, but the sensor is connected only to Analog Input #2 (and Analog Input #3 is left open), a display of **** diagnostic will result. The Engine Overview screen will display the value from Analog Input #3. Warnings and Shutdowns will be monitored for both
Analog Inputs. When troubleshooting inputs, always make sure to check for
configuration conflicts!
The Analog Inputs are often not used for electronic engines that use ADEM
A3, A4 or newer, engine ECM. On these engines, the engine oil pressure sensor and the engine coolant temperature sensors may be wired to the engine ECM and not to the generator set control. In order to receive the sensor information from the data link instead of from sensors wired into the EMCP 4, the setpoints Engine Oil Pressure Sensor Configuration and Engine Coolant Temperature Sensor Configuration must be set to Data Link. If they are not set this way, the sensor values on the Engine Overview screen on the EMCP 4 display will show (asterisks).
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Note
: Improper configuration of these inputs can cause a false event to be triggered, or cause an event to not be triggered when desired. If a user disables an input without including other external protection, or disables the annunciation of an enabled input, detection will not be available. If a spare input is enabled, but not wired to a sensor, a false event may occur.
The programming of the Analog Inputs starts by selecting a “Usage Type”. The rest of the programming is dependent upon what Usage Type is selected. Figure 22 summarizes the paths possible for Programming an Analog Input.
Figure 22: Analog Input Programming Paths
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
9.1 PROGRAMMING ANALOG INPUTS USING THE DISPLAY
The steps to configure the Analog Inputs for each of the Usage Types are described below. Level 3 security is required for Analog Inputs #1 and #2. Level 2 security is required for Analog Input #3.
VIEWING THE CURRENT ANALOG INPUT STATUS
To view the current status of an Analog Input, go through the following menu options:
A
T THE MAIN MENU
,
scroll
DOWN TO
V
IEW
Scroll
DOWN
Press the OK
K
EY
to I/O
S
TATUS
Press the OK
K
EY
.
.
Scroll
DOWN
to A
NALOG INPUTS
Press the OK
K
EY
.
Scroll
DOWN
desired.
to choose the A
NALOG INPUT
Press the OK
K
EY
The programmed Data Identification of the selected
Analog Input is shown.
.
Scroll
DOWN
seen on the input).
to view the remaining parameters for this input (including the actual value
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CONFIGURING ANALOG INPUTS FOR RESISTIVE MODE
To configure an Analog Input for Resistive Mode, go through the following menu options:
A
T THE MAIN MENU
,
scroll down to
CONFIGURE
SCROLL DOWN
Press the OK
K
EY
to I
NPUTS
& O
UTPUTS
Press the OK
K
EY
.
.
SCROLL DOWN
to A
NALOG
I
NPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Select the A
NALOG
I
NPUT
that you want to program
.
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, R
ESISTIVE
,
OR
V
OLTAGE
)
.
Scroll
DOWN
to R
ESISTIVE
Press the OK
K
EY
.
Scroll
DOWN
to D
ATA
I
DENTIFICATION
Press the OK
K
EY
to change the current D
ATA
I
DENTIFICATION
.
Select the D
ATA
I
DENTIFICATION
that you want to program
Press the OK
K
EY
.
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Application and Installation Guide
Scroll
DOWN
to M
AP
S
ELECTION
N
UMBER
Press the OK
K
EY
to change the current
M
AP
S
ELECTION
N
UMBER
.
Select the M
AP
S
ELECTION
N
UMBER
that you want to program
EMCP 4.1, 4.2 Generator Set Control
Press the OK
K
EY
.
The Data Identification will remain the same when switching between Resistive or
Voltage.
Any Analog Input can be configured for any one of the Data Identification parameters in
Table 7:
Engine Oil Pres
Eng Coolant Temp
Engine Oil Temp
Engine Fuel Level
Ext Tank Fuel Level
Custom Parameters
Data Link – SCADA (EMCP 4.2 only)
Engine Speed Control
Generator Voltage Control
Table 7: Analog Input Data Identifications
The Sensor Codes correspond to sensor maps as defined in Chapter 9.3.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CONFIGURING ANALOG INPUTS FOR VOLTAGE MODE
To configure an Analog Input for Voltage Mode, go through the following menu options:
A
T THE MAIN MENU
,
scroll down to
CONFIGURE
SCROLL DOWN
Press the OK
K
EY
to I
NPUTS
& O
UTPUTS
Press the OK
K
EY
.
.
SCROLL DOWN
to A
NALOG
I
NPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Select the A
NALOG
I
NPUT
that you want to program
.
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, R
ESISTIVE
,
OR
V
OLTAGE
)
.
Scroll
DOWN
to V
OLTAGE
Press the OK
K
EY
.
Scroll
DOWN
to S
ENSOR
R
ANGE
Press the OK
K
EY
to change the current
S
ENSOR
R
ANGE
.
Select the S
ENSOR
R
ANGE
that you want to program
Press the OK
K
EY
.
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Application and Installation Guide
Scroll
DOWN
to D
ATA
I
DENTIFICATION
Press the OK
K
EY
to change the current D
ATA
I
DENTIFICATION
.
Select the S
TATUS
P
ARAMETER
that you want to program
EMCP 4.1, 4.2 Generator Set Control
Scroll
DOWN
Press the OK
K
EY
to D
ATA
R
ANGE
M
IN
.
Press the OK
K
EY
to change the current
D
ATA
R
ANGE
M
IN
.
Select the D
ATA
R
ANGE
M
IN
that you want to program
Press the OK
K
EY
For Analog Inputs, the data range can be positive or negative, but Event thresholds are only positive.
Therefore, to prevent nuisance alarms for low warnings, disable the Event Response Configuration if data is acceptable to be negative (see Chapter 5.2).
.
Scroll
DOWN
to D
ATA
R
ANGE
M
AX
Press the OK
K
EY
to change the current
D
ATA
R
ANGE
M
AX
.
Select the D
ATA
R
ANGE
M
AX
that you want to program
Press the OK
K
EY
.
The Data Identification list is the same whether Signal Type is Resistive or Voltage.
Any Analog Input can be configured for any one of the Data Identification parameters in
Table 7.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
DISABLING ANALOG INPUTS
To Disable an Analog Input, go through the following menu options:
A
T THE MAIN MENU
,
scroll down to
CONFIGURE
SCROLL DOWN
Press the OK
K
EY
to I
NPUTS
& O
UTPUTS
Press the OK
K
EY
.
.
SCROLL DOWN
to A
NALOG
I
NPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
Select the A
NALOG
I
NPUT
that you want to program
.
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, R
ESISTIVE
,
OR
V
OLTAGE
)
.
Scroll
DOWN
to D
ISABLED
Press the OK
K
EY
.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
9.2 PROGRAMMING ANALOG INPUTS USING THE CAT SERVICE TOOL
The EMCP 4 Analog Inputs can be configured using the Cat Service Tool. The key to programming them is to program the setpoints related to each input in order from top to bottom. To program an Analog Input, do the following steps:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select Analog Inputs on the left.
3. Determine which input is to be configured. For example, all of the setpoints for
Analog Input #1 have the text “#1” in their name.
4. Next follow the steps below according to which Usage Type is desired.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CONFIGURING ANALOG INPUTS FOR RESISTIVE MODE
The EMCP 4 supports resistive sender maps, which are nonlinear maps representing the transfer function of the resistive sender. Once an Analog Input is configured as a
Resistive input type, a map must be selected.
1. Double click the Analog Input #N Usage type to change this value to Resistive
Sender from the drop down menu. Click the OK button to program.
2. The Analog Input #N Configuration Code and Data Identification parameters will now be visible in the right pane.
3. Double click the Configuration Code setpoint to change this value from the drop down menu. Click the OK button to program.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
4. Double click the Data Identification setpoint to change this value from the drop down menu. Click the OK button to program.
Based on whether or not the selected option supports events, the list of setpoints shown will adjust accordingly. If the selected option does not support events, then the configuration is complete.
5. If the selected option does support events, then continue and configure the event thresholds and delays. The Analog Input #N Threshold and Delay Time parameters will now be visible in the right pane.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Table 8 lists the options and which, if any, events they support. Not all SPN and
FMI combinations are valid. Table 8 indicates which FMIs are valid for which
SPNs. If a combination other than one indicated with a “y” in the table above is configured, the event will not trigger any response by the EMCP 4. The EMCP 4 may not give the option of an invalid FMI for a given SPN. In Cat ET, there is no restriction on the SPN/FMI combination. An invalid combination in Cat ET will result in an “Out of Range” error.
Failure Mode Identifier Valid Options
Low
Warning
y
Suspect Parameter Number
Engine Oil Pressure
Engine Coolant Temperature
Engine Oil Temperature
Fuel Level
External Tank Fuel Level
Gen Volt Control
Custom Event (see note below)
Data Link Only
Desired Engine Speed Command
Table 8: Event Input Function SPN and FMI Options
High
Shutdown
Low
Shutdown
High
Warning
y
Note
: For Custom Events, each input can only trigger the custom event number that matches the Analog Input number (Analog Input #1 can only activate Custom Event #1, etc.).
6. Configure each of these setpoints by double clicking each one and typing a new value. Click the OK button to program.
Note
: The units for the event thresholds are not shown. For pressures, the units are always kPa. For temperatures, they are always degrees Celsius. For levels, they are always percent. For the custom parameter type, they are unitless. The range for custom parameters is defined by the selected sensor map if programmed for resistive.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
CONFIGURING ANALOG INPUTS FOR VOLTAGE MODE
The EMCP 4 supports linear voltage senders, which are senders whose output voltage varies linearly with the change in a physical measurement. Once the Analog Input is configured as a Voltage Input type, the linear mapping must be defined by entering the sensor voltage range and the corresponding minimum and maximum physical measurement range.
1. Double click the Analog Input #N Usage type to change this value to Voltage from the drop down menu. Click the OK button to program.
2. The Analog Input #N Signal Range, Data Identification, and Minimum and
Maximum Data Range parameters will now be visible in the right pane.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
3. Double click the Signal Range setpoint to change this value from the drop down menu to match the range supported by your sensor (or the next larger range).
See Chapter 9.3 for what to do if the desired sensor’s range is not supported.
Click the OK button to program.
4. Double click the Data Identification setpoint to change this value from the drop down menu. Click the OK button to program.
5. Based on whether or not the selected option supports events, the list of setpoints shown will adjust accordingly. Table 8 lists the options and which, if any, events they support.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
6. Configure each of the Minimum and Maximum Data Range setpoints by double clicking each setpoint and typing a new value. Click the OK button to program.
For Analog Inputs, the data range can be positive or negative, but Event thresholds are only positive. Therefore, to prevent nuisance alarms for low warnings, disable the Event
Response Configuration if data is acceptable to be negative (see Chapter 5.2).
7. If the selected Data Identification does support events, then continue and configure the event thresholds and delays. The Analog Input #N Threshold and
Delay Time parameters will be visible in the right pane.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
8. Configure each of these setpoints by double clicking each one and typing a new value. Click the OK button to program.
Note
: The units for the event thresholds are not shown. For pressures, the units are always kPa. For temperatures, they are always degrees Celsius. For levels, they are always percent. For the custom parameter type, they are unitless. The range for custom parameters is defined by the selected sensor map.
DISABLING ANALOG INPUTS
1. Double click the Analog Input #N Usage type to change this value to Disabled from the drop down menu. Click the OK button to program.
Note
: If the Analog Inputs are set to Disabled, then any sensor faults or events will not be broadcast or annunciated on the network.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
9.3 ANALOG INPUT MAPS
Resistive senders can use nonlinear sensor maps. These maps are not available for
Voltage or Current modes. Maps are predefined in the software flash file, and can be selected by the customer. The Analog Inputs are capable of reading resistance from
~5 ohms.
The following maps are predefined:
Analog Input Map #1
Engine Oil Pressure
Map #1
Engine Oil Pressure Map #1
1000
107.3
115.9
124.3
132.5
140.5
148.2
155.8
163.1
170.2
177.2
183.9
Ohms kPa
5.1
10.2
20.9
0
0
50
31.3
41.6
51.6
61.3
70.9
80.4
89.5
98.6
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
800
600
400
200
0
0 50 100
Ohms
150 200
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EMCP 4.1, 4.2 Generator Set Control
Analog Input Map #2
Ohms
0
8
9
9.8
97.5
Engine Oil Pressure kPa
0
0
45
50
1000
1000
800
600
400
200
0
0
Application and Installation Guide
Engine Oil Pressure
25 50
Ohms
75 100
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Application and Installation Guide
Analog Input Map #3
Engine Coolant Temp.
Map #1
28.4
33.4
39.6
46.9
56.1
67.9
82.4
103.6
Ohms
11.0
12.8
15.0
17.9
20.8
24.2
129. 6
168.0
221.9
291.5
387.5
520.6
677.0
890.6
1182.9
1575.6
2249.4
26
20
14
8
2
-5
87
81
75
68
111
105
99
93
61
54
47
40
33
Degrees C
150
143
136
129
123
117
130
105
80
55
30
5
-20
0
EMCP 4.1, 4.2 Generator Set Control
Engine Coolant Temp
(EMCP 3 Engine Coolant Temp Map #1)
500 1000
Ohms
1500 2000
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
Analog Input Map #4
Engine Coolant Temp.
Map #2
11.0
9.18
7.7
6.5
5.5
4.7
4.1
64.5
50
39.2
31
24.8
20
16.3
13.3
Ohms
2442
1518
968.9
633.6
423.9
289.7
201.9
148.8
111.2
84.2
102
110
118
126
134
142
150
70
78
86
94
38
46
54
62
Degrees C
-48
-39
-30
-21
-12
-3
6
14
22
30
150
130
110
90
70
50
30
10
-10
0
-30
-50
500
Application and Installation Guide
Engine Coolant Temp
1000
Ohms
1500 2000 2500
Page 112 All rights reserved.
Application and Installation Guide
Analog Input Map #5
61.9
75.8
93.6
115.6
145.2
184.7
238.0
309.9
408.7
546. 6
773.7
1114.9
1640.3
2473.6
Ohms
10.2
11.9
13.9
16. 4
19.0
22.0
25.7
30.2
35.6
42.5
51.2
Oil Temp
44
37
29
21
13
5
72
65
58
51
100
93
86
79
149
142
135
128
121
114
107
Degrees C
180
172
164
156
200
180
160
140
120
100
80
60
40
20
0
0 500
EMCP 4.1, 4.2 Generator Set Control
Oil Temp
1000
Ohms
1500 2000 2500
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
Analog Input Map #6
Engine Coolant Temp
Map #3
19.6
23.8
28.8
35.4
43.7
54. 5
68.5
87.1
Ohms
6.9
8.2
9.8
11.6
13.8
16.3
111.8
145.1
190.5
253.4
341. 5
467.0
648.8
916.6
1318.5
2046.6
22
15
8
1
50
43
36
29
-6
-14
78
71
64
57
106
99
92
85
Degrees C
150
142
134
127
120
113
140
120
100
80
60
40
20
0
-20
0 500
Application and Installation Guide
Lean2B Temp
1000
Ohms
1500 2000
Page 114 All rights reserved.
Application and Installation Guide
Analog Input Map #7
Ohms
10.5
35.6
60.2
85.2
103.2
Fozmula Fuel Level
%
0
25
50
75
100
100
75
50
25
0
0 25
EMCP 4.1, 4.2 Generator Set Control
Fozmula Fuel Level
50
Ohms
75 100
Analog Input Map #8
Ohms
0
2000
Linear Level
%
0
100
Linear Level
100
75
50
25
0
0 500 1000
Ohms
1500 2000
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
Analog Input Map #9
Power Module Tank
Level #1
Ohms
10. 5
35.6
60.2
85.2
103.2
%
0
25
50
75
100
100
75
50
25
Application and Installation Guide
Power Module Tank Level #1
0
0 20 40 60
Ohms
80 100
Analog Input Map #10
Ohms
10
135
348.2
500
Power Module Tank
Level #2
%
100
100
0
0
120
100
80
60
40
20
0
0
Power Module Tank Level #2
100 200
Ohms
300 400 500
Page 116 All rights reserved.
Application and Installation Guide
Analog Input Map #11
Fuel Level
Ohms
255
240
30
%
0
0
100
15 100
100
80
60
40
20
0
255
EMCP 4.1, 4.2 Generator Set Control
Fuel Level
240
Ohms
30 15
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Analog Input Map #12
Temperature
Temperature
Useful for temperatures based on CAT sensor part number 256-6453. (EMCP
Only supports down to 10 degrees C).
140
120
100
80
60
2541.5
1991.4
1249.5
1000
5
10
20
25
805.5 30
40
20
0
2541.5
652.8
248.7
107.2
51.2
Ohms
652.8 35
532.3 40
436.6 45
360 50
298.4 55
248.7 60
208.2 65
175.2 70
148.1 75
125.7 80
107.2 85
91.7 90
78.8 95
68 100
58.9 105
51.2 110
44.6 115
39 120
30.1 130
23.6 140
18.6 150
For EMCP 4.1 and 4.2, voltage senders can be configured within the ranges in Table 9:
18.6
Page 118 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Voltage Sender Ranges
0 to 5V
1 to 5V
0.5 to 4.5V
Table 9: Analog Input Ranges
Analog Input data ranges can be defined with positive and negative values, but Event thresholds are only programmable as positive values. Therefore, to prevent nuisance alarms for low warnings when using negative numbers for data ranges, the Event
Response Configuration can be disabled, if input data is acceptable to be negative.
WARNINGS AND SHUTDOWNS
Each of these inputs can be configured to have
H
IGH
W
ARNINGS
, L
OW
W
ARNINGS
, H
IGH
S
HUTDOWNS
and
L
OW
S
HUTDOWNS
with configurable thresholds. Any value below the bottom point on the map or above the highest point on the map will raise a corresponding diagnostic event. Also, all of the events associated with the Analog Inputs have programmable time delays. Low Idle Oil Pressure setpoints are also available under the Engine Oil Monitor area. Information on how to program these thresholds and time delays can be found in Chapter 7, Setpoints.
UNSUPPORTED ANALOG INPUT SENSOR RANGES
There may be Voltage sensors available that use ranges not explicitly supported by the
EMCP 4. Depending on the situation, there may be different ways to handle this. The following sections give options on how to handle these situations.
SENSOR RANGE IS SMALLER THAN SETPOINT OPTIONS
If the desired sensor range is smaller than one of the available setpoint options, then extrapolation may be used to support the desired sensor. For example, for a 0-3V temperature sensor reads -30
C to 120C, the only range that includes all of 0-3V is 0-
5V. The 0-5V range should be used. The range between 3V and 5V will simply never be used. To make the data accurate, set the Minimum Data Range to -30
C, and determine the Maximum Data Range mathematically. See Figure 23.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Figure 23: Mathematical Extrapolation of Maximum Data Range
The Maximum Data Range can be found graphically or algebraically. In this example, the Maximum Data Range would be defined by the equation of the line after the slope is determined. Since the data rises by 50 degrees for every volt, increasing two volts above the three volt limit requires the maximum range to be 100 degrees above the sensor limit of 120 degrees, or 220 degrees total. See Figure 24.
Figure 24: Example Calculation for Extrapolation of Maximum Data Range
Page 120 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
SENSOR RANGE IS LARGER THAN SETPOINT OPTIONS,
BUT USABLE RANGE IS NOT
If the desired sensor range is larger than one of the available setpoint options, but the useful range for the sensor is within the supported ranges, then interpolation may be used to support the desired sensor. For example, for a 0-6V temperature sensor that reads -40
C to 500C, the EMCP 4 will not support the analog voltages higher than 5V.
However, as long as the sensor will not exceed 5V, the 0-5V range may be used. To make the data accurate, set the Minimum Data Range to -40
C, and determine the
Maximum Data Range mathematically. See Figure 25.
Figure 25: Mathematical Interpolation of Maximum Data Range
The Maximum Data Range can be found graphically or algebraically. In this example, the Maximum Data Range would be defined by the equation of the line after the slope is determined. Since the data rises by 90 degrees for every volt, decreasing one volt below the six volt limit requires the maximum range to be 90 degrees below the sensor limit of
500 degrees, or 410 degrees total. See Figure 26.
Figure 26: Example Calculation for Interpolation of Maximum Data Range
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
SENSOR RANGE IS LARGER THAN SETPOINT OPTIONS, AND USABLE RANGE
IS LARGER THAN SETPOINT OPTIONS
If the desired sensor range is larger than one of the available setpoint options, and the useful range for the sensor is outside of the supported ranges, a third party device is required to convert the signal range into a supported range. See Figure 27.
Figure 27: Signal Conversion of Sensor Range
Page 122 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
10 OUTPUTS
The EMCP 4.1 and 4.2 support Relay Outputs capable of 2A resistive at 30V DC. The
EMCP 4.1 has six Form A Relay Outputs (normally open) while the EMCP 4.2 has six
Form A Relay Outputs and two Form C Relay Outputs (both normally open and normally closed).
The EMCP 4.2 also supports two programmable discrete outputs capable of sinking
300mA per input. These outputs will sink a current to draw down a voltage of up to 30V
DC down to Battery (-).
Outputs can be configured by using the EMCP 4 display. For some of the setpoints,
L
EVEL
2
OR
L
EVEL
3
ACCESS
is required. For information on obtaining Level 2 or Level 3
Access refer to Chapter 6, Security.
Security. This chapter will assume that the correct Level 2 or Level 3 Access has already been obtained. Alternately, the Cat Service Tool can be used to configure these outputs.
The programming of the Digital and Relay Outputs starts by selecting a “Usage Type”.
The rest of the programming is dependent upon what Usage Type is selected. Figure 28 summarizes the paths possible for Programming Digital and Relay Outputs.
Note
: If the Engine Operating State is configured as Hardwired, then Relay Output #1 must be programmed to Starter Motor Relay.
Figure 28: Digital and Relay Output Programming Paths
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
10.1 PROGRAMMING OUTPUTS USING THE DISPLAY
For some of the setpoints, L
EVEL
2
OR
L
EVEL
3
ACCESS
is required. For information on obtaining Level 2 Access refer to Chapter 6, Security.
This section will assume that Level 2 or Level 3 Access has already been obtained.
VIEWING THE CURRENT OUTPUT STATUS
To view the current status of an Output, go through the following menu options:
A
T THE MAIN MENU
,
scroll
DOWN TO
V
IEW
Scroll
DOWN
Press the OK
K
EY
to I/O
S
TATUS
Press the OK
K
EY
.
.
Scroll
DOWN
O
UTPUTS
to access
R
ELAY OR
D
IGITAL
Press the OK
K
EY
The status of all Relay or Digital Outputs is shown.
A dash under an output number indicates an output that is programmed, but inactive. A large “X” under an output number indicates an output that is disabled. A number under an output number indicates an output that is programmed and active.
.
With the
LEFT ARROW
or
RIGHT ARROW
, select the R
ELAY OR
D
IGITAL
O
UTPUT
that you want to view, then press the OK
K
EY
.
The programmed Usage Type of the selected relay or Digital Output is shown.
Scroll
DOWN
logical state).
to view the remaining parameters for this output (including physical and
Page 124 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
CONFIGURING OUTPUTS FOR STATUS PARAMETERS
Command or Status parameters are used to control specific functions within the control system or to make certain conditions within the system be known.
Note
: The Fuel Control Relay does not pickup when the Engine Operating State is set to
CAN. Engine Start Initiated can be used in Lieu of the Fuel Control Relay for most purposes.
To configure a Digital Output or Relay Output as a Status Parameter, go through the following menu options (substitute Digital Output for Relay Output in the following steps, as needed):
A
T THE MAIN MENU
,
scroll down
CONFIGURE
TO
SCROLL DOWN
to I
Press the OK
K
EY
NPUTS
&
OUTPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
SCROLL DOWN
to R
ELAY
O
UTPUTS
.
.
Press the OK
K
EY
.
Select the R
ELAY
O
UTPUT
that you want to program
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, C
OMMAND
/S
TATUS
,
S
YSTEM
E
VENT
,
OR
SCADA D
ATA
L
INK
)
.
Scroll
DOWN
to C
OMMAND
/S
TATUS
Press the OK
K
EY
.
Scroll
DOWN
to S
TATUS
P
ARAMETER
Press the OK
K
EY
to highlight the current
S
TATUS
P
ARAMETER
.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
Select the S
TATUS
P
ARAMETER
that you want to program
Application and Installation Guide
Press the OK
K
EY
.
Any Output can be configured for any one of the Command/Status parameters in Table 10:
Run Mode
Auto Mode
Stop Mode
Package Not in Auto
Fuel Control Relay*
Starter Motor Relay
Start Aid
Disable Auxiliary AC
Crank Alert
Engine Start Initiated
Engine Started
Rated Speed
V/Hz Within Limits
Engine in Cooldown
Wait Delay Stop
Horn Control
Common Warning
Common Shutdown
ECU Fault Reset
Air Shutoff
Progamable Cycle Time #2 (EMCP 4.2 only) kW Relay Trip #1 (EMCP 4.2 only) kW Relay Trip #2 (EMCP 4.2 only)
Common Alarm
Breaker #1 Trip
Breaker #2 Trip
Reduced Power Off
Transfer Fuel In
Transfer Fuel Out*
Volt Lower Command
Volt Raise Command
Speed Raise Command
Speed Lower Command
Nominal Frequency Selection is Low**
Nominal Voltage Selection is Low**
Ignition Shutoff Relay
Governor ECM Power Relay
*
The Fuel Control Relay does not pickup when the Engine Operating
State is set to CAN. Engine Start Initiated can be used in lieu of the Fuel
Control Relay for most purposes.
** Not available with Standard software
Table 10: Output Command/Status List
Note:
If the Engine State Configuration is configured for Hard Wired, then Relay Output
#1 must be programmed for the Status Parameter of Starter Motor Relay. As of version
4.2.2 PROD software, Relay Output #2 is no longer required to be programmed for Fuel
Control Relay.
Page 126 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
DIGITAL/RELAY OUTPUT COMMAND/STATUS DESCRIPTIONS
Below is a brief description of the purpose of each command/status digital/relay output option:
RUN MODE
Activates when the EMCP is placed in RUN mode (such as when the
‘Run’ button is pressed). Matches the state of ECS LED on the EMCP.
AUTO MODE
Activates when the EMCP is placed in AUTO mode (such as when the
‘Auto’ button is pressed). Matches the state of ECS LED on the EMCP.
STOP MODE
Activates when the EMCP is placed in STOP mode (such as when the
‘Stop’ button is pressed). Matches the state of ECS LED on the EMCP.
PACKAGE NOT IN AUTO
Activates when conditions are present that prevent the EMCP from operating in AUTO mode (such as engine control switch not in auto, engine not in Rated mode, shutdown red lamp is active).
FUEL CONTROL RELAY
Activates when the engine pre-crank timing delay expires during the engine start sequence and the while the engine is running, along with during fuel priming when engine operating state is configured for
Hardwired Input.
STARTER MOTOR RELAY
Activates during the Crank Duration time during the starting state of the engine starting sequence when the engine operating state setpoint is configured for Hardwired Input.
START AID
Activates during the Start Aid Activation Time during the pre-crank state of the engine starting sequence.
DISABLE AUX AC
Activates when the generator set enters the Pre-Crank State. This output will be deactivated during Crank Alert, Start Aid, Cranking, Running,
Cooldown, etc, but will stay activated if the generator set is unable to start due to a shutdown fault. Typically used to turn off equipment such as static battery chargers and water heaters when the engine is running.
CRANK ALERT
Activates during the Crank Alert Activation Time during the pre-crank state of the engine starting sequence.
ENGINE START INITIATED
Activates when the engine has been commanded to start and remains active until the end of cooldown.
ENGINE STARTED
Activates when the engine has been commanded to start and the engine speed is greater than Crank Terminate rpm and remains active until engine speed drops below Crank Terminate rpm.
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
RATED SPEED
Activates when the engine is configured to run at rated speed
(regardless of actual engine speed). Useful to determine when the engine is commanded to run at idle speed. Note: This is NOT an indication that the set is at rated speed. It is an indication that the set has not been requested to run at Idle.
V/HZ WITHIN LIMITS
Activates if voltage and frequency are within the Over/Under Voltage and Over/Under Frequency protection limits (typically 90% to 110% of rated).
ENGINE IN COOLDOWN
Activates when the engine is running in cooldown mode.
WAIT DELAY STOP
Activates when the engine is running in the pre-cooldown state.
Typically a stop signal has been received, but an inhibit cooldown command is preventing the unit from entering cooldown.
HORN CONTROL
Activates when a horn alert is sounding. Typically occurs when any event configured with an audible alert event response is PRESENT or
ACTIVE and unacknowledged.
COMMON WARNING
Activates when any warning is PRESENT in the event log (regardless of source).
COMMON SHUTDOWN
Activates when any shutdown is PRESENT or ACTIVE in the event log
(regardless of source).
ECU FAULT RESET
Activates for a specified period of time when a Reset All Events command is issued. Typically only used to interface to legacy engines.
AIR SHUTOFF
Activates based on engine shutdown conditions such as engine overspeed, engine speed sensor diagnostic, emergency stop, and engine speed failure to decrease. When activated this output will remain active for 15 seconds.
PROGRAMMABLE CYCLE TIMER OUTPUT #2 (EMCP 4.2
ONLY)
Activates for the duration of the Programmable Cycle Timer #N Active
Time as configured in the Programmable Cycle Timer feature (refer to
Chapter 13)
KW RELAY TRIP #1 (EMCP 4.2
ONLY)
Activates based on the programmable trip point trigger conditions of the
Programmable kW Relay Function (refer to Chapter 15)
KW RELAY TRIP #2 (EMCP 4.2
ONLY)
Activates based on the programmable trip point trigger conditions of the
Programmable kW Relay Function (refer to Chapter 15)
Page 128 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
COMMON ALARM
Activates when any shutdown is PRESENT or ACTIVE in the event log or any warning is PRESENT in the event log (regardless of source).
BREAKER #1 TRIP
Activates when any event configured with a Breaker #1 Trip event response is PRESENT or ACTIVE.
BREAKER #2 TRIP
Activates when any event configured with a Breaker #2 Trip event response is PRESENT or ACTIVE.
REDUCED POWER OFF
Activates when the EMCP is NOT in reduced power mode (Useful for placing other controls in a reduced power mode when the EMCP is in
Reduced Power Mode).
TRANSFER FUEL IN
Activates when manual or automatic fuel loading is initiated.
TRANSFER FUEL OUT
Activates when manual or automatic fuel unloading is initiated. (Not available on standard software)
VOLTAGE RAISE COMMAND
Activates when a command to raise voltage is received.
VOLTAGE LOWER COMMAND
Activates when a command to lower voltage is received.
SPEED RAISE COMMAND
Activates when a command to raise speed is received.
SPEED LOWER COMMAND
Activates when a command to lower speed is received.
NOMINAL FREQUENCY SELECTION IS LOW
Activates when a digital input configured for “Nominal Frequency
Selection is Low” is active.
Programmable Digital Input
“Nominal Frequency is Low”
Logical Status
0 (high frequency)
0 (high frequency)
1 (low frequency)
1 (low frequency)
Programmable Digital Input
“Nominal Voltage is Low”
Logical Status
0 (high voltage)
1 (low voltage)
0 (high voltage)
1 (low voltage)
(Not available on standard software)
Ratings
Group
Selected
Group #1
Group #2
Group #3
Group #4
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
NOMINAL VOLTAGE SELECTION IS LOW
Activates when a digital input configured for “Nominal Voltage Selection is Low” is active.
Programmable Digital Input
“Nominal Frequency is Low”
Logical Status
0 (high frequency)
0 (high frequency)
1 (low frequency)
1 (low frequency)
Programmable Digital Input
“Nominal Voltage is Low”
Logical Status
0 (high voltage)
1 (low voltage)
0 (high voltage)
1 (low voltage)
(Not available on standard software)
Ratings
Group
Selected
Group #1
Group #2
Group #3
Group #4
IGNITION SHUTOFF RELAY
Note: this is a shutoff relay so the output is active when ignition is NOT desired. Deactivates during the Engine Purge Cycle with Ignition time and while engine is starting and running. Typically used for gas engine starting/stopping sequence.
GOVERNOR ECM POWER RELAY
Activates at the start of the “Engine Start Sequence Delay Time” prior to engine cranking and deactivates 15 seconds after engine speed has reached zero rpm.
CONFIGURING OUTPUTS FOR SYSTEM EVENTS
System Events are used to know when specific conditions are reached and to alert the control system of warning or shutdown conditions. To configure a Relay or Digital Output as a System Event, go through the following menu options (substitute Digital Output for
Relay Output in the following steps, as needed):
A
T THE MAIN MENU
,
scroll down
TO CONFIGURE
Press the OK
K
EY
to I
NPUTS
&
OUTPUTS SCROLL DOWN
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
SCROLL DOWN
to R
ELAY
O
UTPUTS
Press the OK
K
EY
.
.
.
Page 130 All rights reserved.
Application and Installation Guide
Select the R
ELAY
O
UTPUT
that you want to program
EMCP 4.1, 4.2 Generator Set Control
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, C
OMMAND
/S
TATUS
,
S
YSTEM
E
VENT
,
OR
SCADA D
ATA
L
INK
)
.
Scroll
DOWN
to S
YSTEM
E
VENT
Press the OK
K
EY
.
Scroll
DOWN
to E
VENT
P
ARAMETER
Press the OK
K
EY
to edit the current S
TATUS
P
ARAMETER
.
Select the type of E
VENT
P
ARAMETER
that you want to program (Pressures, Temperatures, Levels, or Others)
Press the OK
K
EY
Select the E
VENT
P
ARAMETER
that you want to program
.
Press the OK
K
EY
to E
VENT
T
RIGGER
.
Scroll
DOWN
Press the OK
K
EY
to edit the current
E
VENT
T
RIGGER
.
Select the E
VENT
T
RIGGER
that you want to program
Press the OK
K
EY
.
©2013 Caterpillar
All rights reserved. Page 131
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Any Output can be configured for any one of the System Events in Table 11:
Pressures Others
Engine Oil Pressure
Any SPN Digital Input #1 Custom
Gas Pressure
Accessory Datalink (4.2 only)
Battery Charging System Voltage
Battery Voltage
Emergency Stop Switch
Engine in Cooldown
Temperatures
Engine Coolant
Temperature
Engine Oil Temperature
Exhaust Temperature
Generator Rear Bearing
Temperature
Generator Winding #1
Temperature
Engine Fail to Start
Engine Speed
Controls Not in Auto
Generator Current
Generator Frequency
Generator Real Power
Generator Voltage
Primary Data Link
SCADA Data Link (4.2 only)
Service Interval Expired
Levels
Engine Coolant Level
Engine Oil Level
Unexpected Engine Shutdown
Earth Fault
Fuel Level
Earth Leakage
External Tank Fuel Level
Engine Control
Fuel Leak
Air Damper Closed
Battery Charger Failure
Digital Input #2 Custom
Digital Input #3 Custom
Digital Input #4 Custom
Digital Input #5 Custom
Digital Input #6 Custom
Analog Input #1 Custom
Analog Input #2 Custom
Analog Input #3 Custom
Generator Breaker Open
Generator Breaker Closed
Table 11: Output System Events
Page 132 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Care must be taken in configuring the correct triggers. Only some of these parameters can be configured for a specific System Event and even if it can be configured, it may not be representative of the system requirements. Output system event trigger conditions are listed in Table 12 below.
Category
Pressures
Temperatures
Levels
Others
SPN Suspect Parameter
100 Engine Oil Pressure
1390 Gas Pressure
175 Engine Oil Temperature
1122 Generator Rear Bearing Temperature
111 Engine Coolant Level
98 Engine Oil Level
96 Fuel Level
38 External Tank Fuel Level n/a Any Suspect Parameter Number
167 Battery Charging System Voltage
168 Battery Voltage
970 Auxiliary Engine Shutdown Switch
4006 Engine in Cooldown
1664 Engine Failure to Start
190 Engine Speed
4007 Generator Control Not in Automatic
2436 Generator Output Frequency
2452 Generator Output Power
3581 SCADA Data Link
2648 Service Maintenance Interval Expired
1383 Unexpected Engine Shutdown
4000 Air Damper Closed
4003 Battery Charger Failure
4013 Generator Circuit Breaker Open
4004 Generator Circuit Breaker Closed
Supported FMI Trigger
Conditions
1, 3, 4, 14, 17
0, 1, 15, 17
0, 3, 4, 14, 15, 17
0, 1, 15, 17
0, 1,15, 17
0, 1, 15, 17
0, 15
0, 1, 15, 17
0, 1, 15, 17
0, 1, 15, 17
0, 1, 15, 17 n/a
11
17
0, 15, 17
14, 31
31
31
0, 1, 2, 5, 17
31
0,1,15, 17
0, 1, 2, 12, 15, 17
1, 15, 17
0, 1, 15, 17
11
11
31
11
31
31
9
31
31
31
6, 31
6, 31
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Category
Custom Events
SPN Suspect Parameter
701 Digital Input #1 Custom Event
702 Digital Input #2 Custom Event
703 Digital Input #3 Custom Event
704 Digital Input #4 Custom Event
705 Digital Input #5 Custom Event
706 Digital Input #6 Custom Event
707 Digital Input #7 Custom Event
708 Digital Input #8 Custom Event
1083 Analog Input #1 Custom Parameter
1084 Analog Input #2 Custom Parameter
4158 Analog Input #3 Custom Parameter
Table 12: Supported Output System Event SPN and FMI Trigger Conditions
Supported FMI Trigger
Conditions
31
31
31
31
31
31
31
31
0, 1, 6, 15, 17
0, 1, 6, 15, 17
0, 1, 6, 15, 17
DIGITAL/RELAY OUTPUT SYSTEM EVENT DESCRIPTIONS
Below is a brief description of the purpose of each system event digital/relay output option:
ENGINE OIL PRESSURE
Activates when an engine oil pressure event (SPN 100) is triggered in the EMCP event log.
GAS PRESSURE
Activates when a gas pressure event (SPN 1390) is triggered in the
EMCP event log.
ENGINE COOLANT TEMPERATURE
Activates when an engine coolant temperature event (SPN 110) is triggered in the EMCP event log.
ENGINE OIL TEMPERATURE
Activates when an engine oil temperature event (SPN 175) is triggered in the EMCP event log.
EXHAUST TEMPERATURE
Activates when an exhaust temperature event (SPN 173) is triggered in the EMCP event log.
GENERATOR REAR BEARING TEMPERATURE
Activates when a generator rear bearing temperature event (SPN 1122) is triggered in the EMCP event log.
GENERATOR WINDING #1 TEMPERATURE
Activates when a generator winding #1 temperature event (SPN 1124) is triggered in the EMCP event log.
ENGINE COOLANT LEVEL
Activates when an engine coolant level event (SPN 111) is triggered in the EMCP event log.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
ENGINE OIL LEVEL
Activates when an engine oil level event (SPN 98) is triggered in the
EMCP event log.
FUEL LEVEL
Activates when a fuel level event (SPN 96) is triggered in the EMCP event log.
EXTERNAL FUEL LEVEL
Activates when an external fuel level event (SPN 38) is triggered in the
EMCP event log.
ANY SUSPECT PARAMETER NUMBER
Activates when any suspect parameter number is triggered in the EMCP event log.
ACCESSORY DATA LINK
Activates when an accessory data link diagnostic (SPN-FMI: 1231-11) is triggered in the EMCP event log.
BATTERY CHARGING SYSTEM VOLTAGE
Activates when a battery charging system voltage event
(SPN-FMI: 167-17) is triggered in the EMCP event log.
BATTERY VOLTAGE
Activates when a battery voltage event (SPN 168) is triggered in the
EMCP event log.
AUXILLARY ENGINE SHUTDOWN SWITCH
Activates when an auxiliary engine shutdown switch event (SPN 970) is triggered in the EMCP event log.
ENGINE IN COOLDOWN
Activates when an engine in cooldown event (SPN 4006) is triggered in the EMCP event log.
ENGINE FAILURE TO START
Activates when an engine fail to start event (SPN 1664) is triggered in the EMCP event log.
ENGINE SPEED
Activates when an engine speed event (SPN 190) is triggered in the
EMCP event log.
GENERATOR CONTROL NOT IN AUTOMATIC
Activates when a generator control not in auto event (SPN 4007) is triggered in the EMCP event log.
GENERATOR CURRENT (AMP)
Activates when a generator current event (SPN 2448) is triggered in the
EMCP event log.
GENERATOR OUTPUT FREQUENCY
Activates when a generator output frequency event (SPN 2436) is triggered in the EMCP event log.
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GENERATOR OUTPUT POWER(
K
W)
Activates when a generator output power(kW) event (SPN 2452) is triggered in the EMCP event log.
GENERATOR OUTPUT VOLTAGE
Activates when a generator output voltage event (SPN 2440) is triggered in the EMCP event log.
PRIMARY DATA LINK
Activates when a primary data link diagnostic (SPN 639) is triggered in the EMCP event log.
SCADA DATA LINK
Activates when a SCADA data link diagnostic (SPN 3581) is triggered in the EMCP event log.
SERVICE MAINTENANCE INTERVAL EXPIRED
Activates when a service maintenance interval expired event (SPN
2648) is triggered in the EMCP event log.
UNEXPECTED ENGINE SHUTDOWN
Activates when an unexpected engine shutdown event (SPN 1383) is triggered in the EMCP event log.
EARTH FAULT
Activates when an earth fault event (SPN 4028) is triggered in the
EMCP event log.
EARTH LEAKAGE
Activates when an earth leakage event (SPN 4029) is triggered in the
EMCP event log.
ENGINE CONTROLLER
Activates when an engine controller diagnostic (SPN 3543) is triggered in the EMCP event log.
FUEL LEAK
Activates when a fuel leak event (SPN 1239) is triggered in the EMCP event log.
AIR DAMPER CLOSED
Activates when an air damper closed event (SPN 4000) is triggered in the EMCP event log.
BATTERY CHARGER FAILURE
Activates when a battery charger failure event (SPN 4003) is triggered in the EMCP event log.
GENERATOR CIRCUIT BREAKER OPEN
Activates when a generator circuit breaker open event (SPN 4013) is triggered in the EMCP event log.
GENERATOR CIRCUIT BREAKER CLOSED
Activates when a generator circuit breaker closed event (SPN 4004) is triggered in the EMCP event log.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
DIGITAL INPUT #N CUSTOM EVENT
Activates when a digital input #N custom event (SPN 701 to 708) is triggered in the EMCP event log.
ANALOG INPUT #N CUSTOM EVENT
Activates when an analog input #N custom event (SPN 1083, 1084,
4158) is triggered in the EMCP event log.
CONFIGURING OUTPUTS FOR SCADA DATA LINK
When an Output is configured for SCADA Data Link, an active state will be sent over
MODBUS. No alarms or warnings will be generated by the EMCP. To configure a Relay
Digital Output for SCADA Data Link, go through the following menu options (substitute
Digital Output for Relay Output in the following steps, as needed):
A
T THE MAIN MENU
,
scroll down
CONFIGURE
TO
SCROLL DOWN
to I
Press the OK
K
EY
NPUTS
&
OUTPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
SCROLL DOWN
to R
ELAY
O
UTPUTS
Press the OK
K
EY
Select the R
ELAY
O
UTPUT
that you want to program
.
.
.
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, C
OMMAND
/S
TATUS
,
S
YSTEM
E
VENT
,
OR
SCADA D
ATA
L
INK
)
.
Scroll
DOWN
to SCADA
D
ATA
L
INK
Press the OK
K
EY
.
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DISABLING OUTPUTS
To disable an Output, go through the following menu options (substitute Digital Output for Relay Output in the following steps, as needed):
A
T THE MAIN MENU
,
scroll down
TO CONFIGURE
SCROLL DOWN
Press the OK
K
EY
to I
NPUTS
&
OUTPUTS
Press the OK
K
EY
Alternately, access to
THE
I
NPUTS
&
OUTPUTS
submenu is accessible from
ALL SETPOINTS
.
SCROLL DOWN
to R
ELAY
O
UTPUTS
Press the OK
K
EY
Select the R
ELAY
O
UTPUT
that you want to program
.
.
.
Press the OK
K
EY
.
Press the OK
K
EY
to highlight the current configuration (D
ISABLED
, C
OMMAND
/S
TATUS
,
S
YSTEM
E
VENT
,
OR
SCADA D
ATA
L
INK
)
.
Scroll
DOWN
to D
ISABLED
Press the OK
K
EY
.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
10.2 PROGRAMMING OUTPUTS USING THE CAT SERVICE TOOL
The EMCP 4 Outputs can be configured by using the Cat Service Tool. The key to programming them is to program the setpoints related to each input in order from top to bottom. Relay and Digital Outputs follow the same steps. For simplicity, the examples below show Relay Outputs. For Digital Outputs, just substitute Digital Output for Relay
Output. To program an Output, do the following steps:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select Relay (or Digital Outputs) on the left.
3. Determine which output is to be configured. For example, all of the setpoints for Relay Output #1 have the text “#1” in their name.
4. Next follow the steps below according to which Usage Type is desired.
CONFIGURING OUTPUTS FOR STATUS PARAMETERS
Command or Status parameters are used to control specific functions within the control system or to make certain conditions within the system be known.
Note
: The Fuel Control Relay does not pickup when the Engine Operating State is set to CAN. Engine Start Initiated can be used in Lieu of the Fuel Control Relay for most purposes.
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To configure an Output as a Command or Status Parameter, go through the following menu options:
1. Double click the Output #N Usage type to change this value to Command/Status
Parameter from the drop down menu. Click the OK button to program.
2. The Output #N Command/Status Parameter Data Identification parameter will now be visible in the right pane.
3. Double click the Configure the Command/Status Parameter Data Identification setpoint to change this value from the drop down menu. Click the OK button to program.
See Table 10 in Chapter 10.1 for a complete list of possible Status Parameter Data
Identifications.
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CONFIGURING OUTPUTS FOR SYSTEM EVENTS
System Events are used to know when specific conditions are reached and to alert the control system of warning or shutdown conditions. To configure an Output as a System
Event, go through the following menu options:
1. Double click the Output #N Usage type to change this value to System Event from the drop down menu. Click the OK button to program.
2. The Output #N Suspect Parameter Number (SPN) and Event Trigger Condition parameters will now be visible in the right pane.
3. Double click the Output #N Suspect Parameter Number (SPN) setpoint to change this value from the drop down menu. Click the OK button to program.
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4. Double click the Output #N Event Trigger Condition setpoint to change this value from the drop down menu. Click the OK button to program.
See Table 11 in Chapter 10.1 for a complete list of possible System Events.
CONFIGURING OUTPUTS FOR SCADA DATA LINK
When an Output is configured for SCADA Data Link, an active state will be sent over
MODBUS. No alarms or warnings will be generated by the EMCP. To configure an
Output for SCADA Data Link, go through the following menu options:
1. Double click the Output #N Usage type to change this value to Data Link from the drop down menu. Click the OK button to program.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
DISABLING OUTPUTS
To disable an Output, go through the following menu options:
1. Double click the Relay Output #N Usage type to change this value to Disabled from the drop down menu. Click the OK button to program.
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11 MODIFIABLE TEXT STRINGS
The EMCP 4 supports the renaming of Custom Events for the event log. This feature is called M
ODIFIABLE
T
EXT
S
TRINGS
. This is useful when an existing SPN and text string do not exist for the required event. These events can be configured and triggered similar to other events. However, these events are unique in that their displayed text strings can be customized via the Cat Service Tool using any character in the supported character set of the EMCP 4 software flash file. Furthermore, the Cat Service Tool has the capability to upload a Modifiable Text Strings configuration file (containing previously saved custom event text strings) from the computer, or download a configuration from the EMCP 4 to the computer.
In order to display a custom text string for an event, the following steps must be taken:
1. One of the Digital Inputs must be configured as a Custom Event with a Failure
Mode Identifier of Status (or Condition Exists). For more information on configuring Digital Inputs, see Chapter 8.1.
2. A custom string must be entered, using the Modifiable Text Strings tool in the
Cat Service Tool, as described in Chapter 11.2.
3. The language must be set to the customer language, not to Technician English.
An example of entering a modifiable text string for Custom Event #1 is given in Figure 29.
Figure 29: Customizing A Text String With the Cat Service Tool
The EMCP 4 supports one Modifiable text string per Custom Event on each programmable Digital Input.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
11.1 LANGUAGE SUPPORT
The primary language for the EMCP 4 control will always be Technician English. The user will always be able to revert back to Technician English from the selected language that is supported by the flash file. However, when the EMCP 4 display is viewed in
Technician English, the user will not be able to view the custom text strings and will only be able to view the default strings (Custom Event #N) for a given input.
The EMCP 4 has the capability of supporting one flash file containing one secondary language at any particular time. If the user is interested in having a new secondary language, a new flash file to configure the new language must be installed. Therefore, the user is not able to install multiple flash files supporting different languages simultaneously.
The EMCP 4 supports Unicode characters from the English character set, as well as the character set from the local language supported by the file. It is the user’s responsibility to install the preferred flash file with the correct language support that will allow the modification of text strings.
The user is also responsible for choosing the appropriate operating system or Unicode text entry system for the chosen language. The Cat Service Tool software accepts input from the PC keyboard settings. If, for example, the PC keyboard setting is for U.S.
English, it may be difficult to enter Russian (or other non-English) characters.
Different language software supports different sets of characters. Therefore, Modifiable
Text String configuration files created in one language will not become translated if new language software is flashed into the EMCP 4. The original text string will still show as originally entered, or it may not show correctly if the new software language does not support all the characters in the original language.
11.2 PROGRAMMING MODIFIABLE TEXT STRINGS USING THE CAT
SERVICE TOOL
To configure a Modifiable Text String using the Cat Service Tool, go through the following menu options:
1. Connect the EMCP to the Cat Electronic Technician as described in Chapter 4.2.
Note
: The Service Tool must be connected to CAN 1 and the EMCP must be selected during the connection if multiple ECMs are present.
2. Select “Modifiable Strings” under “Service” from the choices at the top of the software screen.
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EMCP 4.1, 4.2 Generator Set Control
3. The “Modifiable Strings” screen will appear.
Application and Installation Guide
4. In order to load the existing text string file from the ECM, click the “Load From
ECM” button on the bottom of the screen.
5. The stored strings, if any, will appear. For first time configuration, the strings will be blank.
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6. Click in the Value column next to the event to be modified. Type the desired text string. The Modifiable Text String is considered a pair of text strings, and the user has the option of customizing the pair of text strings. The second line has less available space, because the event log index is also displayed on that line.
7. Once all text strings are entered for all events desired, click on the “Save to ECM” button on the bottom of the screen.
8. To then save the same file to the hard disk, click on the “Save to File...” and browse to the appropriate folder.
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EMCP 4.1, 4.2 Generator Set Control
9. Once the file destination is found, click “Save”.
Application and Installation Guide
10. To edit a saved text string in ET while not connected to the ECM, navigate to
File>Open>Modifiable String Data File. This is equivalent to clicking on the “Load
From File...” button on the bottom left side of the “Modifiable Strings” screen.
11. Select the desired string data and click “Open”. This opens the “Modifiable
Strings” screen again.
12. Edit as desired, then save to ECM, or save to a file.
Note
: The Modifiable Text String parameter value’s field is initially blank until it is replaced with a custom text string parameter value. The custom text string parameter value entered will replace the default strings.
The user’s Custom Text Strings are displayed in the user’s preferred language. If the service tool doesn’t support the user’s preferred language, US English will be used.
It is advisable to split the text across both lines even if it can fit on a single line since the default terms will show if text has not been entered.
Note
: The user must save any offline changes before attempting to connect the Service
Tool to the EMCP 4, or the changes will not be saved.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
12 SAVING AND RESTORING SETPOINTS
The EMCP 4 supports the saving and uploading of the EMCP 4 setpoints through a setpoint configuration file. This file, called the ECM Replacement File, or Fleet
Replacement File, is accessible via the ECM Replacement tool of the Cat Service Tool software. The file contains information specific to the EMCP 4, and includes the setpoint values that are specific to a given EMCP 4 module. The user has the option of saving the data to an ECM Replacement File from an EMCP 4 module or uploading the data from the ECM Replacement File to another EMCP 4 module. The user also has the option of uploading general configuration data to several EMCP 4 modules by means of a similar tool called Fleet Configuration. Both of these options are accomplished through the Cat Service Tool software.
Note
: This chapter only addresses setpoints residing in the EMCP 4. To save and restore setpoints for other (optional) modules on the EMCP 4 CAN data links, a similar procedure must be followed for each individual module.
12.1 SAVING EMCP 4 CONFIGURATION DATA
The Cat Service Tool is used to save an EMCP 4 configuration.
The EMCP 4 configuration should be saved upon initial access or after any configuration change. This will be required for future accessibility when exchanging or replacing the
EMCP 4 module.
After connecting to the EMCP 4, navigate to Service > Copy Configuration (see Figure 30).
There are two options:
Fleet Configuration
Figure 30: Cat Service Tool EMCP 4 GSC Summary Screen
The loading of EMCP 4 configuration data is very similar between ECM
R
EPLACEMENT
and F
LEET
C
ONFIGURATION
. For illustration purposes, the ECM
R
EPLACEMENT
option will be described here.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
FLEET CONFIGURATION OPTION
Select the F
LEET
C
ONFIGURATION
option when there is a need to save and copy
GENERAL DATA
to several ECMs (non-module-specific).
The F
LEET
C
ONFIGURATION
tool works very similar to the ECM Replacement tool, with the exception of ignoring module-specific data such as E
NGINE
S
ERIAL
N
UMBER
and
E
NGINE
O
PERATING
H
OURS
.
ECM REPLACEMENT OPTION
To save EMCP 4 configuration data to an ECM Replacement file:
1. From the Service Tool menu, select the following: Service > Copy Configuration
> ECM Replacement. See Figure 30.
2. The software will prompt the user to open a previously saved ECM Replacement file. Click “Cancel”.
3. The following message is displayed: “No Data Is Available. Load From ECM
Now
?” Press “No”.
4. Click “Load from ECM” from the bottom left of the ECM Replacement screen to upload the setpoints. See Figure 31.
Figure 31: Load from ECM
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
5. After the software loads the data, the replacement file parameters will be shown.
See Figure 32.
Figure 32: ECM Replacement File Parameters
6. Select which ECM’s configuration data is to be viewed and/or saved for future use by adding, or removing check boxes from the side of the parameters.
7. After any selection changes are completed, click “Save to File” from the bottom of the ECM Replacement screen to save the file. See Figure 33. Make sure to note where the file is stored.
Figure 33: Save to File
Note
: The configuration data must be saved to a file before disconnecting from the service tool or the data
WILL BE LOST
and must be re-loaded from the source module again.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
12.2 LOADING EMCP 4 CONFIGURATION DATA
The loading of EMCP 4 configuration data is very similar between ECM
R
EPLACEMENT
and F
LEET
C
ONFIGURATION
. For illustration purposes, the ECM
R
EPLACEMENT
option will be described here.
Warning:
When loading an ECM Replacement File, the engine operating hours will increase to the newly loaded value (if larger than the old value). To avoid this, deselect the Engine Operating Hours setting.
To load an ECM Replacement file to an EMCP 4:
1. From the Service Tool menu, select the following: Service > Copy Configuration
> ECM Replacement. See Figure 30.
2. The software will prompt the user to open a previously saved ECM Replacement file.
3. Navigate to the location where the file is stored and click “Open”.
4. The software will confirm opening the file. See Figure 34. Click “OK”.
Figure 34: Load from File
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
5. The replacement file parameters will be shown. See Figure 35.
Figure 35: ECM Replacement File Parameters
6. Select which ECM’s configuration data is to be programmed into the EMCP 4 by adding, or removing check boxes from the side of the parameters.
7. After any selection changes are completed, click “Program ECM” from the bottom of the ECM Replacement screen to load the file into the EMCP 4.
See Figure 36.
Figure 36: Program ECM
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
8. If another replacement file is to be programmed or if the user is already at the
ECM Replacement screen prior to opening a replacement file, press the “Load from File” button at the bottom of the screen and follow steps 3 through 7 above.
See Figure 37.
Figure 37: Load ECM Replacement File
Note
: By default, ECM Replacement files are stored in the ECM Replacement folder, while Fleet Configuration files are stored in the Fleet Configuration folder.
The above steps, for uploading saved configuration data, will need to be repeated for each EMCP 4 module needing same or similar setpoint configurations. For programming multiple units with the same setpoints, it is recommended to use Fleet Configuration files.
Note
: When programming EVENT
RESPONSE CONFIGURATION
setpoints, the control must be in
STOP
mode. If the control is not in
STOP
, there will be a message after the programming is complete. The message will show that none of the Event Response
Configuration setpoints were changed.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
13 PROGRAMMABLE CYCLE TIMER (EMCP 4.2 ONLY)
The Programmable Cycle Timer (PCT) feature allows the operator to program seven independent times, when tasks (called PCT Outputs), will be activated or deactivated automatically during the week. This is useful for exercising gensets, or cases where two or more generators are required to automatically share the duty of supplying a load throughout the week.
Using the PCT, each genset can be programmed to start and stop at pre-set times.
The PCT is capable of handling a seven day sequence with seven independent starts happening one or more times each week. The timing of these start/stop cycles may be programmed in advance, either locally or via the service tool.
For example, if a standby set does not have access to a utility supply to power a trickle charger, the PCT can be set for an hour a week to run the genset to have the charging alternator help keep the battery charged.
Caution:
External equipment such as a transfer switch is required to ensure that the gensets are not stopped on load.
The PCT
F
EATURE
consists of seven independent timers; each timer has the following setpoints (setpoints shown are for PCT #1):
P
ROGRAMMABLE
C
YCLE
T
IMER
#1:
Activation Day of the Week:
This permits independent selection of each day (Sun -> Sat) that the timer will activate. All seven days can be selected, if desired.
P
ROGRAMMABLE
C
YCLE
T
IMER
#1:
Activation Start Time
The time of day (in hours and minutes) that the timer will activate. The time must be programmed using a 24-hour clock.
P
ROGRAMMABLE
C
YCLE
T
IMER
#1:
Active Time
The duration (in hours and minutes) for which the timer will be active (up to
24 hours).
P
ROGRAMMABLE
C
YCLE
T
IMER
#1:
Output #1 Activation Configuration
The Programmable Cycle Timer’s first output will be activated when this timer is active and will allow the genset to start if in Auto.
P
ROGRAMMABLE
C
YCLE
T
IMER
#1:
Output #2 Activation Configuration
The Programmable Cycle Timer’s second output will be activated when this timer is active. Output # 2 can be assigned to a programmable output for connection to an external device. This external device can be used to control a load bank, transfer switch or other device.
The PCT has two internal outputs; these should not be confused with the physical outputs of the control. The outputs are connected internally to the control module. In the standard configuration, PCT
O
UTPUT
#1
is connected to an internal Remote Initiate command. O
UTPUT
#2
is customer configurable via a discrete output. This allows the operator to configure a timed relay, for external connectivity.
Note
: The outputs of all seven timers are tied together in an “OR” fashion. This means that if any one, or more, timer is activated, then any output will activate (depending on programming).
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
The status of each output is indicated by a 1, 0, or
-
in the P
ROG
C
YCLE
column under #1 through #7. See Figure 38.
A number
ONE
(1) means that this PCT is driving that output to be
TRUE
A number
ZERO
(0) means that this PCT is
NOT
driving this output true now, but, this output is programmed to be TRUE at another time.
A D
ASH
(-) means that this PCT is
NOT
programmed to activate this output.
Figure 38: PCT Main Screen
In Figure 38,
PCT
#1
is I
NACTIVE
on Output #1. Output #2 is
NOT
enabled and will never activate, as programmed.
PCT
#3
is
ACTIVE
on Output #1, and
NOT
enabled on Output #2.
PCT
#5
is
NOT
enabled and will never activate, as programmed, on Output #1. Output #2 is
ACTIVE
.
PCT
#2,
PCT
#4,
PCT
#6,
and
PCT
#7
are
DISABLED
.
They
NEVER
activate Output #1 or
Output #2, as programmed.
To select a specific Programmable Cycle Timer, use the
LEFT
and
RIGHT
buttons until the desired PCT is within the selection box and then press the
OK K
EY
.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
13.1 CONFIGURING THE PROGRAMMABLE CYCLE TIMER USING THE
DISPLAY
To configure a Programmable Cycle Timer with the display, go through the following menu options:
At
MAIN MENU
,
scroll down to
CONTROL
Scroll
DOWN
Press the OK
K
EY
to P
ROG
C
YCLE
T
IMER
Press the OK
K
EY
The box surrounding the first column outlines the first of seven timers.
.
.
Press the
OK K
EY
to program this timer.
The box surrounding the first row outlines the day selection.
Press the
Use the
UP
OK K
EY
to select the day(s) for this timer.
and
DOWN
arrow keys along with the
LEFT
and
RIGHT
arrow keys to select the days that this timer will activate.
Scroll
DOWN
Press the
OK K
EY
when done.
to select the S
TART
T
IME
.
Press the OK
K
EY
Use the arrow keys to enter the S
TART
T
IME
Press the
OK K
EY
when done.
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Scroll
DOWN
to select the R
UN
F
OR
time
Press the OK
K
EY
.
Use the arrow keys to enter the R
UN
F
OR
time
Press the
OK K
EY
when done.
Scroll
DOWN
Output #1
to select the O
UTPUT
S
TATE
for
Press the OK
K
EY
Select the O
UTPUT
S
TATE
that you want to program
.
Press the
OK K
EY
when done.
Scroll
DOWN
Output #2
to select the O
UTPUT
S
TATE
for
Press the OK
K
EY
Select the O
UTPUT
S
TATE
that you want to program
.
Press the
OK K
EY
when done.
Application and Installation Guide
Press the E
SCAPE
K
EY
to return to the Programmable Cycle Timer main screen. Use the
LEFT
and
RIGHT
buttons to select the other timers and repeat the above steps.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
13.2 CONFIGURING THE PROGRAMMABLE CYCLE TIMER USING THE
CAT SERVICE TOOL
To configure a Programmable Cycle Timer with the Cat Service Tool, go through the following menu options:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select Programmable Cycle Timer on the left.
3. Double click the Programmable Cycle Timer #N Activation Day setpoint for a given day to change this value from the drop down menu. Click the OK button to program.
4. Double click the Programmable Cycle Timer #N Activation Start Time setpoint to change this value. Click the OK button to program.
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5. Double click the Programmable Cycle Timer #N Active Time setpoint to change this value. Click the OK button to program.
6. Double click the Programmable Cycle Timer #N Output #1 Active Configuration setpoint to change this value from the drop down menu. Click the OK button to program.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
7. Double click the Programmable Cycle Timer #N Output #2 Active Configuration setpoint to change this value from the drop down menu. Click the OK button to program.
8. Repeat the above steps to program additional timers.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
14 REDUCED POWER MODE
R
EDUCED
P
OWER
M
ODE
(RPM) is a feature that puts the control into a state where the power consumption is reduced. RPM is intended to extend the amount of time the generator can sit between runs before the control drains the batteries too low to crank the generator in cases where a battery trickle charger is not fitted.
In order to reduce the power consumed when in RPM, many functions within the control are turned
OFF
.
T
URNED OFF DURING
RPM
The display
The communication lines, including Annunciator communication
All inputs except Remote Initiate
All outputs
LED’s (lamps) on the front of the control blink briefly every second (rather than being on continuously).
When RPM is enabled, the control will only enter RPM after a programmable time delay provided the generator is stopped and no keys have been pressed during the delay time.
The control will wake from RPM on any one of the following conditions:
W
AKE FROM
RPM
Sending a hardwired remote start signal to the controller
Cycling power to the controller
A key on the keypad is pressed
The Programmable Cycle Timer is about to enter a period when it will activate an output.
A
CTIONS TO ENABLE
RPM
1. Change the setpoint Reduced Power Mode Enable Status to
ENABLED
. This can be done with either ET or using a level 3 password to navigate to Configure -> All
Setpoints -> Reduced Power Mode.
2. The setpoint Reduced Power Mode Delay Time should be checked. It should be at a desirable value. This value is the amount of time (once the generator is at rest and after the last key-press) before the control will go into Reduced Power
Mode.
The following conditions must be met in order for the EMCP 4 to enter Reduced Power
Mode:
1. Engine speed must be 0
2. Remote Initiate signal cannot be active
3. Must not be close to the starting time of a Programmed Cycle Timer
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S
EMI
-A
WAKE
The EMCP 4 becomes
SEMI
-
AWAKE
when in Reduced Power Mode. Approximately every 30 minutes it will do status checks of the control for about 40 seconds. During
SEMI
-
AWAKE
the display remains off and the LED’s (lamps) continue to blink. The EMCP will start up to check for Analog Input faults, engine speed sensor diagnostics, and AC faults. If any of these faults become active at this time, the system will respond accordingly (warning or shutdown LED indicators may turn on). During the semi-awake time any active relays (such as common alarm) will energize.
Once the
SEMI
-
AWAKE
time is completed the control will return to full RPM (deactivating any relays that are active). An active event will not prevent the control from entering reduced power mode. If a programmable cycle timer is set to become active in the near future, the timer before waking will be adjusted to ensure the controller wakes in time to process the programmable cycler timer.
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15 PROGRAMMABLE KW RELAY FUNCTION
(EMCP 4.2 ONLY)
The EMCP 4.2 has two Programmable kW Relay functions configured to respond to the %kW of the genset. These functions can be mapped to the EMCP Outputs. In addition, these functions can be used to trigger events using an event response configuration located under Events/Generator Protection Configuration. These events will then be recorded within the Event Log, and may be sent back if remote monitoring of events is being performed.
The setpoints within the Programmable kW Relay functions can be changed from the display, and are as follows:
P
ROGRAMMABLE
T
RIP
P
OINT
#N T
RIGGER
C
ONDITION
Choices: Disabled, Trip Above Threshold, Trip Below Threshold
This selects whether the output will be active if the value is above or below the threshold.
P
ROGRAMMABLE
T
RIP
P
OINT
#N P
ERCENTAGE
T
HRESHOLD
Range: -100-120%
This is the threshold of rated kW that the function must pass in order to change the state of the output.
P
ROGRAMMABLE
T
RIP
P
OINT
#N H
YSTERESIS
P
ERCENTAGE
Range: -100-100%
Once the output is on, the value must return by this much past the Threshold before the output turns off again. For example, if this value is 5% and the Percentage Threshold is 90%, then the relay will activate at 90% but not turn off again until 85% of rated kW (90-5). This hysteresis is used to ensure that a value close to the threshold does not cause the output to oscillate.
P
ROGRAMMABLE
T
RIP
P
OINT
#N T
RIP
A
CTIVATION
D
ELAY
T
IME
Range: 0-999 seconds
This is the time that the value must exceed the threshold before the relay becomes active. It is used to ensure that the momentary transients are ignored.
P
ROGRAMMABLE
T
RIP
P
OINT
#N T
RIP
D
EACTIVATION
D
ELAY
T
IME
Range: 0-999 seconds
This is the time that the value must return past the threshold before the relay becomes inactive again. It is used to ensure that the momentary transients are ignored.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
15.1 CONFIGURING THE PROGRAMMABLE KW RELAY FROM THE
DISPLAY
To configure a Programmable kW Relay with the display, go through the following menu options:
A
T THE MAIN MENU
,
scroll down
CONFIGURE
to
Press the OK
K
EY
.
SCROLL DOWN
to A
LL
S
ETPOINTS
Press the OK
K
EY
SCROLL DOWN
to P
ROG K
W R
ELAY
T
RIP
Press the OK
K
EY
Select the P
ROG K
W R
ELAY
T
RIP
that you want to program
.
Press the OK
K
EY
.
.
Press the OK
K
EY
configuration.
to highlight the current
Select the type of P
ROG K
W R
ELAY
T
RIP
#N T
RIGGER
C
ONDITION
that you want to program (D
ISABLED
,T
RIP
B
ELOW
T
HRESH
, T
RIP
A
BOVE
T
HRESH
).
Press the OK
K
EY
Scroll
DOWN
to P
ROG K
W R
ELAY
T
RIP
#N
P
ERCENTAGE
T
HRESHOLD
.
Press the OK
K
EY
to edit the current
P
ROG
K
W R
ELAY
T
RIP
#N P
ERCENTAGE
T
HRESHOLD
.
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Select the P
ROG K
W R
ELAY
T
RIP
#N P
ERCENTAGE
T
HRESHOLD
that you want to program
Press the OK
K
EY
.
Scroll
DOWN
to P
ROG K
W R
ELAY
T
RIP
#N
H
YSTERESIS
P
ERCENTAGE
Press the OK
K
EY
to edit the current
P
ROGRAMMABLE
T
RIP
P
OINT
F
UNCTION
#N
H
YSTERESIS
P
ERCENTAGE
.
Select the P
ROG K
W R
ELAY
T
RIP
#N H
YSTERESIS
P
ERCENTAGE
that you want to program
Press the OK
K
EY
.
Scroll
DOWN
to P
ROG K
W R
ELAY
T
RIP
#N
T
RIP
A
CTIVATION
D
ELAY
T
IME
Press the OK
K
EY
to edit the current
P
ROGRAMMABLE
T
RIP
P
OINT
F
UNCTION
#N T
RIP
A
CTIVATION
D
ELAY
T
IME
.
Select the P
ROG K
W R
ELAY
T
RIP
#N T
RIP
A
CTIVATION
D
ELAY
T
IME
that you want to program
Press the OK
K
EY
.
Scroll
DOWN
to P
ROG K
W R
ELAY
T
RIP
#N
T
RIP
D
EACTIVATION
D
ELAY
T
IME
Press the OK
K
EY
to edit the current P
ROG
K
W R
ELAY
T
RIP
#N T
RIP
D
EACTIVATION
D
ELAY
T
IME
.
Select the P
ROG K
W R
ELAY
T
RIP
#N T
RIP
D
EACTIVATION
D
ELAY
T
IME
that you want to program
Press the OK
K
EY
.
Application and Installation Guide
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
15.2 CONFIGURING THE PROGRAMMABLE KW RELAYS USING
THE CAT SERVICE TOOL
To configure a Programmable kW Relay with the Cat Service Tool, go through the following menu options:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select kW Relay Setpoints on the left.
3. Double click the Programmable Trip Point #N Trigger Condition setpoint to change this value from the drop down menu. Click the OK button to program.
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4. Double click the Programmable Trip Point #N Percentage Threshold setpoint to change this value. Click the OK button to program.
5. Double click the Programmable Trip Point #N Hysteresis Percentage setpoint to change this value. Click the OK button to program.
6. Double click the Programmable Trip Point #N Output #1 Trip Activation Delay
Time setpoint to change this value from the drop down menu. Click the OK button to program.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
7. Double click the Programmable Trip Point #N Output #12 Trip Deactivation Delay
Time setpoint to change this value from the drop down menu. Click the OK button to program.
8. Repeat the above steps to program an additional timer.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
16.1 PRIMARY CAN DATA LINK (CAN 1)
The Primary CAN Data Link is supported by all levels of the EMCP 4.
The Primary CAN Data Link is used for local communication among modules associated with a single genset. These include one or two engine Electronic Control Modules
(ECM), the Cat Digital Voltage Regulator (Cat DVR), a Thermocouple Module, and the
Cat Clean Emissions Module System.
For the other modules, logs are not kept in the EMCP if power is cycled to the EMCP.
Other modules may log the events and repopulate the EMCP with the logged events.
PRIMARY CAN WIRING
The Primary CAN communication wires are brought out of the EMCP 4 as part of the 70-pin connector. The pins, as designated on the EMCP 4 connector, are shown in Table 13.
PRIMARY CAN COMMUNICATION WIRES
Pin # Name Description
34
42
50
CAN 1 -
CAN 1 SH
CAN 1 +
Differential (-) for CAN
Shield for CAN
Differential (+) for CAN
Table 13: Primary CAN Data Link on the 70-pin EMCP 4 connector
NETWORK TOPOLOGY
The physical topology of the CAN network used in the Primary CAN Data Link is a bus topology, consisting of a main trunk and small drops.
The maximum allowable trunk length is 130 ft (40 m), and the maximum drop length is 3 ft (1 m).
The CAN network requires a 120 ohm termination resistor on the extreme ends of the main trunk.
An example of the topology for the EMCP 4.1 and 4.2 is illustrated in Figure 39.
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Figure 39: EMCP 4.1 CAN 1 Wiring Diagram
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16.2 ACCESSORY CAN DATA LINK (CAN 2) (EMCP 4.2 ONLY)
The Accessory CAN Data Link is not supported by the EMCP 4.1.
The Accessory Data Link (CAN 2) is used for local or remote communication among modules associated with a single genset. These include a Resistance Temperature
Device (RTD) Module, a Thermocouple Module, up to four Digital Input/Output Modules, and up to four Annunciators.
ACCESSORY CAN WIRING
The Accessory CAN communication wires are brought out of the EMCP 4.2 as part of the 70-pin connector. The pins, as designated on the EMCP 4 connector, are shown in
Table 14.
ACCESSORY CAN COMMUNICATION WIRES
Pin # Name Description
62 CAN 2 + Differential (+) for CAN
63 CAN 2 SH Shield for CAN
64 CAN 2 - Differential (-) for CAN
Table 14: EMCP 4.2 Accessory CAN Data Link on 70-pin EMCP 4 connector
NETWORK TOPOLOGY
The physical topology of the CAN network used in the Accessory CAN Data Link is a bus topology, consisting of a main trunk and small drops.
The maximum allowable trunk length is 800 ft (250 m), and the maximum drop length is 9 ft (3 m).
The CAN network requires a 120 ohm termination resistor on the extreme ends of the main trunk.
The topology for the EMCP 4.2 in the default configuration, with no remote devices connected, is illustrated in Figure 39.
The topology for the EMCP 4.2 with some remote devices connected is illustrated in Figure 40.
Note
: The devices shown in Figure 40 are only representative; more remote devices can be connected, as long as the proper lengths are maintained, and the termination resistor is placed at the end of the trunk. Refer to Chapter 17 for the maximum number of devices supported on each level.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Figure 40: EMCP 4.2 CAN 1 and CAN 2 Wiring Diagram (With Optional Modules)
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
The EMCP 4 consists of the EMCP 4 Genset Controller, as well as some optional auxiliary modules. These modules connect to the EMCP 4 via either the Primary or
Accessory CAN Data Link, or an RS-485 SCADA Data Link (Modbus RTU, Half Duplex).
The EMCP 4 can also communicate with a Cat engine ECM on the CAN network
(though this is not considered an optional module for those engines).
Different numbers of modules are supported for different levels of EMCP 4. The maximum numbers of modules supported on the CAN networks are given in Table 15.
MODULE
Engine ECM
EMCP 4.1
Primary
CAN 1
1 or 2
EMCP 4.2
Primary
CAN 1
1 or 2
Accessory
CAN 2
0
CAN Annunciator 0 0 4
Table 15: Number of Optional Modules Supported on CAN Networks
Note
: The number of RS-485 Annunciators is only limited by the RS-485 standard impedance for wiring and devices. (EMCP 4.1 does not support the RS-485 annunciator.)
For more information about connecting modules to the CAN data links, refer to Chapter
16.2, Accessory CAN Data Link.
THE ANNUNCIATORS
The CAN Annunciator module is an auxiliary alarm indication device, consisting of 16 pairs of indicator LED’s, and an audible horn. Each pair can be individually configured based for an application, and a custom film kit is available to customize the graphic/text indication. For further information see Chapter 17.1.
The RS-485 Annunciator module is an auxiliary alarm indication device, consisting of 16 pairs of indicator LED’s, and an audible horn. Each annunciator can be mapped to one of four predefined group of alarms (including custom groups) based on application needs. A custom film kit is available to customize the graphic/text indication. For further information see Chapter 17.2.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
THE THERMOCOUPLE, RTD, & DIO
EMCP 4 uses a common form factor for the three modules known as the Thermocouple,
RTD (Resistance Temperature Detector) and DIO (Discrete I/O) modules. The same case design is used for all three.
The Thermocouple module, RTD module and DIO module feature identical rugged packaging and Deutsch IPD connectors. The only physical difference in packages between these three optional modules is that the DIO module has an LED to indicate communication network status.
Applications can include networked power generator set control systems.
For further information on the Thermocouple module see Chapter 17.23, for the RTD module see Chapter 17.4, and for the DIO module see Chapter 17.5.
THE CAT DIGITAL VOLTAGE REGULATOR
The Cat Digital Voltage Regulator (Cat DVR) module is an auxiliary voltage regulator device, regulating the generator voltage to provide optimal response to various load types and changes in load. It is connected to the generator exciter and field, and communicates with the EMCP 4 for monitoring purposes. For further information see
RENR7941 Cat Digital Voltage Regulator.
17.1 CAN ANNUNCIATOR
The EMCP CAN Annunciator serves to display system alarm conditions and status indications. The
CAN Annunciator has been designed for use on the
EMCP 4 Accessory CAN Data Link and may be used in either Local or Remote applications, providing customers with enhanced site flexibility.
In Local application, the CAN Annunciator may be mounted on the Package generator set with the
EMCP 4 to provide a complete package-mounted monitoring solution.
The Annunciator may also be mounted separately from the generator set to provide Remote indication of system operating and alarm conditions.
A maximum of four CAN Annunciators can be mounted locally or remotely and connected to the
Accessory CAN 2 data link.
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CAN ANNUNCIATOR FEATURES
The Annunciator includes:
Sixteen (16) LED pairs for annunciation of up to 32 system events
An additional pair of LED’s provides status indication of the CAN data link connection
Annunciation of alarm conditions received from any module on the CAN data link
Alarm Horn with Lamp Test and Alarm Acknowledge pushbuttons
Configurable to NFPA 99/110 requirements for local and remote annunciation on
Emergency Standby Generator Systems
Provides a simple means to change the labels for the annunciation LED’s for site specific requirements (Custom Label Kit purchased separately)
Superior visibility of the LED’s in direct sunlight
Graphic symbols along with text labels are provided next to each LED pair to indicate various alarms and events
Can be Mounted either locally on the package generator set or remotely (up to
800 feet) on the Accessory CAN Data Link
Designed and tested to meet stringent Impulse Shock and Operating Vibration requirements
288 mm (11.34 in) High x 158 mm (6.22 in) Wide x 66 mm (2.37 in) Deep
ANNUNCIATOR SPECIFICATIONS
E
LECTRICAL
S
PECIFICATIONS
Control Power 12 VDC & 24 VDC nominal (9 – 32 VDC acceptable)
Over voltage capability is 80 VDC for 2 minutes @ 70
C
Reverse voltage capability is –32 VDC for 1 hour @ 70
C
Single, 6-pin connector provides both power and communication
Designed to meet relevant European standards for EMI/RFI/Immunity without the use of external filtering (UL Listed).
E
NVIRONMENTAL
S
PECIFICATIONS
Operating Temperature -40
C to 70C
Storage Temperature -50
C to +85C
Relative Humidity 90%, non-condensing, 30
C to 60C.
Can be mounted directly on the generator set panel or remotely
N
ETWORK
C
OMMUNICATIONS
I
NTERFACE
Incorporates a communications port, able to operate on the EMCP 4 Accessory
CAN Data Link
Node address is auto configurable
Optical isolation is provided for the CAN line
Module retains configured setpoints in non-volatile memory with loss of communications and power
Configuration is accomplished with the Cat Service Tool over the CAN 2 network
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
ANNUNCIATOR WIRING
The back of the CAN Annunciator module contains an 8-terminal screw terminal block.
Attached to the block is a 6-pin Deutsch adapter. The pin outs for both are shown in
Figure 41 and Table 16.
Figure 41: Annunciator Deutsch Connector Pin Configuration and Terminal Block
ANNUNCIATOR TERMINAL BLOCK PIN CONFIGURATION
Terminal # Function
1
2
PWR-
PWR+
Description
- Battery Input
+ Battery Input, also connects to Horn(+)
4
5
6
7
8
CAN2-L CAN Data link LOW
CAN2-H CAN Data link HIGH
Lamp Test Lamp Test
Alarm Ack Alarm Acknowledge
Horn Driver Connects to negative terminal of Horn
Table 16: Annunciator Terminal Block Pin Configuration
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LED COLORS
Each pair of LED’s on the Annunciator consists of two of the following three colors:
Green, Amber, and Red, which allows for custom configuration of S
TATUS
, W
ARNING
and
S
HUTDOWN
conditions. The available colors and combinations are listed in Table 17 LED
Colors:
ROW LED 1
LED COLORS
LED 2 ROW LED 1 LED 2
Table 17: LED Colors
M
ODULE
S
TATUS
LED
A red/green pair located at the bottom of the CAN Annunciator, is used to report
Module/Network Status. The various states indicated are explained in Table 18.
BEHAVIOR EXPLANATION
Red solid CAN 2 data link diagnostic. For example: the module is wired wrong (Data Link), wrong cable, or no terminating resistor.
Green solid CAN 2 data link OK
Green flashing
Red/Green alternating
No CAN 2 data link diagnostic, but no communication detected.
Hooking the Annunciator up with the power on.
No application software loaded
Table 18: CAN Annunciator Module / Network Status LED Behavior
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
CAN ANNUNCIATOR SOFTWARE CONFIGURATION
The CAN Annunciator is field-programmable using the Cat Service Tool. It is also flash programmable to update software using the Cat Service Tool.
The service tool software must be installed on a Windows PC. The Cat communication adapter must be connected between the PC and the CAN 2 Accessory data link on which the target CAN 2 Annunciator is connected.
GLOBAL ACKNOWLEDGE
The CAN Annunciator can be configured to both initiate and respond to an Event
Acknowledge message over the CAN Accessory data link. If this setpoint is enabled, the CAN Annunciator events may be acknowledged locally on the CAN Annunciator by pressing the Alarm Acknowledge button or remotely by pressing the Alarm Acknowledge button on the EMCP 4 or by pressing the Acknowledge button on another CAN
Annunciator configured for Global Acknowledge that is on the same data link.
Acknowledging events also silences the horn.
The default setting for this setpoint is DISABLED, but it can be enabled from the
Configuration tool within Cat Electronic Technician.
ECU INSTANCE NUMBER
The Module Description will also indicate a number that identifies the CAN Annunciator uniquely from any other CAN Annunciator modules on the Accessory CAN Data Link.
This number is called the ECU
I
NSTANCE
and it is programmable.
The service tool configuration screen identifies the serial number of the CAN
Annunciator that is connected. This is important in matching the desired ECU Instance to the actual hardware.
Note
: If two CAN Annunciators on the same communications network are programmed for the same ECU Instance number, neither will communicate.
CONFIGURING ANNUNCIATOR LED BEHAVIOR
1. Connect to the Annunciator using the Cat Service Tool as stated in Chapter 4.2.
2. Select Configuration Group #N from the left pane.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
3. Double click ECU Instance Number to enter a new ECU Instance Number.
4. Double click Annunciator Data Link Global Acknowledge Enable Status to change this value from the drop down menu.
5. Select Service > LED Pair Configuration.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
6. The LED pairs will become visible in a new window.
7. Double click on an LED pair to configure the pair.
8. Select the Trigger condition for the pair in the drop down menu.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
9. Select the Severity Level for the pair in the drop down menu.
10. Select the Suspect Parameter Number for the pair in the drop down menu.
11. The Failure Mode Identifier does not normally need to be programmed since the Severity Level typically has this information embedded.
To configure the behavior of the LED pairs, enter the LED Pair Configuration screen by selecting Service LED Pair Configuration.
Each LED pair has four parameters associated with it. Each parameter is dependent on the parameter(s) preceding it (to the left); first Trigger Condition, next Severity Level, then Suspect Parameter Number, and finally Failure Mode Identifier (if required).
TRIGGER CONDITION
There are three possible selections for Trigger Condition: S
PECIFIC
E
VENT
, G
ENERAL
E
VENT
, and D
ISABLED
.
S
PECIFIC
E
VENT
is used to assign an LED pair to a specific data link parameter, such as Oil Pressure, Engine Speed, Coolant Temperature, etc. The desired parameter must be chosen in the Suspect Parameter Number column.
G
ENERAL
E
VENT
is used to assign an LED pair as a general alarm or shutdown indicator.
When configured as General Event, the LED will not be assigned to a particular parameter. It will respond to any event with a severity level chosen in the Severity Level column, regardless of the Suspect Parameter Number.
For this reason, when General Event is selected, the Suspect Parameter Number cannot be changed.
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Figure 42: Cat Service Tool CAN 2 Annunciator Led Configuration Screen
D
ISABLED
is used to disable the LED pair. When Disabled is selected, the other three parameters cannot be changed.
SEVERITY LEVEL
Severity Level defines which types of events the LED pair will react to. Selections that begin with Condition Exists will respond to CAN Event messages for Failure Mode
Identifier (FMI) 31 Condition Exists.
For example, LED pair #2 is configured for Condition Exists, Red On, Other Not Used,
Horn On with SPN 190 (Emergency Stop Active). This means that when the Annunciator received a CAN message indicating Emergency Stop with FMI 31, the Red LED will turn on and the Horn will also turn on.
Other Not Used indicates that the other LED color in the pair is never used.
Green Off (for example) indicates that the green LED lights when the condition chosen for this LED pair is NOT active.
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Most Severity Level selections imply (a) CAN Failure Mode Identifier (FMI) code(s):
C
ONDITION
E
XISTS
is equivalent to FMI 31
H
IGH
W
ARNING
can be FMI 15 or FMI 16
L
OW
W
ARNING
can be FMI 17 or FMI 18
H
IGH
S
HUTDOWN
is equivalent to FMI 0
L
OW
S
HUTDOWN
is equivalent to FMI 1
H
IGH OR
L
OW
S
HUTDOWN
is equivalent to FMI 0 or FMI 1
Since the FMI codes are implied by this column, the FMI column is grayed out for any of these selections.
The only option that will allow an FMI to be configured is S
PECIFIC
D
IAGNOSTIC
.
SUSPECT PARAMETER NUMBER
The Suspect Parameter Number column is used to select or type in the SPN for the parameter assigned to the LED pair. Most supported SPNs can be selected from the list.
Refer to the UENR1209 Systems Operation Testing and Adjusting Manual for a complete list of supported SPNs.
17.2 RS-485 ANNUNCIATOR (EMCP 4.2 ONLY)
The EMCP RS-485 Annunciator serves to display system alarm conditions and status indications.
The RS-485 Annunciator has been designed for use on a dedicated EMCP 4 fully isolated two wire RS-
485 SCADA Data Link (Half Duplex), and may be used in either Local or Remote applications, providing customers with enhanced site flexibility. The
RS-485 Annunciator uses a custom master-slave communication protocol. The EMCP 4.2 controller will be the Master, and the RS-485 Annunciator(s) will be the slave(s). Configuration takes place within the
EMCP 4.
In Local application, the RS-485 Annunciator may be mounted on the Package generator set with the
EMCP 4 to provide a complete package-mounted monitoring solution.
The RS-485 Annunciator may also be mounted separately from the generator set to provide Remote indication of system operating and alarm conditions.
The number of RS-485 Annunciators is limited by the RS-485 standard.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
ANNUNCIATOR FEATURES
The Annunciator includes:
Sixteen (16) LED pairs for annunciation of up to 32 system events
An additional pair of LED’s provides status indication of the dedicated RS-485
Annunciator Network communication connection
Ability to annunciate alarm conditions sent from the EMCP 4 within preconfigured alarm groups
Alarm Horn with Lamp Test and Alarm Acknowledge pushbuttons
Configurable to NFPA 99/110 requirements for local and remote annunciation on
Emergency Standby Generator Systems
Provides a simple means to change the labels for the annunciation LED’s for site specific requirements (Custom Label provided with Custom Alarm Group #1 and
#2 RS-485 Annunciator)
Superior visibility of the LED’s in direct sunlight
Graphic symbols along with text labels are provided next to each LED pair to indicate various alarms and events
Configurable with Cat ET via settings within the EMCP 4
Can be mounted either locally on the package generator set or remotely (up to
4000 feet)
Designed and tested to meet stringent Impulse Shock and Operating Vibration requirements
286 mm (11.26 in) High x 157 mm (6.18 in) Wide x 68 mm (2.67 in) Deep
ANNUNCIATOR SPECIFICATIONS
E
LECTRICAL
S
PECIFICATIONS
Control Power 12 VDC & 24 VDC nominal (9 – 32 VDC acceptable)
Reverse voltage capability is -32 VDC for 1 hour @ 70
C
Over voltage capability is 80 VDC for 2 minutes @ 70
C
Single, 8-pin connector provides both power and communication
Designed to meet relevant European standards for EMI/RFI/Immunity without the use of external filtering
E
NVIRONMENTAL
S
PECIFICATIONS
Operating Temperature -40 to 70
C
Storage Temperature -50
C to +85C
Relative Humidity 90%, non-condensing, 30
C to 60C.
Failure Point 85
C. If the ambient temperature were to exceed 85C, the device would NOT be expected to return to proper operation.
Can be mounted directly on the generator set panel or remotely
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
N
ETWORK
C
OMMUNICATIONS
I
NTERFACE
EMCP 4 provides a dedicated, fully isolated RS-485 SCADA Data Link (Half
Duplex) separate from the RS-485 (MODBUS) port used on the EMCP 4
Operates at 19200 bits per second
Configuration is accomplished with the Cat Service Tool by connecting to the EMCP 4
RS-485 Annunciator communication is not compatible with third party devices.
RS-485 ANNUNCIATOR WIRING
The back of the RS-485 Annunciator module contains an 8-terminal screw terminal block. Attached to the block is an 8-pin Deutsch receptacle, Cat part number 3E-3388
(Deutsch DT04-08PA-E005). The mating plug is Cat part number 155-2264 (Deutsch
DT06-08SA-EP08, or equivalent). The pin outs for both the receptacle and terminal block are shown in Figure 42 and Table 19 and 20.
Figure 43: RS-485 Annunciator Deutsch Connector Pin Configuration and Terminal Block
RS-485 ANNUNCIATOR DEUTSCH CONNECTOR PIN CONFIGURATION
Pin # Function
1
2
3
BATT +
BATT -
+ Battery input
- Battery input
NOT USED NOT USED
4
5
Comments
RS-485 B (+) + Non-Inverting Positive RS-485 input signal
RS-485 A (-) - Inverting Negative RS-485 input signal
6
7
8
RS-485 R RS-485 Reference
NOT USED NOT USED
NOT USED NOT USED
Table 19: RS-485 Annunciator Deutsch Connector Pin Configuration
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RS-485 ANNUNCIATOR TERMINAL BLOCK PIN CONFIGURATION
Terminal #
1
Function
BATT - - Battery input
Description
2
BATT + + Battery input
3
RS-485 R RS-485 Reference
4
RS-485 A (-) - Inverting Negative RS-485 input signal
5
RS-485 B (+) + Non- Inverting Positive RS-485 input signal
6
7
8
Lamp Test SW Lamp Test
Alarm ACK
Horn Drive
Alarm Acknowledge
Connects to negative terminal on Horn
Table 20: RS-485 Annunciator Terminal Block Pin Configuration
LED COLORS
Each pair of LED’s on the RS-485 Annunciator consists of two of the following three colors: Green, Amber, and Red, which allows for custom configuration of S
TATUS
,
W
ARNING
and S
HUTDOWN
conditions. The available colors and combinations are listed in Table 21 LED Colors:
ROW LED 1
LED COLORS
LED 2 ROW LED 1 LED 2
Table 21: LED Colors
M
ODULE
S
TATUS
LED
A red/green pair located at the bottom of the RS-485 Annunciator, is used to report
Module/Network Status. The various states indicated are explained in Table 22.
BEHAVIOR EXPLANATION
Red solid Data link diagnostic. For example: the module is wired wrong (Data Link), or no terminating resistor.
Green solid Data is being received from the EMCP 4
Green flashing
Loss of communication
Red/Green flashing
No application software loaded, or Alarm
Group Selection Mode is active
Table 22: Annunciator Module / Network Status LED Behavior
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LAMP TEST FUNCTION
The Annunciator supports a lamp test function from a button press on the EMCP 4.
The lamp test function cycles continuously through two test modes while pressing and holding in the Lamp Test button. The first mode is a column test mode. The left column of LED’s will be lit for one second while the right column is off. Then the right column of LED’s will be lit for one second, while the left column is off. This will occur twice.
During the second run of this test mode (during the first cycle only), the horn will be on.
The second test mode is an individual LED test mode. In this mode, the LED’s will light one at a time, starting from the top left LED, down to the left hand module status LED, then over to the right hand module status LED, then up to the top right LED. Each LED will be lit for 1/2 second, after which it will turn off and the next LED will be lit. At the completion of this test mode, the cycle will restart with the first test mode. However, on subsequent runs of the first test mode, the horn will not turn on.
The RS-485 Annunciator returns to normal operation once the lamp test button is released.
ALARM ACKNOWLEDGE
The RS-485 Annunciator supports an acknowledge event/silence horn function from a button press on the RS-485 Annunciator or from the EMCP 4. Both cases have different behavior and are outlined below.
When an active event is received from the EMCP 4 and is acknowledged locally with a button press on the RS-485 Annunciator module, any flashing LED tied to that event will stop flashing and maintain a steady illumination and the horn will be silenced.
Note
: Only the local RS-485 Annunciator module that acknowledges the active event will change the state of its flashing LED(s) and silence the horn. The acknowledge signal of the annunciation is not broadcast to any other units on the RS-485 Annunciator Data Link.
When an active event is received from the EMCP 4 and is acknowledged globally with a button press on the EMCP 4 controller, it is transmitted to the RS-485 Annunciator(s) module(s). Any flashing LED tied to that event will stop flashing and maintain a steady illumination and the horn will be silenced.
Note
: In this case, the EMCP 4 may acknowledge active events on multiple RS-485
Annunciators simultaneously.
The horn silence/acknowledge function will cause the local horn to be silenced until another event causes an LED to be activated.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
RS-485 ANNUNCIATOR ALARM GROUPS
The RS-485 Annunciator supports four different Alarm Groups. Alarm Group 01, 02, 03, and Alarm Group 04. Two of these Alarm Groups, 03 and 04, are fixed and are not configurable and two Alarm Groups, 01 and 02, are reserved for custom event settings and are fully configurable.
Selecting which of the four Alarm Groups to configure the RS-485 Annunciator is determined by the film that is placed on the front left panel. The Alarm Groups and the events that make up the films for each of the Alarm Groups are detailed below in Tables
24, 25 and 26. Configuring the RS-485 Annunciator to one of the four Alarm Groups is accomplished through the front panel of the RS-485 Annunciator and is described further in Alarm Group Selection Mode below.
ALARM GROUP SELECTION MODE (AGSM)
The RS-485 Annunciator supports an Alarm Group Selection Mode (AGSM) that provides the ability to configure the RS-485 Annunciator to monitor a predetermined set of 32 events communicated by the EMCP 4 through the dedicated RS-485 Annunciator
Data Link.
Alarm Group selection and assignment are determined by the desired functions of the
RS-485 Annunciator (Custom or non-configurable) and the film that is placed on the front left panel that reflects the predefined events monitored by the RS-485 Annunciator.
When in AGSM, the top first four rows of LED’s will indicate which Alarm Group the
RS-485 Annunciator has been assigned to by powering ‘on’ both LED’s in each row, i.e. row 1 for Alarm Group 01, row 2 for Alarm Group 02, row 3 for Alarm Group 03, and row
4 for Alarm Group 04. (Note: The RS-485 Annunciator will be preprogrammed to Alarm
Group 04.)
The RS-485 Annunciator will continue to communicate to the EMCP 4 while in AGSM.
Events received from the EMCP 4 while in AGSM will not be annunciated until AGSM has been exited only if the event that is received is an event in the selected Alarm Group.
Once the RS-485 Annunciator has successfully been assigned to an Alarm Group, it shall receive and process any Event transmitted from the EMCP 4 to the assigned
Alarm Group without power cycling the module.
The Network Status LED’s will alternate flashing at a 2Hz rate at all times while in
AGSM.
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ENTERING AGSM
The RS-485 Annunciator shall enter AGSM by depressing the two buttons on the front panel of the RS-485 Annunciator (Lamp Test and Alarm ACK) for 3 seconds.
The RS-485 Annunciator shall acknowledge entrance of AGSM by flashing the top
4 rows of LED’s 4 times at a 1 second rate.
After the 3 second period has timed out, the row representing the currently assigned alarm group address will be powered on, the remaining 11 rows of LED’s will not be powered on. See Table 23 AGSM LED Behavior below.
Row Column 1
1
Column 2
Solid if Assigned to Alarm Group 01, else off Solid if Selected to Alarm Group 01, else off
2
3
Solid if Assigned to Alarm Group 02, else off Solid if Selected to Alarm Group 02, else off
Solid if Assigned to Alarm Group 03, else off Solid if Selected to Alarm Group 03, else off
4 Solid if Assigned to Alarm Group 04, else off Solid if Selected to Alarm Group 04, else off
5 Off Off
6 Off
7 Off
8 Off
9 Off
10 Off
11 Off
12 Off
13 Off
14 Off
15 Off
16 Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Table 23: AGSM LED Behavior
RE-CONFIGURING/SELECTING ALARM GROUP ADDRESS
While the RS-485 Annunciator is still in AGSM it will cycle through the four Alarm Groups by pressing one of the two buttons on the front panel. Pressing the Lamp Test button will cycle up through the 4 Alarm Groups and pressing the Alarm ACK button will cycle down through the 4 Alarm Groups.
Upon reaching Alarm Group 04 (row 4) while cycling down through the Alarm Groups with the Alarm ACK button, an additional Alarm ACK button press will bring the selection to Alarm Group 01 (row 1). Upon reaching the Alarm Group 01 (row 1) while cycling up through the Alarm Groups with the Lamp Test button, an additional Lamp Test button press will bring the selection to Alarm Group 04 (row 4).
When selecting a new Alarm Group address, the left column (red LED) will represent the previously configured Alarm Group selection. The right column (amber LED) will represent the currently selected Alarm Group. When AGSM is exited, the currently selected register address will be configured as the new Alarm Group.
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EXITING AGSM
The Annunciator will exit AGSM under two possible conditions:
• A time out period without any button presses
• Pressing and holding the two buttons (ACK and Horn buttons) for 3 seconds
After a period of 15 seconds without any button presses, the RS-485 Annunciator will automatically exit AGSM and disregard any changes made to the Alarm Group selection and remain configured to the Alarm Group prior to entering AGSM.
When an Alarm Group selection has been made and the two buttons are pressed (Lamp
Test and Alarm ACK) and held in continuously for 3 seconds, the RS-485 Annunciator will update the current configured Alarm Group to the current selected Alarm Group and then exit AGSM. Be sure to pay attention to confirm that the group being saved is the correct Alarm Group.
After exiting AGSM under either one of the two exit conditions listed, the RS-485
Annunciator will flash all 16 rows of LED’s for 3 seconds at which time the RS-485
Annunciator will enter regular annunciation mode.
RS-485 ANNUNCIATOR CUSTOM ALARM GROUP CONFIGURATION
The RS-485 Annunciator is field-programmable by the EMCP 4 via the Cat Service Tool when configured for Alarm Group’s 01 and 02. Alarm Group’s 01 and 02 support customization of the 32 events for the 16 LED’s.
The service tool software must be installed on a Windows PC. The Cat communication adapter must be connected between the PC and the CAN Primary data link on which the target EMCP 4 is connected.
CUSTOM ALARM GROUP SELECTION
When the Cat Service Tool is communicating, the EMCP 4 shall be selected as the target module. Located at the top of the Cat Service Tool screen is the tool bar, select
Service RS-485 Annunciator. The RS-485 Annunciator configuration screen will be displayed with the Alarm Group Select at the top left of the screen. There are two possible selections for Alarm Groups: #1 and #2.
To configure the RS-485 Annunciator LED’s, select each of the LED’s individually.
With the selected LED window displayed the initial selection is for Trigger Condition.
There are three possible selections for Trigger Condition: S
PECIFIC
E
VENT
, G
ENERAL
E
VENT
, and Disabled.
S
PECIFIC
E
VENT
is used to assign an LED pair to a specific data link parameter, such as Oil Pressure, Engine Speed, Coolant Temperature, etc. The desired parameter must be chosen in the Suspect Parameter Number column.
G
ENERAL
E
VENT
is used to assign an LED pair as a general alarm or shutdown indicator.
When configured as General Event, the LED will not be assigned to a particular parameter. It will respond to any event with a severity level chosen in the Severity Level column, regardless of the Suspect Parameter Number.
For this reason, when General Event is selected, the Suspect Parameter Number cannot be changed.
D
ISABLED
is used to disable the LED pair. When Disabled option is selected, the other three parameters cannot be changed.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
SEVERITY LEVEL
Severity Level defines which types of events the LED pair will react to. Selections that begin with Condition Exists will respond to CAN Event messages for Failure Mode
Identifier (FMI) 31 Condition Exists.
For example, LED pair #1 is configured for Condition Exists, Red On, Other Not Used,
Horn On with SPN 970 (Emergency Stop Active). This means that when the RS-485
Annunciator receives data from the EMCP 4 over the RS-485 Annunciator Data Link indicating Emergency Stop with FMI 31, the Red LED will turn on and the Horn will also turn on.
Other Not Used indicates that the other LED color in the pair is never used.
Green Off (for example) indicates that the green LED lights when the condition chosen for this LED pair is NOT active.
Most Severity Level selections imply (a) Failure Mode Identifier (FMI) code(s):
C
ONDITION
E
XISTS
is equivalent to FMI 31
H
IGH
W
ARNING
can be FMI 15 or FMI 16
L
OW
W
ARNING
can be FMI 17 or FMI 18
H
IGH
S
HUTDOWN
is equivalent to FMI 0
L
OW
S
HUTDOWN
is equivalent to FMI 1
H
IGH OR
L
OW
S
HUTDOWN
is equivalent to FMI 0 or FMI 1
Since the FMI codes are implied by the choice made in the Severity Level column, the FMI column is grayed out for any of these selections.
The only option that will allow a specific FMI to be configured is S
PECIFIC
D
IAGNOSTIC
.
SUSPECT PARAMETER NUMBER
The Suspect Parameter Number column is used to select one of the listed SPN’s in the drop down menu or type in a specific SPN number for an SPN that may not be listed in the drop down menu for the parameter assigned to the LED pair. Most supported SPNs can be selected from the list.
ENGINE RUNNING
When configuring the RS-485 Annunciator for ENGINE RUNNING, special consideration must be taken to trigger the event. The event can be triggered in a variety of ways. A selection of Engine Running trigger conditions is provided in ET and on the EMCP display.
Figure 44: Cat Service Tool Engine Running Conditions Configuration Screen
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Figure 45: EMCP 4.2 Display Engine Running Conditions Configuration Screen
The Engine Running Conditions are logically combined together such that any selection will activate the condition and consist of the following options:
Custom Event Digital Input (SPN 701)
Engine Running (based on Engine Overview state with non-zero engine speed)
V/Hz Within Limits (unit is close to rated voltage and rated frequency)
Engine Running at Rated Speed (Engine Running, not in Idle, not in Cooldown)
For using the Custom Event Digital Input trigger condition, the SPN shall be configured for Auxiliary I/O #1 (SPN 701) and it shall have a Severity Level configured for any one of the Condition Met setpoints. Digital Input #1 shall be physically wired to the active status signal that is to be used to trigger this programmed LED. If it is only to be based upon the status of the generator set controlled by the EMCP, then an output such as
Relay Output #2, Fuel Control Relay, or Engine Start Initiated for Common Engine
Interface generator sets on the EMCP 4 can be used. The Fuel Control Relay or Engine
Start Initiated active status signal is continually active only while the engine is in running.
Alarm Group #3 has LED #15 pre-configured for Engine Running and requires selecting one or multiple Engine Running Conditions to trigger an Engine Running event on the
RS-485 Annunciator. If using a custom Alarm Group, use SPN 4244 and Severity Level of Condition Met.
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Figure 46: RS-485 Annunciator Custom Alarm Group Engine Running LED Configuration
ALARM GROUPS
The RS-485 Annunciator is capable of being configured for one of four Alarm Groups.
Two of these Alarm Groups are fixed, two are configurable. Selection of the Alarm Group to be used is accomplished by using the front panel of the RS-485 Annunciator module as explained above in Alarm Group Selection Mode (AGSM).
The assignment of films for each of the Alarm Groups is outlined below:
Alarm Group # 1 (Custom Configurable 1) - Film #1 (see Table 24) and custom film
Alarm Group # 2 (Custom Configurable 2) - Film #1 (see Table 24) and custom film
Alarm Group # 3 (Fixed) - Film #1 (see Table 24)
Alarm Group # 4 (Fixed) - Film #2, or Film #3 (see Tables 25 and 26)
Note
: Alarm Groups #1 and #2 are blank until configured.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Row LED
Colors
1 Red
Amber
2 Red
Amber
3 Red
Amber
4 Red
Amber
7
8
5 Red
Amber
6 Red
Green
Red
Amber
Red
Amber
9 Red
10
Amber
Red
Amber
11 Red
Amber
12 Red
Amber
13 Green
Amber
14 Green
Amber
15 Red
Green
16 Red
Amber
Default LED and Setpoint
Assignments
Overcrank
Used
High Coolant Temp Shutdown
High Coolant Temp Warning
Low Coolant Temp Warning
Low Oil Pressure Shutdown
Low Oil Pressure Warning
Low Coolant Level Shutdown
Low Coolant Level Warning
Low Fuel Level Shutdown
Low Fuel Level Warning
Generator Not in Auto Warning
High Battery Voltage Shutdown
High Battery Shutdown Warning
Low Battery Voltage Warning
Not
Low Cranking Voltage Warning
Battery Charger AC Failure
Not
EPS Supplying Load
Horn
NA
Y
Y
Y
NA
Y
NA
Y
NA
Y
NA
N
NA
N
Y
Y
Y
NA
Y
NA
Y
Y
NA
Y
Y
Y
Y
Y
Y
Y
Y
NA
SCR – Tier 4
SCR – Tier 4
Table 24: Film #1. Alarm Group 01 & 02 default film and Alarm Group 03 film assignments.
NFPA 99/110 events. Includes Fuel Level, Engine Running, and Tier 4 SCR events
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Row LED
Colors
1 Red
Amber
2 Red
Amber
3 Red
Amber
4 Red
Amber
7
8
5 Red
Amber
6 Red
Green
Red
Amber
Red
Amber
9 Red
10
Amber
Red
Amber
11 Red
Amber
12 Red
Amber
13 Green
Amber
14 Green
Amber
15 Red
Green
16 Red
Amber
Default LED and Setpoint
Assignments
Overcrank
Used
High Coolant Temp Shutdown
High Coolant Temp Warning
Low Coolant Temp Warning
Low Oil Pressure Shutdown
Low Oil Pressure Warning
Low Coolant Level Shutdown
Low Coolant Level Warning
Low Fuel Level Shutdown
Low Fuel Level Warning
Generator Not in Auto Warning
High Battery Voltage Shutdown
High Battery Shutdown Warning
Low Battery Voltage Warning
Not
Low Cranking Voltage Warning
Battery Charger AC Failure
Not
EPS Supplying Load
Air Damper Shutdown
Not
SCR – Tier 4
SCR – Tier 4
Table 25: Film #2. Alarm Group 04. NFPA 99/110 events.
Includes Fuel Level, Air Damper Shutdown, and Tier 4 SCR events.
Horn
NA
Y
Y
Y
NA
Y
NA
Y
NA
Y
NA
N
Y
NA
Y
Y
Y
NA
Y
NA
Y
Y
NA
Y
Y
Y
Y
Y
Y
Y
Y
NA
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Row LED
Colors
1 Red
Amber
2 Red
Amber
3 Red
Amber
4 Red
Amber
7
8
5 Red
Amber
6 Red
Green
Red
Amber
Red
Amber
9 Red
10
Amber
Red
Amber
11 Red
Amber
12 Red
Amber
13 Green
Amber
14 Green
Amber
15 Red
Green
16 Red
Amber
Default LED and Setpoint
Assignments
Overcrank
Used
High Coolant Temp Shutdown
High Coolant Temp Warning
Low Coolant Temp Warning
Low Oil Pressure Shutdown
Low Oil Pressure Warning
Low Coolant Level Shutdown
Low Coolant Level Warning
Low Fuel Level Shutdown
Low Fuel Level Warning
Generator Not in Auto Warning
High Battery Voltage Shutdown
High Battery Shutdown Warning
Low Battery Voltage Warning
Not
Low Cranking Voltage Warning
Battery Charger AC Failure
Not
EPS Supplying Load
Air Damper Shutdown
Not
Used
Not
Table 26: Film #3. Alarm Group 04 film assignments. NFPA 99/110 events.
Includes Fuel Level and Air Damper Shutdown. Does not include Tier 4 SCR
Horn
NA
Y
Y
Y
NA
Y
NA
Y
NA
Y
NA
N
Y
NA
NA
NA
Y
NA
Y
NA
Y
Y
NA
Y
Y
Y
Y
Y
Y
Y
Y
NA
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CONFIGURING CUSTOM ALARM GROUPS USING CAT SERVICE TOOL
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select Service > RS-485 Annunciator Configuration.
Note
: This option will not appear if the EMCP 4 was not selected in the ECM Summary
Screen when connecting to Cat ET.
3. The LED pairs will become visible in a new window.
4. Select the Alarm Group for the Annunciator by choosing from the drop down menu.
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5. Double click on an LED pair to configure the pair.
6. Select the Trigger condition for the pair in the drop down menu.
7. Select the Severity Level for the pair in the drop down menu.
For a complete list of choices for Severity Level, see the tables below.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
8. Select the Suspect Parameter Number for the pair in the drop down menu.
For a complete list of choices for Suspect Parameter Number, see the tables below.
9. The Failure Mode Identifier does not normally need to be programmed since the
Severity Level typically has this information embedded. See information below for a Diagnostic SPN.
If the LED Trigger Condition is configured as General Event, the Severity Level can be configured according to Table 27.
Trigger Condition Severity Level
Low Warning
Low Shutdown
High Warning
High Shutdown
High or Low Warning
High or Low Shutdown
Low Warning or Low Shutdown
High Warning or High Shutdown
High or Low Warning, High or Low Shutdown
High or Low Warning, High or Low Shutdown or
Diagnostic
Diagnostic Other Than Warning/Shutdown/Condition
Exists
Table 27: General Event Severity Levels
Allowed for LED Pairs…
1-5, 7-12, 16 13-14 6, 15
√ √
√
√
√
√
√
√
√
√
√
√
√
√
√
√ √ √
√ √
Page 200 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
If the LED Trigger Condition is configured as Specific Event, the Severity Level can be configured according to Table 28.
Trigger Condition Severity Level
Low Warning
Low Shutdown
High Warning
High Shutdown
High or Low Warning
High or Low Shutdown
Low Warning or Low Shutdown
High Warning or High Shutdown
High or Low Warning, High or Low Shutdown
High or Low Warning, High or Low Shutdown or Diagnostic
Diagnostic Other Than Warning/Shutdown/Condition Exists
Specific Diagnostic
Condition Exists, Red On, Other Not Used
Condition Exists, Amber On, Other Not Used
Condition Exists, Green On, Other Not Used
Condition Exists, Red On, Amber Off
Condition Exists, Red On, Green Off
Condition Exists, Amber On, Red Off
Condition Exists, Amber On, Green Off
Condition Exists, Green On, Red Off
Condition Exists, Green On, Amber Off
Condition Does Not Exist, Red On, Other Not Used
Condition Does Not Exist, Amber On, Other Not Used
Condition Does Not Exist, Green On, Other Not Used
Condition Exists, Red On, Other Not Used, Horn On
Condition Exists, Amber On, Other Not Used, Horn On
Condition Exists, Green On, Other Not Used, Horn On
Condition Does Not Exist, Red On, Other Not Used, Horn On
Condition Does Not Exist, Amber On, Other Not Used, Horn On
Condition Does Not Exist, Green On, Other Not Used, Horn On
Table 28: Specific Event Severity Levels
Allowed for LED Pairs…
√
√
√
√
√
√
√
√
√
√
√
√
√
√
1-5, 7-12, 16 13-14 6, 15
√ √
√
√ √
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
©2013 Caterpillar
All rights reserved. Page 201
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
For Trigger Condition Severity Level listed in the table above from ‘Low Warning’ to ‘Specific Diagnostic the following Suspect Parameter Number options can be us:
Suspect Parameter Number Text
Fuel Level (External Tank)
Aftercooler Temperature
Starting Air Pressure
Fuel Filter Differential Pressure
Fuel Level (Local Tank)
Engine Oil Level
Oil Filter Differential Pressure
Engine Oil Pressure
Crankcase Pressure
Air Filter Differential Pressure
Barometric Pressure
Engine Coolant Temperature
Engine Coolant Level
Battery Voltage (switched)
Battery Charging System Voltage
Battery Voltage
Ambient Air Temperature
Inlet Air Temperature
Exhaust Temperature
Engine Oil Temperature
Engine Speed
Long Distance Annunciator Data Link Fault
(Root Cause Not Known)
Primary Data Link Fault
Emergency Stop Shutdown
Analog Input #1 Custom Parameter
Analog Input #2 Custom Parameter
Generator Rear Bearing Temperature
Generator Front Bearing Temperature
Generator Winding Temperature #1
Generator Winding Temperature #2
Generator Winding Temperature #3
Accessory Data Link Fault
Unexpected Engine Shutdown
Right Exhaust Temperature
Left Exhaust Temperature
Generator Frequency
Generator AC Voltage
Value
38
100
101
107
108
110
111
52
82
95
96
98
99
158
167
168
171
172
173
175
190
625
639
970
1083
1084
1122
1123
1124
1125
1126
1231
1383
2433
2434
2436
2440
Page 202 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Suspect Parameter Number Text
Generator AC Current
Generator Real Power (kW)
Generator Reactive Power (kVAr)
Generator to Bus Synchronization Failure (Low)
Dead Bus Arbitration Failure (Low)
Engine Controller (Abnormal Update Rate)
Modbus Data Link
Generator Breaker Closed
Generator Breaker Open
Utility to Generator Transfer Failure (High)
Analog Input #4 Custom Parameter
Analog Input #3 Custom Parameter
Cranking Voltage
Value
2448
2452
2456
2529
2530
3543
3581
4004
4013
4015
4157
4158
4256
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
For the Trigger Condition Severity Levels listed in the table above from ‘Condition Exists,
Red On, other Not Used’ to ‘Condition Does Not Exists, Green On, other Not used, Horn
On’ the following Suspect Parameter Number options can be used:
Suspect Parameter Number Text
Value
Digital Input # 1 Custom Event
Digital Input # 2 Custom Event
Digital Input # 3 Custom Event
Digital Input # 4 Custom Event
Digital Input # 5 Custom Event
Digital Input # 6 Custom Event
Digital Input # 7 Custom Event
Digital Input # 8 Custom Event
Isolated Digital Input #1 Custom Event
Isolated Digital Input #2 Custom Event
Isolated Digital Input #3 Custom Event
Isolated Digital Input #4 Custom Event
Emergency Stop Shutdown
Emergency Shutdown Override Mode Active
Fuel Tank Leak
Engine Failure to Start
701
702
703
704
705
706
707
708
3920
3921
3922
3923
970
1237
1239
1664
Service Interval Warning
Generator Unavailable to Start/Run
EPS Supplying Load
Air Damper Closed
ATS in Normal Position
ATS in Emergency Position
Battery Charger Failure
Generator Breaker Closed
Utility Breaker Closed
Engine in Cooldown
2648
3677
3829
4000
4001
4002
4003
4004
4005
4006
Generator Control Not in Automatic Warning
Generator Breaker Failure to Open
Generator Breaker Failure to Close
Generator Breaker Open
4007
4009
4011
4013
Loss of Utility 4017
Generator Breaker Locked Out
Utility Breaker Locked Out
Bus Phase Sequence Incorrect
Generator Phase Sequence Incorrect
Earth Fault
4018
4019
4024
4025
4028
Earth Leakage 4029
Engine Running 4244
Page 204 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
If the Trigger Condition Severity Level is programmed for Diagnostic, then the Failure
Mode Identifier for any pair of LED’s can be configured as any of the following:
Data Erratic, Intermittent, or Incorrect Abnormal Rate of Change
Voltage Above Normal, or Shorted to High
Source
Voltage Below Normal, or Shorted to Low
Source
Current Below Normal or Open Circuit
Current Above Normal or Grounded Circuit
Mechanical System Not Responding or Out of
Adjustment
Root Cause Not Known
Bad Intelligent Device or Component
Out Of Calibration
Special Instructions
Received Network Data In Error
Abnormal Frequency or Pulse Width or Period Data Drifted High
Abnormal Update Rate Data Drifted Low
17.3 THERMOCOUPLE MODULE (EMCP 4.2 ONLY)
THERMOCOUPLE FEATURES
Reads up to 20 Type J or K thermocouple inputs
Temperatures are configured to indicate the SAE
CAN J1939 SPN to be transmitted by that temperature input. Suspect Parameter Numbers
(SPNs) for configuration of temperature inputs are customer specific. Resolution: One byte parameters have a resolution of 1
C / bit and a range of -40
C to 210 C. Two byte parameters have resolution of 0.03125
C / bit and a range of -
273
C to 1735 C
Cold junction compensation is provided
System throughput has all 20 channels scanned in 2 seconds (100 ms/channel)
Overall drift with temperature is 0.015% /
C of span (maximum)
Module is fully functional during configuration and communications
Parameter values and diagnostic error codes are retained when the modules are de-energized
Open-circuit and short-circuit diagnostics are supported
Can be mounted directly on the generator set panel or remotely
Suitable for moist, high shock and vibration environments
Compact size (see mechanical drawing, Figure 47).
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
THERMOCOUPLE SPECIFICATIONS
E
LECTRICAL
S
PECIFICATIONS
Accept 5-32 VDC power (12 or 24 VDC nominal)
Over voltage capability is 32 VDC for 1 hour @ 85
C
Power supply inputs are protected against transient surges and short circuits and are isolated from I/O
Three way isolation is provided for the CAN line, inputs and power supply
Burden is limited to less than 200 mA; inrush not to exceed 800 mA
Common mode rejection is -80 db@ 5V p-p (50-60 Hz)
Common mode input range is +/- 4 V minimum
Designed to meet relevant European standards for EMI/RFI/Immunity without the use of external filtering
E
NVIRONMENTAL
S
PECIFICATIONS
Encapsulated in a rugged aluminum housing with watertight Deutsch connectors
(IP65 rating)
Operating temperature range -40
C to 85C (-40F to 185F)
The ambient storage temperature range is -50
C to +120C
It is protected against 95% humidity non-condensing, 30
C to 60C
N
ETWORK
C
OMMUNICATIONS
I
NTERFACE
Capable of operating on the EMCP 4 Accessory CAN (2) data link
Optical isolation is provided for the CAN line
Retains current date and time relative to synchronization every 24 hours (or upon boot up) with equipment system time via an explicit command from the EMCP 4 or Service Tool when the EMCP 4 is not available; synchronization time is accurate to within 1 second
Includes a watchdog timer to atomically reboot should the microprocessor lock
Module operates normally with loss of communication link, retaining configured values and error codes in non-volatile memory
Configuration and firmware updates are accomplished with the Cat Service Tool over the CAN network
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Application and Installation Guide
THERMOCOUPLE WIRING
EMCP 4.1, 4.2 Generator Set Control
P
OWER AND
CAN B
US
W
IRING
T
HERMOCOUPLE
S
ENSOR
W
IRING
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control
THERMOCOUPLE PHYSICAL LAYOUT
Application and Installation Guide
Figure 47: Thermocouple, RTD, And Discrete I/O Module Physical Layout
THERMOCOUPLE MODULE – CONFIGURATION
The Thermocouple module is field programmable using the Cat Service Tool. It is also flash programmable to update software using the Cat Service Tool.
The service tool software must be installed on a Windows PC. The Cat communication adapter must be connected between the PC and the CAN data link on which the target
Thermocouple module is connected. When connecting the Thermocouple module, the user will first see the Module Summary screen shown in Figure 48.
Figure 48: Cat Service Tool Thermocouple Module Summary Screen
Page 208 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
The service tool configuration tool contains setpoints for configuring the Thermocouple module identification, as well as the thermocouple inputs.
Figure 49 shows the ECM Identification Parameters list. This list shows the ECM serial number (read-only) of the module that is connected, and allows for configuration of the
ECU instance. Each thermocouple module on the data link must have a unique ECU instance. If ECU instances are duplicated, one of the modules must be disconnected and the other reconfigured to a different ECU instance.
Note
: ECU Instance #1 is reserved for the Accessory Data Link (CAN 2), while ECU
Instance #2 is reserved for the Primary Data Link (CAN 1).
Figure 49: Cat Service Tool Thermocouple Module Identification Parameters
Upon changing the ECU instance, the Cat Service Tool will automatically reconnect to the data link, and the Thermocouple module name should reflect the new ECU instance. In this example, as shown in Figure 50, the module was previously named Thermocouple Module #1, and after the ECU instance is changed to 2 and the service tool reconnects, the name reads Thermocouple Module #2.
Figure 50: Cat Service Tool Thermocouple Module After ECU Instance Change
©2013 Caterpillar
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
CONFIGURING THERMOCOUPLE INPUTS
Figure 51 shows the T
HERMOCOUPLE
I
NPUT
#1
Configuration list, when using the Cat
Service Tool. All twenty thermocouple inputs have identical parameters and options.
Figure 51: Cat Service Tool Thermocouple Input Configuration
The
SENSOR TYPE CONFIGURATION
selects either a J or K type configuration. Select the appropriate configuration based on the type of thermocouple installed. Reference the
TC Module specification sheet (LEHE0126) for available Temperature Inputs.
The
SUSPECT PARAMETER NUMBER
(SPN) is a numerical entry between a predetermined list of SPNs that are supported by the Thermocouple module. All of the thermocouple inputs support the same list of SPNs. To change the SPN, type in the number that corresponds with the desired parameter as shown in Figure 52. See UENR1209 for specific information on what possible SPN values can be used.
The
HIGH TEMPERATURE SHUTDOWN EVENT THRESHOLD
sets the temperature at which a high shutdown event will occur.
The
HIGH TEMPERATURE WARNING EVENT THRESHOLD
sets the temperature at which a high warning event will occur.
Figure 52: Cat Service Tool Thermocouple Module Suspect Parameter Number
Page 210 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
The
LOW TEMPERATURE WARNING EVENT THRESHOLD
sets the temperature at which a low warning event will occur.
The
EVENT NOTIFICATION DELAY TIME
sets the amount of time the threshold must be exceeded until the Thermocouple module triggers that particular event on the data link.
Each of the delay time options corresponds with a particular event type.
17.4 RTD MODULE (EMCP 4.2 ONLY)
RTD FEATURES
Reads up to eight (8) Platinum RTD inputs with 2, 3, and 4 wire configurations
System throughput has all 8 channels scanned in
2 seconds (250 ms/channel)
Overall drift with temperature is 15M Ohm/
C
(maximum)
Module is fully functional during configuration and communications
Parameter values and diagnostic error codes are retained when the modules are de-energized
Suitable for moist, high shock and vibration environments
Compact size (see mechanical drawing, Figure 53)
©2013 Caterpillar
All rights reserved. Page 211
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
RTD SPECIFICATIONS
E
LECTRICAL
S
PECIFICATIONS
Accept 5-32 VDC power (12 or 24 VDC nominal)
Over voltage capability is 32 VDC for 1 hour @ 85
C
Power supply inputs are protected against transient surges and short circuits and are isolated from I/O
Optical isolation is 500 VDC from input to ground (three way isolation is provided for the CAN line, inputs and power supply)
Burden is limited to less than 200 mA; inrush not to exceed 800 mA
Designed to meet relevant European standards for EMI/RFI/Immunity without the use of external filtering
E
NVIRONMENTAL
S
PECIFICATIONS
Encapsulated in a rugged aluminum housing with watertight Deutsch connectors
(IP65 rating)
Operating temperature range -40
C to 85C (-40F to 185F)
The ambient storage temperature range is -50
C to +120C
Protected against 95% humidity non-condensing, 30
C to 60C
N
ETWORK
C
OMMUNICATIONS
I
NTERFACE
Operates on the EMCP 4 Accessory CAN Data Links
Optical isolation is provided for the CAN line
Retains current date and time relative to synchronization every 24 hours (or upon boot up) with equipment system time via an explicit command from the EMCP 4 or Service Tool when the GSC is not available; synchronization time is accurate to within 1 second
Includes a watchdog timer
Module operates normally with loss of communication link, retaining configured values and error codes in non-volatile memory
Configuration and firmware updates are accomplished with the Cat Service Tool over the CAN network
Page 212 All rights reserved.
Application and Installation Guide
RTD WIRING
EMCP 4.1, 4.2 Generator Set Control
P
OWER AND
CAN B
US
W
IRING
RTD S
ENSOR
W
IRING
©2013 Caterpillar
All rights reserved.
RTD W
IRING
T
YPICAL
C
ONNECTIONS
Page 213
EMCP 4.1, 4.2 Generator Set Control
RTD PHYSICAL LAYOUT
Application and Installation Guide
Figure 53: Thermocouple, RTD, And Discrete I/O Module Physical Layout
RTD MODULE – CONFIGURATION
The RTD (Resistance Temperature Detector) module is field programmable using the
Cat Service Tool. It is also flash programmable to update software using the Cat Service
Tool.
The service tool software must be installed on a Windows PC.
The Cat communication adapter must be connected between the PC and the CAN data link on which the target RTD module is connected.
When connecting to the RTD module, the user will first see the Module Summary screen shown in Figure 54.
Figure 54: Cat Service Tool RTD Module Summary Screen
Page 214 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
The service tool configuration tool, accessed by pressing F5 or clicking the configuration tool icon on the toolbar, contains setpoints for configuring the RTD module identification, as well as the RTD inputs.
CONFIGURING RTD INPUTS
The RTD Input #1 Configuration list of the service tool configuration tool is shown in Figure 55. All eight RTD inputs have identical parameters and options.
Figure 55: Cat Service Tool RTD Module Digital Input Configuration
The
SENSOR TYPE CONFIGURATION
selects between a 2, 3, or 4 wire configuration. Select the appropriate configuration based on the type of RTD sensor installed. Reference the
RTD Module specification sheet (LEHE0124) for available Temperature Inputs.
The
TEMPERATURE COEFFICIENT CONFIGURATION
selects between an IEC Platinum, JIS
Platinum, Legacy US Platinum, SA MA Platinum or US Platinum type of RTD sensor.
Select the appropriate configuration based on the type of RTD sensor installed.
The
SUSPECT PARAMETER NUMBER
(SPN) is a choice between a predetermined list of
SPNs that are supported by the RTD module. All of the RTD inputs support the same list of SPNs. To change the SPN, type in the number that corresponds to the desired parameter as shown in Figure 56. See UENR1209 for specific information on what possible SPN values can be used.
The
HIGH TEMPERATURE SHUTDOWN EVENT THRESHOLD
sets the high temperature at which a shutdown event will occur.
The
HIGH TEMPERATURE WARNING EVENT THRESHOLD
sets the high temperature at which a high warning event will occur.
The
LOW TEMPERATURE WARNING EVENT THRESHOLD
sets the low temperature at which a low warning event will occur.
The
EVENT NOTIFICATION DELAY TIME
sets the amount of time the threshold must be reached until the RTD module triggers that particular event on the data link. Each of the delay time options corresponds with a particular event type.
©2013 Caterpillar
All rights reserved. Page 215
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Figure 56: Cat Service Tool RTD Module Suspect Parameter Number
17.5 DISCRETE I/O MODULE (EMCP 4.2 ONLY)
The EMCP Discrete I/O (DIO) module is designed for mounting on generator sets or remotely, to provide auxiliary switch inputs or relay contact outputs. Up to 4
DIO modules can be used on the EMCP 4.2 Accessory
CAN Data Link, given that they are programmed to unique ECU Instance numbers.
DISCRETE I/O FEATURES
Reads twelve (12) discrete inputs and sets eight
(8) Form C Relay Outputs
Converts between physical I/O and CAN data link commands
System throughput: All channels are scanned in 100 ms
Low-Level input voltage range: 0 to 0.8 V
High-Level input voltage range: 3.75 to 24V
Inputs have internal pull-up resistors
LED to indicate communication network status
Compact size (see mechanical drawing, Figure 57)
Page 216 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
DISCRETE I/O SPECIFICATIONS
E
LECTRICAL
S
PECIFICATIONS
Accept 5-32 VDC power (12 or 24VDC nominal)
Over voltage capability is 32 VDC for 1 hour @ 85
C
Resistive Loads rated for 3A@30 VDC
Normally Closed (NC) relay contacts rated for 2A@125 V AC / 2A@30 VDC
Normally Open (NO) relay contacts rated for 2A@125 V AC / 2A@30 VDC
Maximum current draw of 400mA + 50mA per energized relay @ 12VDC/24VDC
Power supply inputs are protected against transient surges and short circuits and are isolated from I/O
E
NVIRONMENTAL
S
PECIFICATIONS
Encapsulated in a rugged aluminum housing with Deutsch connectors
(IP65 rating)
Operating temperature range -40
C to 85C (-40F to 185F)
The ambient storage temperature range is -50
C to +120C
It is protected against 95% humidity non-condensing, 30
C to 60C
Designed to meet relevant European standards for EMI/RFI/Immunity without the use of external filtering
N
ETWORK
C
OMMUNICATIONS
I
NTERFACE
Operates on the EMCP 4.2 Accessory CAN Data Link
Node address is auto configurable
Optical isolation is provided for the CAN line
Retains current date and time relative to synchronization every 24 hours (or upon boot up) with equipment system time via an explicit command from the EMCP 4 or Service Tool when the GSC is not available; synchronization time is accurate to within 1 second
Includes a watchdog timer to automatically reboot should the microprocessor lock
Module operates normally with loss of communication link, retaining configured values and error codes in non-volatile memory
Configuration and firmware updates are accomplished with the Cat Service Tool over the CAN network
Monitored parameters and alarms are read-only over the network
©2013 Caterpillar
All rights reserved. Page 217
EMCP 4.1, 4.2 Generator Set Control
DISCRETE I/O WIRING
P
OWER AND
CAN B
US
W
IRING
Application and Installation Guide
I
NPUT
I/O W
IRING
T
YPICAL
C
ONNECTIONS
O
UTPUT
LOAD - LOAD
DIN GND
NO NC C
INPUTS PIN OUTPUTS PIN OUTPUTS PIN
DIN1 1 NC_1 5 C_6 19
DIN2 11 C_1 6 NO_6 20
DIN3 21 NO_1 7 NC_7 28
DIN4 31 NC_2 15 C_8 29
DIN5 2
DIN6 12
DIN10 13
DIN11 23
DIN12 33
NO_2 17 NC_8 38
DIN7 22 NC_3 25 C_8 39
DIN8 32 C_3 26 NO_8 40
DIN9 3 NO_3
NC_4 35
C_4 36
GND 4 NC_5 8
GND 14
GND 24
C_5 9
NO_5 10
C = Common
GND 34 NC_6 18
Table 29: Discrete I/O
Note
: The GND pin is not the package ground, but the Isolated Reference for the module.
Page 218 All rights reserved.
Application and Installation Guide
DISCRETE I/O PHYSICAL LAYOUT
EMCP 4.1, 4.2 Generator Set Control
Figure 57: Thermocouple, RTD, And Discrete I/O Module Physical Layout
DISCRETE I/O SOFTWARE CONFIGURATION
The DIO module is field-programmable using the Cat Service Tool. It is also flash programmable to update software using the Cat Service Tool.
The service tool software must be installed on a Windows PC. The Cat communication adapter must be connected between the PC and the CAN data link on which the target
DIO module is connected. (The service tool may be connected to the EMCP 4
Accessory Data Link service connector).
Figure 58: Cat Service Tool DIO Summary Screen
When connecting to the DIO, the user will first see the Module Summary screen shown in Figure 58. The service tool configuration tool, accessed by pressing F5 or clicking the configuration tool icon on the toolbar, contains setpoints for configuring the DIO identification, as well as the inputs and outputs.
©2013 Caterpillar
All rights reserved. Page 219
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Figure 59: Cat Service Tool DIO Identification Parameters
Figure 59 shows the ECM Identification Parameters list. This list shows the ECM serial number (read-only) of the module that is connected, and allows for configuration of the
ECU instance.
Note
: It is important to match a specific module to a certain ECU Instance. The system will not function properly if ECU instances are duplicated.
Upon changing the ECU instance, the Cat Service Tool will automatically disconnect and reconnect to the data link, and the DIO module name should reflect the new ECU instance.
In the example shown in Figure 60, the module was previously named Discrete I/O
Module #1, and after the ECU instance is changed to 2 and the service tool reconnects, the name reads Discrete I/O Module #2.
Figure 60: Cat Service Tool DIO After ECU Instance Change
Page 220 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
CONFIGURING DIGITAL INPUTS
Figure 61 shows the Discrete Input #1 Configuration list using the service tool configuration tool. All twelve discrete inputs have identical parameters and options.
Figure 61: Cat Service Tool DIO Digital Input Configuration
The active state configuration determines which state (high or low) triggers the event, and depends on the sensor/switch wiring configuration.
The event notification delay time sets the amount of time the input must remain active until the DIO module triggers an event on the data link.
©2013 Caterpillar
All rights reserved. Page 221
EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
SUSPECT PARAMETER NUMBER (SPN)
The suspect parameter number (SPN) is a choice from a predetermined list of SPNs that are supported by the DIO module. All of the discrete inputs support the same list of
SPNs, except Custom Event.
Discrete Input #1, when set to Custom Event, will trigger an event for Custom Event #1.
Discrete Input #2, when set to Custom Event, will trigger an event for Custom Event #2; likewise for all twelve discrete inputs.
Note
: Discrete Inputs configured for Custom Event SPNs (701-718) are shared between the EMCP and DIO Modules. Therefore ONLY one Custom Event SPN-FMI can be used between the two modules for each Input #.
FAILURE MODE IDENTIFIER (FMI)
The F
AILURE
M
ODE
I
DENTIFIER
(FMI) configures what type of failure this event will represent. The technician is free to configure any FMI for any SPN, but discretion must be used. Certain combinations may not be meaningful (i.e. the EMCP 4 may not be configurable to display or trigger a response for certain combinations of SPN and FMI).
For example, a Fuel Level SPN with a Condition Exists FMI is not meaningful; the EMCP 4 can be configured to display or react to only fuel level low or high warnings or shutdowns.
CONFIGURING RELAY OUTPUTS
The Relay Output #1 Configuration list of the service tool configuration tool is shown in Figure 62. All eight Relay Outputs have identical parameters and options.
The suspect parameter number (SPN) is a choice from a predetermined list of SPNs that are supported by the DIO module. If you wish to configure the DIO to trigger an output based on an event on the data link related to a specific SPN, the SPN must be selected here.
Figure 62: Cat Service Tool DIO Relay Output Configuration
The trigger condition is a list of conditions that will trigger this output. For the conditions labeled specific event, the relay will be activated upon receiving a category of events (either a single FMI or a set of FMIs) for the SPN selected in the suspect
parameter number parameter. For the conditions labeled general event, the relay will be activated upon receiving a category of events (either a single FMI or a set of FMIs) for any SPN.
In this case, the DIO module will ignore the entry in the suspect parameter number parameter. If the disabled condition is chosen, the Relay Output will not activate on any condition.
Page 222 All rights reserved.
Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
18 SCADA (MODBUS) DATA LINK (EMCP 4.2 ONLY)
The SCADA
D
ATA
L
INK
or M
ODBUS
is supported on the EMCP 4.2.
The EMCP 4.2 has a S
UPERVISORY
C
ONTROL AND
D
ATA
A
CQUISITION
(SCADA) communications link between the controller and a host device using the M
ODBUS
protocol. The host device is able to remotely monitor or control the genset package equipped with the EMCP 4 in much the same way an operator does from the panel.
The host device connects to the EMCP GSC through an RS-485 SCADA
Data Link (Modbus RTU, Half Duplex).
The data is transmitted in a binary format over the serial connection.
The host device acts as Modbus Master, and the EMCP 4 acts as the
Modbus Slave, also called a R
EMOTE
T
RANSMITTER
U
NIT
(RTU).
The host device initiates all communication, sending commands or requests for information to the EMCP 4.
The EMCP 4 then takes action based on the query and/or sends a response to the query over Modbus.
Baud rates can be configured on the EMCP 4. Various data rates between 9600 bits/second (baud) and 57,600 bits/second are available. See the S
OFTWARE
C
ONFIGURATION
Chapter 18.3 for instructions.
For more information on the SCADA Data Link, refer to the EMCP 4 SCADA DATA
LINKS A & I GUIDE (LEBE0010).
Note
: The EMCP 4 controller defaults to NOT allowing Remote Genset Control via
SCADA communications. This setting can be changed from the display under MAIN
MENU/CONFIGURE/ALL SETPOINTS/CONTROL/AUTO START/STOP/REMOTE
GENSET CONTROL ENABLE STATUS.
Note
: This port may be required to be used to communicate to switchgear or other monitoring device. Only a single host device can be used with this port.
18.1 WIRING
SCADA
COMMUNICATION
wires are brought out of the EMCP 4.2 as part of the 70-pin connector. The pins, as designated on the EMCP connector, are shown in Table 30.
SCADA COMMUNICATION WIRES
Pin # Name Description
3
4
5
MODBUS – Optically isolated half-duplex differential (-) for Modbus
MODBUS Reference Half-duplex RS-485 Reference for Modbus
MODBUS + Optically isolated half-duplex differential (+) for Modbus
Table 30: SCADA Pins on EMCP 70 Pin Connector
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MODBUS D
ATA
T
RANSMISSION
over RS-485 is accomplished over a single shielded twisted pair for differential signaling with transmit and receive alternating over the same wire pair (MODBUS+ and MODBUS-). The Reference (MODBUS
R
EF
) should be connected to the shield, to prevent ground loop currents.
Figure 63 shows a possible wiring configuration to a RS-485 device.
Figure 64 shows a possible wiring configuration to a RS-485 to RS-232 converter.
Note
: See documentation of connected device to verify wiring configuration.
Figure 63: Possible Wiring Configuration To An RS-485 Device
Figure 64: Possible Wiring Configuration To An RS-485 To RS-232 Converter
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
18.2 LINE TERMINATION AND POLARIZATION
Both ends of the Modbus lines (or the extreme ends of the trunk, for a multipoint network) should have termination between MODBUS+ (B) and MODBUS- (A).
A 0.5W 150Ω resistor may be adequate.
If line polarization is implemented (see Software Configuration, Chapter 18.3), a better choice is a 10 µF capacitor (10V minimum) in series with a 0.25W 120Ω resistor.
A bias resistor may be used for Line Polarization. Line Polarization is used to keep the network voltages at well-defined levels during silent times to prevent potential false diagnostics and communication failures. This bias resistor is unique from a termination resistor. There should only be one device on the network with bias resistors enabled to polarize the network.
Note
: For more details on setting up a Modbus network over a serial line, please refer to
RS-485 specifications or Modbus specifications. See the Software Configuration Chapter
18.3 for instructions on enabling line polarization.
18.3 SOFTWARE CONFIGURATION
CONFIGURING THE SCADA DATA LINK USING THE DISPLAY
The SCADA
DATA LINK
may require software configuration. The configuration parameters are accessible on the EMCP 4 via the following menu options:
At
MAIN MENU
,
scroll
D
OWN
to C
ONFIGURE
Press the OK
K
EY
.
Scroll D
OWN
to
ALL SETPOINTS
.
Scroll D
OWN
Scroll D
OWN
Press the OK
K
EY
to N
ETWORK
Press the OK
K
EY
to D
ATA
L
INK
SCADA
Press the OK
K
EY
.
.
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EMCP 4.1, 4.2 Generator Set Control
Press the OK
K
EY
D
ATA
L
INK
B
AUD
R
ATE
.
to edit the current SCADA
Select the SCADA
D
ATA
L
INK
B
AUD
R
ATE
that you want to program
Press the OK
K
EY
to SCADA
D
ATA
L
INK
P
ARITY
.
Scroll
DOWN
Press the OK
K
EY
to edit the current
SCADA
D
ATA
L
INK
P
ARITY
.
Select the SCADA
D
ATA
L
INK
P
ARITY
that you want to program
Scroll
A
DOWN
DDRESS
Press the OK
K
EY
to SCADA
D
ATA
L
INK
S
LAVE
.
Press the OK
K
EY
to highlight the current
SCADA D
ATA
L
INK
S
LAVE
A
DDRESS
. Select the
SCADA D
ATA
L
INK
S
LAVE
A
DDRESS
that you want.
Scroll
DOWN
E
NABLE
S
TATUS
Press the OK
K
EY
to RS-485
B
IAS
R
ESISTOR
.
Press the OK
K
EY
to edit the current
RS-485
B
IAS
R
ESISTOR
E
NABLE
S
TATUS
.
Select the RS-485
B
IAS
R
ESISTOR
E
NABLE
S
TATUS
that you want to program
Press the OK
K
EY
.
Application and Installation Guide
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
CONFIGURING THE SCADA DATA LINK USING THE CAT SERVICE TOOL
The EMCP 4 SCADA Data Link can be configured using the Cat Service Tool. To program this Data Link, do the following steps:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Select Data Link – SCADA on the left.
3. Double click SCADA Data Link Baud Rate to change this to the desired value from the drop down menu. Click the OK button to program.
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4. Double click SCADA Data Link Parity to change this value from the drop down menu. Click the OK button to program.
5. Double click SCADA Data Link Slave Address. Change this value by typing a new value. Click the OK button to program.
6. Double click SCADA Data Link Access Password. Change this value by typing a new value. Click the OK button to program.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
7. Double click RS-485 Bias Resistor Enable Status to change this value from the drop down menu. Keep in mind that the Bias Resistor is not a termination resistor, but polarizes the RS-485 line. Click the OK button to program.
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19 INTEGRATED VOLTAGE REGULATOR
The EMCP Integrated Voltage Regulator (IVR) feature is a substitute for a traditional voltage regulator topology consisting of a dedicated controller (CDVR, VR6…etc) for regulating voltage. The EMCP 4 internal controller regulates generator output voltage by sending a command to the Excitation Module (EM10/EM15) that controls generator excitation and therefore generator output voltage.
This feature is available with revised EMCP 4.1 (CAT part number: 435-7931) and
EMCP 4.2 (CAT part number 431-1966) controllers with software version 4.3PROD and above. This capability does NOT exist in original EMCP 4.1 and EMCP 4.2 controllers, regardless of software version.
Figure 65: EMCP Integrated Voltage Regulator System
19.1 IVR FEATURES
When used with an Excitation Module the revised EMCP 4.1 and EMCP 4.2 controllers with Integrated Voltage Regulator logic provide:
Automatic Voltage Regulation (AVR)
Programmable stability settings
Soft start control with an adjustable time setting in AVR control mode
Dual Slope, Configurable Under Frequency (Volts/Hz) regulation
Three-phase or single-phase generator voltage (RMS) sensing/regulation in AVR mode
Setpoint configuration adjustment from the EMCP display or CAT ET Service Tool
Voltage Output Adjustment via Display, Analog Input, Digital Input, or SCADA
(Modbus)
IVR Operating Status and Voltage Bias Overview screens to provide an enhanced level of user interface
Integrated Voltage Regulator event monitoring
The revised EMCP 4.2 controllers also offer:
Power Factor Regulation (PF)
Reactive Droop compensation
Line drop compensation
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19.2 HARDWARE INSTALLATION
EMCP 4.1, 4.2 Generator Set Control
EMCP IVR CONNECTIONS
To regulate the generator terminal voltage the EMCP communicates the desired excitation command to the Excitation Module via a PWM signal. It is recommended that twisted pair shielded cable is used for this communication link. Table 31 details the connections to be made between the EMCP and Excitation Module.
EMCP 4.1, EMCP 4.2
70-Pin Connector
Digital Output #2 / IVR CS+
Battery Negative Splice
Excitation Module
3-Pin Connector
68 CS+
60 or 65 CS-
P3-2
P3-3
Battery Negative Splice 60 or 65 Shield
Table 31: EMCP 4.1 & EMCP 4.2 Connections to Excitation Module
P3-1
IVR EXCITATION MODULE
The Integrated Voltage Regulator consists of an EMCP 4 interfacing with an Excitation
Module. There is a range of Excitation Modules available to cover the full range of CAT generator sets.
Figure 66: EM10 Excitation Module & EM15 Excitation Module
Table 32 provides information on the technical specification of the EM10 and EM15 modules. Selection of the appropriate module should be determined by the nominal and maximum generator excitation current at full load (standby, 0.8PF), and the maximum
AC voltage Input.
Details on nominal field current are available in TMI (Technical Marketing Information) or from the generator datasheet. Care must be taken on Self-Excited (shunt) generators to understand how the connections are being made from the winding to the excitation module in order to understand the maximum AC voltage input. It is recommended that an intermediate, half-phase to Neutral connection is used for Self-Excited generators.
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EMCP 4.1, 4.2 Generator Set Control
CAT Part Number
Compatible Generator Excitation Types
Nominal Field Current Output
Maximum (forcing) Field Current Output
Maximum AC Voltage Input
Exciter Field Resistance (recommended)
Table 32: EM10 & EM15 Technical Specifications
Application and Installation Guide
EM10 EM15
398-7247 398-7248
Permanent Magnet (PM)
Self-Excitation (SE)
Internal Excitation (AREP)
6 Amps 7 Amps
10 Amps
180 Vrms
15 Amps
240 Vrms
6 to 16 ohms
IVR EXCITATION MODULE PHYSICAL LAYOUT
It is recommended that the Excitation Module should be mounted within the genset control panel or the generator terminal box in landscape orientation in order to achieve optimum cooling from the module heat sink. The module should be fixed in place using
4 M6 x 30mm mounting bolts. The torque applied to the mounting bolts should be
5 N.m ± 1 N.m. It is recommended that an M6 washer (external diameter 12mm) is used with the mounting bolts to protect the module. A dimensioned diagram of the EM10 module is presented in Figure 67. Note that the same dimensions also apply for the
EM15 module.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Connector
“P3”
Connector
“P2”
Connector
“P4”
Figure 67: EM10 Excitation Module Dimensions (in millimeters)
IVR EXCITATION MODULE CONNECTIONS
The EM10 and EM15 Excitation Modules have three multiple-pin, Mate-n-Lok plug type connectors. These connectors are labeled “P2”, “P3” and “P4” as shown in Figure 67.
Table 33 describes the signal and function of each connector pin.
Terminal Label
P2-1 F+
P2-2 F-
P3-1
P3-2
P3-3
P4-1
P4-2
P4-3
P4-4
Shield
CS+
CS-
X2
Z1
X1
Z2
Signal/Function
Exciter Field Positive
Exciter Field Negative
Excitation Command Control Signal Shield
Excitation Command Control Signal Positive
Excitation Command Control Signal Negative
Excitation Power Supply Input X2
Excitation Power Supply Input Z1
Excitation Power Supply Input X1
Excitation Power Supply Input Z2
Table 33: Excitation Module Connector Pins
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Note that connections X2 and Z1 are internally linked within the Excitation Module, providing a point of common connection for the auxiliary windings where an AREP/IE excitation supply is available. Alternatively, connections X2 and Z1 may be linked external to the Excitation Module, and only three connections made to the device (X1,
X2 and Z2). Fully detailed Excitation Module connection diagrams for self-excitation
(shunt), auxiliary windings (AREP/IE) and permanent magnet (PM) are provided in
Appendix C .
IVR EXCITATION MODULE OVER-EXCITATION PROTECTION
The Excitation Module has a built-in over-excitation protection strategy that is designed to protect the generator from thermal damage. The protection strategy employed is illustrated in Figure 68.
Under normal conditions the excitation current will remain well below the upper limit and the GREEN LED on the Excitation Module will be lit continuously.
In the event of a fault condition, for example during a short-circuit on the generator terminals, the excitation current will increase rapidly, known as ‘field forcing’. The
Excitation Module will limit the forcing current to the defined upper limit for a fixed period of 10 seconds.
When the Excitation Module is actively limiting the field current a RED LED will flash indicating a fault condition. After the fixed delay time has expired, the Excitation Module will ‘limit’ the excitation current to a safer level that is 10% of the upper limit.
When the Excitation Module has shut down the excitation current, the RED LED is lit continuously and the GREEN LED is not lit. The RED LED will be lit only while voltage is being supplied to the Excitation Module. In order to reset the excitation current limiting the excitation current, the power supply must be removed from the Excitation Module by shutting down the genset.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Figure 68: Excitation Module Over- Excitation Protection Strategy
The Excitation Limit Potentiometer on the Excitation Module has 270 degrees of rotation and is used to configure the Excitation Current Upper Limit as shown in Figure 69. Keep in mind that this must be set for maximum forcing current, and not nominal excitation current.
Minimum Position
Maximum Position
EM10
4 Amps
10 Amps
EM15
6 Amps
15 Amps
Figure 69: Maximum and Minimum Limits of Excitation Current Limit Potentiometer
IVR EXCITATION MODULE FUSING
The EM10 has internal fusing, therefore it is not necessary to fit external fuses on the excitation power supply inputs.
The EM15 requires external fusing to be fitted on inputs X1 and Z2. The recommended fuse for UL listed gensets is a Bussman KTK-10 (Cat part number 6V7802). For non-UL listed gensets an alternative fuse of Bussman AGC-10RX (Cat part number 3K8782) may also be used.
Connection diagrams showing the location of external fusing on the EM15 are provided in Appendix C.
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19.3 IVR SOFTWARE CONFIGURATION
The Integrated Voltage Regulator parameters can be accessed using either the CAT ET
Service tool, or directly through the EMCP display. Some setpoints are locked at ET only or at Security Level 3 and cannot be changed from the EMCP display or will require a level 3 password. Please note that ET Service Tool version 2012C or later is recommended for accessing and adjusting IVR parameters.
To access the Integrated Voltage Regulator setpoints using the ET Service Tool, connect to the EMCP Genset Control and click on the ‘Configuration Tool’ button
(alternatively press F5) to enter the configuration menu. Select ‘Integrated Voltage
Regulator’ from the menu on the left and set Voltage Regulator Control Source
Configuration equal to ‘Genset Control’ to display the following default settings:
To access the Integrated Voltage Regulator setpoints through the EMCP display, navigate to the following sub-menu:
MAIN MENU
CONFIGURE
ALL SETPOINTS
VOLTAGE REGULATOR
If replacing a CDVR with IVR, the parameters can be programmed the same as the
CDVR (using ET scaling) in order to achieve similar performance.
If the IVR is a new installation, or a R450 or VR6 voltage regulator is being replaced, the parameters can be programmed to the default values with a low loop gain starting in the region
1.0%-5.0%. Note that the default parameters should provide stable voltage control for most generator sets, however some optimization and tuning may be required to achieve the desired performance. The following subsections provide further detail on each individual setpoint, including range, resolution and default values.
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VOLTAGE REGULATOR CONTROL SOURCE CONFIGURATION
Name Options Default Value Access
Voltage Regulator Control
Source Configuration
0 = External Control
1 = Genset Control
0 (External Control) ET Service Tool Only
The Voltage Regulator Control Source Configuration parameter is used to enable or disable the Integrated Voltage Regulator feature.
If set to ‘External’ the Integrated Voltage Regulator feature of the EMCP is disabled and the genset can run with an external voltage regulator, for example, CDVR, R450, VR6, etc.
If set to ‘Genset Control’ the Integrated Voltage Regulator feature of the
EMCP is enabled and the genset will run using an Excitation Module.
Note that this parameter will only change state if the genset is stopped (stop button pressed and engine speed 0 rpm), and can only be changed via ET, and not directly through the EMCP display.
It is important that the Voltage Regulator Control Source
Configuration is correctly programmed BEFORE starting the genset.
In the case where an external voltage regulator is used, if
Voltage Regulator Control Source Configuration is set to
‘Genset Control’, there is a risk of nuisance triggering of
IVR-related warning and shutdown events.
In the case where IVR is to be used but the Voltage
Regulator Control Source Configuration is set to
‘External’, there is a risk that the PWM (DO#2) output may float high causing the Excitation Module to force the excitation current to the upper limit and risking damage to the generator set and/or load.
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STARTING PROFILE
Name Min Max Resolution Units Default
Value
Access
Voltage Regulator
Starting Voltage Percent
Voltage Regulator
Starting Time
0.0 90.0 0.1 % 10.0
0.0 60.0 0.1 seconds 3.0
ET Service
Tool or
EMCP
Display
The starting profile setpoints defined above are used to determine the slope of the voltage ramp when starting the genset.
If the Voltage Regulator Starting Voltage Percent is zero, the Voltage Regulator Starting
Time defines the time to reach the rated voltage setpoint from the point that the frequency exceeds the Voltage Regulator Minimum Frequency Threshold. An example
Starting Profile with Voltage Regulator Starting Voltage Percentage set to 0% and
Voltage Regulator Starting Time set to 5 seconds is illustrated in Figure 70.
Figure 70: Starting Profile with Voltage Regulator Starting Voltage set to 0% and Voltage
Regulator Staring Time set to 5 seconds
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
If the Voltage Regulator Starting Voltage Percent is non-zero, the Voltage Regulator
Starting Time defines the time to get to the rated voltage setpoint from the point that the
Voltage Regulator Starting Voltage Percent is reached by following the programmed
Volts/Hz slope. An example Starting Profile with Voltage Regulator Starting Voltage
Percentage set to 10% and Voltage Regulator Starting Time set to 3 seconds is illustrated in Figure 71.
Figure 71: Starting Profile with Voltage Regulator Starting Voltage set to 10% and Voltage
Regulator Staring Time set to 3 seconds
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A further example with Voltage Regulator Starting Voltage Percentage set to 90% and
Voltage Regulator Starting Time set to 3 seconds is illustrated in Figure 72.
Figure 72: Starting Profile with Voltage Regulator Starting Voltage set to 90% and Voltage
Regulator Staring Time set to 5 seconds
If the Voltage Regulator Starting Time is set to zero, or the engine has a slow starting ramp, the Integrated Voltage Regulator will follow the programmed Volts/Hz slopes. The voltage setpoint during starting is therefore the minimum of the Starting Profile setpoint and the Under-Frequency Roll-Off (Loading) Profile setpoint.
In order to avoid a large voltage overshoot during starting, particularly on generators with
Shunt or AREP excitation systems, the Excitation Command output from the EMCP is limited to a maximum value of 20% during starting. This prevents integral windup within the PID controller in the case where, during starting, there is insufficient residual voltage at the generator output to build excitation.
Once the frequency exceeds the Voltage Regulator Corner <Knee> Frequency threshold and the nominal voltage setpoint has been reached, the Integrated Voltage Regulator will follow the Under-Frequency Roll-Off (Loading) Profile. The Starting Profile will not be initiated again until the frequency drops below the Voltage Regulator Minimum
Frequency Threshold.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
IVR PID GAIN SETPOINTS
Name Min Max Resolution Units Default
Value
Access
Voltage Regulator Loop Gain
Percentage
0.00 100.00 0.01 % 5.00
ET
Service
Tool or
EMCP
Display
Voltage Regulator
Proportional Gain Percentage
Voltage Regulator Integral
Gain Percentage
Voltage Regulator Derivative
Gain Percentage
Voltage Regulator Noise
Filter Time Constant
0.00 100.00 0.01
0.00 100.00 0.01
0.00 100.00 0.01
% 20.00
% 60.00
% 3.00
ET
Service
Tool Only
(Level 3
Password)
0.00 1.00 0.01 seconds 0.00
The PID gain setpoints can be tuned to achieve the desired voltage response depending on the application and genset configuration. The default parameters have been selected to provide stable voltage control on most generators, however some optimization may be required.
If the voltage regulation appears unstable, it may be necessary to reduce the Voltage
Regulator Loop Gain Percentage to achieve stability. As a guideline, decreasing in steps of 0.5-1.0% is generally sufficient to observe a noticeable improvement.
If the voltage response appears sluggish, it is recommended to increase the Voltage
Regulator Loop Gain Percentage to achieve the desired response. Increasing in steps of
0.5-1.0% is generally sufficient to observe a noticeable improvement.
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UNDER-FREQUENCY ROLL-OFF (LOADING) PROFILE
Name Min Max Resolution Units Default
Value
Access
Voltage Regulator Corner
<Knee> Frequency
Voltage Regulator Deviation
From Corner <Knee>
Frequency
Voltage Regulator Volts/Hz
Slope 1
Voltage Regulator Volts/Hz
Slope 2
Voltage Regulator Minimum
Voltage <Setpoint>
Percentage
Voltage Regulator Minimum
Frequency Threshold
45.0 65.0 0.1 Hz 48.0
0.0 10.0 0.1 Hz 5.0
0.0 10.0 0.1 Volts/Hz 2.0
ET Service Tool
0.0 10.0 0.1 Volts/Hz 2.0 or EMCP
Display
30 100 1 % 50
20 40 1 Hz 20
The “Voltage Regulator Knee Frequency” needs to be configured for your specific package requirements. The Knee Frequency for 50Hz operation will usually be between
48.0 and 49.8Hz, whereas for 60Hz operation this parameter should be set between
58.0 to 59.8 Hz.
An example Under-Frequency Roll-Off (Loading) Profile is illustrated in Figure 73.
Figure 73: Example Under-Frequency (Loading) Profile, Slope1 = 1.0 V/Hz, Slope2 = 2.0 V/Hz
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
VOLTAGE REGULATOR LOAD COMPENSATION TYPE CONFIGURATION
Name
Voltage Regulator Load
Compensation Type Configuration
Options
0 = OFF
1 = IR Compensation
2 = Voltage Droop
Default Value
0
Access
ET Service Tool or EMCP
Display
The load compensation features of IR Compensation and Voltage Droop are explained in sections below.
Note
: IR Compensation and Voltage Droop are mutually exclusive features designed for different applications; therefore it is not possible to enable both compensation types at the same time.
LINE LOSS (IR) COMPENSATION
Name
Voltage Regulator Voltage
(IR) Compensation
Percentage
Min Max Resolution Units Default Value
0.0 10.0 0.1 % 0.0
Access
ET Service Tool or EMCP
Display
In some installations where a single generator is used with long feeder lines to the load, it may be advantageous to provide line loss compensation. Line loss compensation is commonly referred to as IR compensation.
Current flowing through a long conductor causes a voltage drop due to the resistance of the wire. Therefore, the voltage at the load end of the conductor will be lower than the voltage at the generator end due to the voltage drop along the conductor. This condition is commonly referred to as line loss. In order to improve the power quality the IVR can compensate for this phenomenon. As generator load increases, the IVR will increase the output voltage at the generator terminals in order to compensate for line losses. The
Voltage Regulator Voltage (IR) Compensation Percentage setpoint controls the quantity of voltage compensation at the rated kVA load. It should be adjusted to yield a constant voltage at the location of the load.
For example, if it is observed that the voltage at the load side of the feeder line has decreased by 5% from rated voltage when the generator is supplying rated kVA load, the
Voltage Regulator (IR) Compensation Percentage should be set to 5.0%. In this case, the output voltage measured at the generator terminals will increase from 100% to 105% of rated voltage as the generator load increases from 0% to 100% of rated kVA, as illustrated in Figure 74.
If a bias is applied to the voltage setpoint from an external source, the IR compensation percentage is applied to the nominal setpoint plus the bias percentage. For example, if a
+10% or -10% bias were applied to the nominal voltage, the voltage setpoint would increase linearly as shown by the Upper and Lower Bias Limit dashed lines indicated on the diagram presented in Figure 74.
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Figure 74: Line Loss voltage setpoint change based on total (kVA) load
Note
: It is important that the capability of the machine is not exceeded during operation.
REACTIVE DROOP COMPENSATION
Name
Voltage Regulator Maximum
Droop Percentage
Min Max Resolution Units Default Value
0.0 10.0 0.1 % 0.0
Access
ET Service Tool or EMCP
Display
When generators operate in parallel, two primary objectives are for the generators to share both the real power requirements and the reactive power requirements of the system electrical load. The engine governors will control sharing of the real power requirements (kW) and the voltage regulators will control sharing of the reactive power requirements (kVAr) of the total system load. When one or more generators are connected in parallel, the voltage measured at the output terminals of each generator will be the same. However, if the voltage setpoint of one generator is slightly higher than the other generators, it will increase excitation in an attempt to raise the system voltage and in doing so will supply lagging reactive current to the other generators connected in the group. This current will circulate between generators, causing excessive heating of the generator windings and an increased risk of thermal damage.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
One method of minimizing this effect is to cause an individual generator's voltage setpoint to sag, or “droop”, in proportion to its’ reactive power output. For proper reactive load sharing, the regulator must know the rated generator reactive power (kVAr), which is calculated from the genset rated kVA and kW, and the desired percentage of output voltage droop when the generator is supplying rated reactive power.
As the reactive power output increases, the IVR will cause the output voltage to droop
(reduce the voltage) proportionally. If the measured reactive power output is leading, the output voltage will rise in the same linear fashion. In either case, this action will tend to support better kVAr sharing with other generators. Note that it is important that the generator operation remains within its capability.
The Voltage Regulator Maximum Droop Percentage setpoint controls how much the generator output voltage will vary for a given amount of reactive power output. For example, if the Maximum Droop Percentage is set to 5.0%, the voltage setpoint will drop from 100% to 95% of rated voltage as the reactive power output increases from 0% to
100% of rated kVAr (lagging). This is illustrated in the diagram presented in Figure 75.
If a bias is applied to the voltage setpoint from an external source, the reactive droop percentage is applied to the nominal setpoint plus the bias percentage. For example, if a
+10% or -10% bias were applied to the nominal voltage, the voltage setpoint would droop as shown by the Upper and Lower Bias Limit dashed lines indicated on the diagram presented in Figure 75.
Figure 75: Reactive Droop voltage setpoint change based on reactive (kVAr) load
Note
: It is important that the capability of the machine is not exceeded during operation.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
VOLTAGE REGULATOR LOCKOUT CONFIGURATION
Name Options Default Value Access
Voltage Regulator Lockout
Configuration
0 = Not Locked Out
1 = Locked Out
0.0
ET Service Tool
Only
When Voltage Regulator Lockout Configuration is set to ‘Not Locked Out’, the Integrated
Voltage Regulator will operate normally and control the generator voltage output to the reference setpoint.
When Voltage Regulator Lockout Configuration is set to ‘Locked Out’, the Integrated
Voltage Regulator will be prevented from controlling the generator voltage output and the Excitation Command output will remain at zero. Excitation is therefore disabled in this scenario, and the generator will only produce residual voltage.
The Voltage Regulator Lockout Configuration setpoint can only be changed when the genset is STOPPED (EMCP stop button pressed) and engine speed equals zero.
LOSS OF SENSING SHUTDOWN EVENT
Name Min Max Resolution Units Default Value Access
Voltage Regulator Loss Of
Sensing Shutdown Event
Notification Delay Time
0.0 25.0 0.1 Seconds 2.0
The Voltage Regulator Loss Of Sensing Shutdown Event Notification Delay Time
ET Service Tool or EMCP
Display determines the time delay between when a loss of sensing voltage is recognized and when a Loss of Sensing Shutdown event (SPN-FMI: 611-0) is generated. Based on average line-to-line voltage monitoring, loss of sensing is triggered under the following conditions:
For Single Phase configuration: Average line-to-line voltage < 8% of rated
For Three Phase configuration:
Balanced three phase average < 8% of rated OR
Imbalance between a line quantity and three phase average > 20% of rated OR
Loss of a phase (line-to-neutral voltage < 8% of rated).
The Loss of Sensing Shutdown event is inhibited when a generator short circuit condition is detected (any phase current exceeds 300% of rated) during voltage starting profile (IVR operating mode equals SOFT START) for 5 seconds after frequency increases above the Voltage Regulator Minimum Frequency Threshold setpoint when excitation is disabled (Voltage Regulator Lockout Configuration is set to ‘Locked Out’)
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
OVER EXCITATION SHUTDOWN EVENT
Name Min Max Resolution Units Default Value Access
Voltage Regulator Over
Excitation Shutdown Event
Threshold
Voltage Regulator Over
Excitation Shutdown Event
Notification Delay Time
10 100 1 %
0.1 20.0 0.1 Seconds
100.0
10.0
ET Service Tool or EMCP
Display
The Over Excitation Shutdown Event Threshold configuration determines the percentage of excitation command that will cause an Over Excitation Shutdown event. If the excitation command percentage exceeds the Over Excitation Shutdown Event Threshold for longer than the Over Excitation Shutdown Event Notification Delay Time an Over
Excitation Shutdown event (SPN-FMI: 3381-0) will be generated.
Note
: The Over Excitation Shutdown event monitors and triggers an event based on
Excitation Command Percentage and does NOT trigger based on measured excitation current. See the section on Excitation Module Over-Excitation Protection for a description of the Excitation Module over-excitation protection feature that is based on measured excitation current.
19.4 IVR VOLTAGE ADJUSTMENT
Voltage adjustments are categorized into two types: Manual biasing and Analog biasing.
Manual voltage adjustment includes fine tuning the generator output voltage via digital input, EMCP display or SCADA (Modbus). Analog voltage adjustment is performed via programmable analog inputs to the EMCP and provide a voltage control interface for external potentiometers or external control systems (such as switchgear).
It is important to note that the setpoint Gen Maximum Voltage Bias Percentage must be correctly configured to be greater than the expected bias range, otherwise it may not be possible to achieve the required voltage bias. The parameter Gen Maximum Voltage Bias
Percentage is accessed within the CAT ET Service Tool configuration menu under
Generator AC Monitor, or can be accessed from the EMCP display by navigating to the following sub-menu:
MAIN MENU
CONFIGURE
ALL SETPOINTS
GEN AC MONITOR
Note
: All manual voltage biasing is removed and reset to zero when the engine is stopped. Manual voltage bias levels are not carried over to the next start up after an engine shutdown.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
DIGITAL INPUTS
Remote voltage adjustment toggle switches may be used to fine tune the generator output voltage by programming an EMCP digital input for Raise Voltage and Lower
Voltage. Each activation of the digital input raises or lowers the voltage by 0.2% of rated.
When the digital input is activated continuously, the voltage bias is raised or lowered by
0.2% of rated approximately every 400ms.
Refer to Chapter 8 for further details on programming digital inputs on EMCP 4 controllers.
VOLTAGE/HZ CONTROL (EMCP DISPLAY)
The EMCP display may be used to fine tune the generator output voltage. Each press of the voltage raise or voltage lower key raises or lowers the voltage by 0.2% of rated voltage. When the voltage raise or voltage lower key is pressed and held continuously, the voltage bias is raised or lowered by 0.2% of rated approximately every 400ms.
The Voltage/Hz Control screen can be found on the EMCP display by navigating to the following sub-menu:
MAIN MENU
CONTROL
VOLTAGE/Hz CONTROL
Figure 76: EMCP 4.1 & EMCP 4.2 Volts/Hz Control Screen
SCADA MODBUS (EMCP 4.2 ONLY)
EMCP 4.2 SCADA data link also provides a means for adjusting voltage remotely.
EMCP 4.2 Modbus registers are defined for reading and controlling the target output voltage of the generator. Refer to EMCP 4 SCADA Data Links Application and
Installation Guide (LEBE0010) for more details on EMCP 4.2 dedicated SCADA data links.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
ANALOG INPUTS
Analog voltage adjustment is done via a programmable analog input to the EMCP configured for Generator Voltage Control. Analog inputs provide a voltage control interface for external potentiometers or external control systems (such as switchgear).
The following analog input types can be configured on an EMCP 4.1 or EMCP 4.2 to adjust the generator voltage setpoint:
Resistive (a range of input maps are available depending on the potentiometer size)
Voltage o
0 to 5 V o
1 to 5 V o
0.5 to 4.5 V
The Generator Voltage Control analog input signal is interpreted and converted by the
EMCP into a voltage bias percentage of (nominal) rated voltage. For example, consider an analog input configured for a signal range of -10 to +10 V and a data range of -10% to 10%. When this analog input signal value equals +2 V, a voltage bias percentage of
+2.0 % of rated will be applied to the generator output voltage.
Refer to Chapter 9 for further details on programming analog inputs on EMCP 4 controllers.
19.5 IVR DISPLAY SCREENS
The Integrated Voltage Regulator Overview and Voltage Bias Overview can be accessed directly through the EMCP display. To access the IVR Overview and Voltage
Bias Overview through the EMCP display, navigate to the following sub-menus:
MAIN MENU
VIEW
IVR OVERVIEW
VOLTAGE BIAS OVERVIEW
The IVR Overview screen provides IVR operating mode, target voltage, excitation command and voltage compensation information. The Voltage Bias Overview screen provides information on all active voltage biasing on the generator system.
Note
: Excitation command percentage is NOT a measurement of excitation current, but rather a commanded excitation operating point. A non-zero excitation command percentage MAY be displayed on screen during a fault scenario even though zero excitation current output is present.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
Figure 77: EMCP 4.1 & EMCP 4.2 IVR Overview Screens
The IVR operating modes for EMCP 4.1 and EMCP 4.2 are described below:
VOLTS/Hz – voltage is regulated according to the under frequency roll off (Volts/Hz) profile.
V/Hz + DROOP – voltage is regulated according to the under frequency roll off (Volts/Hz) profile .
V/Hz + LINE LOSS - voltage is regulated according to the under frequency roll off (Volts/Hz) profile in addition to any line loss (IR) compensation bias.
SOFT START – voltage is ramped during start up from 0 voltage to rated voltage according to the starting profile.
IVR LOCKED OUT – voltage regulation is locked out and the excitation command is disabled (forced to 0 %). Generator output voltage will not build beyond residual voltage.
PF CONTROL – voltage regulation is performed in order to control power factor to a desired level (EMCP 4.2 only)
STOPPING – voltage is ramped down in proportion to engine speed during shutdown.
The Voltage Bias Overview screen on the EMCP 4.1 and EMCP 4.2 displays manual, analog, load compensation and total voltage bias percentages applied to the generator output.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Figure 78: EMCP 4.1 & EMCP 4.2 Voltage Bias Overview Screens
The voltage biasing information for EMCP 4.1 and EMCP 4.2 is described below:
MANUAL – summation of any voltage bias applied via programmable digital input, Voltage/Hz Control screen on the EMCP display or SCADA
(Modbus) voltage bias.
ANALOG – any voltage bias applied via a programmable analog input described in Chapter 9.
DROOP or LINE LOSS – any voltage bias applied as a result of reactive droop or line loss load compensation. (EMCP 4.2 only)
TOTAL – total voltage bias applied to the generator system. This total percentage bias is the summation of any manual, analog, or compensation (droop or line loss) biasing in the system.
Note
: The total percentage bias that can be applied to the generator system is limited by the Maximum Generator Voltage Output Bias Percentage setpoint configured in the
EMCP.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
20 INSTALLING & UPGRADING SOFTWARE
The EMCP 4 supports field-programming (called flashing) of software for all of the modules. This is done by using the Cat Service Tool software and a Cat Communication
Adapter. The Primary Data Link (CAN 1) service connector must be used for modules connected to the Primary Data Link. The Accessory Data Link (CAN 2) service connector must be used for modules connected to the Accessory Data Link. Refer to your generator set package documentation for the location of the service connectors.
To flash the EMCP 4 requires the following hardware and software:
SOFTWARE AND HARDWARE REQUIRED
The Cat Service Tool software installed and licensed on a PC
A Cat Communication Adapter
A 9-pin Deutsch service connection to the Primary Data Link (CAN 1)
The new application software flash file for the EMCP 4
In order to install software into the EMCP 4, the genset must be stopped. If upgrading software, it may be important to back up the current configuration (see Chapter 4.2).
Flashing application software does not affect the setpoints. However, if a problem occurs during flashing, this backup can be used to quickly configure a replacement module.
Record the current software version information. This is seen in the ECM Summary screen. See Figure 79. This is information is useful to obtain the correct flash file if it is desired to return to the previous version of software after flashing.
Figure 79: ECM Summary Information
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
Flashing of modules other than the EMCP 4 follow similar steps as the ones outlined below.
In order to flash an EMCP 4 module, do the following steps:
1. Connect to the EMCP 4 using the Cat Service Tool as stated in Chapter 4.2.
2. Enter the WinFlash Utility by selecting Utilities > WinFlash, or by clicking the WinFlash Icon.
3. The WinFlash screen will appear.
Note
: If WinFlash does not find all of the modules on the CAN J1939 data link to which it is connected, re-scan the data link by pressing F8 (or selecting File > Update ECM
List).
4. Select the Genset Control if multiple modules are listed, then click the “Browse for a File” button on the right hand side.
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EMCP 4.1, 4.2 Generator Set Control
5. Browse to the appropriate file and click “Open”.
Application and Installation Guide
6. The new file information will be displayed.
7. Click “Begin Flash” in the lower left corner.
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Application and Installation Guide
8. A confirmation screen will appear. Click “OK”.
EMCP 4.1, 4.2 Generator Set Control
9. A progress meter will show the status of the flash and the EMCP display will show that software installation is occurring.
10. When the flashing process is complete, the ECM that was flashed will reboot.
Also, WinFlash will bring up a window giving options for what to do next. This indicates that the software has finished flashing, and is ready to use.
11. On startup, the EMCP 4 shows the software part number. Verify the software part number matches the new application software that was flashed.
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
APPENDIX A M
ENU
S
TRUCTURES
For details on the setpoints available within each submenu, refer to the appropriate section above.
Main Menu
View
Control
Configure
Software Info
Preferences
I/O Status
Event Logs
Engine Overview
AC Overview
IVR Overview*
Network Status
Analog Inputs
Digital Inputs
Relay Outputs
Digital Outputs
EMCP 4.1
Menu Structure
Primary Data Link
Volt/Hz Control
Idle/Rated*
Fuel Transfer
Engine Fuel Priming*
Security
Inputs & Outputs
All Setpoints
Engine Operating Hrs
Reset Counters
Time/Date
*When enabled
Digital Inputs
Relay Outputs
Digital Outputs
Analog Inputs
Control
Eng Monitor/Protection
Events
Gen Monitor/Protection
Voltage Regulator*
Reduced Power Mode
Inputs & Outputs
Automatic Start/Stop
Fuel Transfer
Battery Voltage Monitor
Crank/Start Counters
Engine Speed Monitor
Crank Counter
Start Counter
Diagnostic Resp Config
Eng Protect Resp Config
Gen Protect Resp Config
Custom Event Resp Config
Other System Resp Config
Generator AC Monitor
Gen Over/Under Frequency
Gen Over/Under Voltage
Contrast
Pressure
Temperature
Volume
Lamp Test
Language
Digital Inputs
Relay Outputs
Digital Outputs
Analog Inputs
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Application and Installation Guide
Main Menu
View
Control
Configure
Software Info
Preferences
I/O Status
Event Logs
Engine Overview
AC Overview
IVR Overview*
Network Status
Contrast
Pressure
Temperature
Volume
Lamp Test
Language
EMCP 4.1, 4.2 Generator Set Control
Analog Inputs
Digital Inputs
Relay Outputs
Digital Outputs
Primary Data Link
Accessory Data Link
RS-485 SCADA Data Link
RS-485 Annunciator Data Link
EMCP 4.2
Menu Structure
Volt/Hz Control
Idle/Rated*
Programmable Cycle Timer
Fuel Transfer
Engine Fuel Priming*
Security
Inputs & Outputs
All Setpoints
Engine Operating Hrs
Reset Counters
Time/Date
*When enabled
Digital Inputs
Relay Outputs
Digital Outputs
Analog Inputs
Control
Eng Monitor/Protection
Events
Gen Monitor/Protection
Voltage Regulator*
Network
Reduced Power Mode
Prog kW Relay Trip
Inputs & Outputs
Crank Counter
Start Counter
Serv Maint Interval kWh Meter kVArh Meter
Automatic Start/Stop
Fuel Transfer
Battery Voltage Monitor
Crank/Start Counters
Engine Coolant Temp Monitor
Engine Oil Pres Monitor
Engine Speed Monitor
Enhanced Engine Monitor
Service Maintenance Interval
Diagnostic Resp Config
Eng Protect Resp Config
Gen Protect Resp Config
Custom Event Resp Config
Other System Resp Config
Event System
Enhanced Gen Monitor
Generator AC Monitor
Gen AC Power Monitor
Generator Over Current
Gen Over/Under Frequency
Gen Over/Under Voltage
Generator Reverse Power
RS-485 SCADA
Digital Inputs
Relay Outputs
Digital Outputs
Analog Inputs
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
APPENDIX B EMCP 4 F
RONT
V
IEW
& N
AVIGATION
K
EYS
EMCP 4.1 AND 4.2
(1) Display Screen
(2) AC Overview Key
(3) Engine Overview Key
(9) Auto Key
(10) Stop Key
(11) Escape Key
(4) Main Menu Key
(5) Alarm Acknowledge/Silence Key with
Amber Warning Lamp
(12) Scroll Up Key
(13) Scroll Right Key
(6) Event Reset Key with Red Shutdown Lamp (14) OK Key
(7) Event Log Key (15) Scroll Down Key
(8) Run Key
(1) SCREEN
(16) Scroll Left Key
Displays various genset information and parameters.
(2) AC
OVERVIEW
(3) ENGINE
OVERVIEW
The AC Overview Key will navigate the display to the first screen of
AC information. The AC Overview Key information contains various
AC parameters that summarize the electrical operation of the generator set.
The Engine Overview Key will navigate the display to the first screen of engine information. The Engine Overview information contains various engine parameters that summarize the operation of the generator set.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
(4) MAIN MENU
The Main Menu key will navigate the display to the main menu directly without having to navigate out of menus.
(5) ALARM
ACKNOWLEDGE/
SILENCE
Pressing the Alarm Acknowledge/Silence Key will cause the horn
Relay Output to turn off and silence the horn. Pressing the key will also cause any amber or red flashing lights to turn off or to become solid depending on the active status of the alarms. The Alarm
Acknowledge/Silence Key may also be configured to send out a global alarm silence on the CAN Data Link which will silence horns on Annunciators, if the CAN Annunciator is configured to respond.
(6) EVENT RESET The Event Reset button will clear all inactive fault conditions.
(7) EVENT LOG
The Event Log button will navigate the display to the list of event logs.
(8) RUN
(9) AUTO
(10) STOP
Pressing the RUN Key will cause the EMCP to enter the RUN mode.
Note
: If a Digital Input is programmed for ECS in Auto, or Stop, and a maintained switch latches that input to make it active, the front panel RUN key will not have any effect.
Pressing the AUTO Key will cause the EMCP to enter the AUTO mode.
Note
: If a Digital Input is programmed for ECS in RUN, or Stop, and a maintained switch latches that input to make it active, the front panel AUTO key will not have any effect.
Pressing the STOP Key will cause the EMCP to enter the STOP mode.
Note
: If a Digital Input is programmed for ECS in Auto, or RUN, and a maintained switch latches that input to make it active, the front panel STOP key will not have any effect.
(11) ESCAPE
The Escape Key is used during menu navigation in order to navigate up through the menu/sub-menu structure. Each key press causes the user to move backwards/upwards through the navigation menus. The
Escape Key is also used to cancel out of data entry screens during setpoint programming. If the Escape Key is pressed during setpoint programming, none of the changes made on screen will be saved to memory. Pressing this key will bring the user back one menu/submenu.
(12) SCROLL UP
The Scroll Up Key is used to navigate up through the various menus or monitoring screens. The Scroll Up Key is also used during setpoint entry. During numeric data entry the Scroll Up Key is used in order to increment the digits (0-9). If the setpoint requires selection from a list, the Scroll Up Key is used to navigate through the list.
(13) SCROLL
RIGHT
The Scroll Right Key is used during setpoint adjustment. During numeric data entry, the Scroll Right Key is used to choose which digit is being edited. The Scroll Right Key is also used during certain setpoint adjustments to select or deselect a check box. If a box has a check mark inside the box, pressing the Scroll Right Key will cause the check mark to disappear, disabling the function. If the box does not have a check mark inside the box, pressing the Scroll
Right Key will cause a check mark to appear, enabling the function.
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EMCP 4.1, 4.2 Generator Set Control
(14) OK
(15) SCROLL
DOWN
(16) SCROLL
LEFT
Application and Installation Guide
The OK Key is used during menu navigation to select menu items in order to navigate forward/downward in the menu/sub-menu structure.
The OK Key is also used during setpoint programming in order to save setpoints changes. Pressing the OK Key during setpoint programming causes setpoint changes to be saved to memory.
The Down Key is used to navigate down through the various menus or monitoring screens. The Down Key is also used during setpoint entry. During numeric data entry the Down Key is used in order to decrement the digits (0-9). If the setpoint requires selection from a list, the Down Key is used to navigate down through the list.
The Scroll Left Key is used during setpoint adjustment. During numeric data entry, the Scroll Left Key is used to choose which digit is being edited. The Scroll Left Key is also used during certain setpoint adjustments to select or deselect a check box. If a box has a check mark inside the box, pressing the Scroll Left Key will cause the check mark to disappear, disabling the function. If the box does not have a check mark inside the box, pressing the Scroll Left Key will cause a check mark to appear, enabling the function.
ALARM INDICATORS
AMBER
WARNING
LIGHT
The Amber Warning Light is located directly above the Alarm
Acknowledge/Silence Key (5). A flashing amber light indicates that there are unacknowledged active warnings. A solid amber light indicates that there are acknowledged warnings active. If there are any active warnings, the amber light will change from flashing yellow to solid amber after the Alarm Acknowledge/Silence Key (5) is pressed. If there are no longer any active warnings, the amber light will turn off after the Alarm Acknowledge/Silence Key (5) is pressed.
RED
SHUTDOWN
LIGHT
The Red Shutdown Light is located directly above the Event Reset
Key (6). A flashing red light indicates that there are unacknowledged active shutdown events. A solid red light indicates that there are acknowledged shutdown events active. If there are any active shutdown events the red light will change from flashing red to solid red after the Alarm Acknowledge/Silence Key (5) is pressed. Any condition that has caused an EMCP shutdown event must be manually reset. If there are no longer any active shutdown events, the red light will turn off.
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
APPENDIX C IVR E
XCITATION
M
ODULE
C
ONNECTION
D
IAGRAMS
EM10 – Self-Excitation (SHUNT)
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EM10 – Auxiliary Winding (Internal) Excitation (AREP / IE), 4-wire
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
EM10 – Auxiliary Winding (Internal) Excitation (AREP / IE), 3-wire
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EMCP 4.1, 4.2 Generator Set Control
EM10 – Permanent Magnet Excitation (PM)
Application and Installation Guide
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Application and Installation Guide
EM15 – Self Excitation (SHUNT)
EMCP 4.1, 4.2 Generator Set Control
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EMCP 4.1, 4.2 Generator Set Control Application and Installation Guide
EM15 – Auxiliary Winding (Internal) Excitation (AREP / IE), 4-wire
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
EM15 – Auxiliary Winding (Internal) Excitation (AREP / IE), 3-wire
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EMCP 4.1, 4.2 Generator Set Control
EM15 – Permanent Magnet Excitation (PM)
Application and Installation Guide
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Application and Installation Guide EMCP 4.1, 4.2 Generator Set Control
ECS
ECU
EM
EUI
FMI
FPT
Glossary of Terms
ACK
AGSM
CAN
CDVR
DIO
EMCP 4
ECM
GSC
IVR
MUI
NFPA
PCT
Acknowledge
Alarm Group Selection Mode. The mode in which group of alarms the
RS-485 annunciator will respond is selected in.
Controller Area Network. This will often refer to our CAN J1939
Communications between ECMs.
Cat Digital Voltage Regulator. A microprocessor based digital voltage regulator which communicates with the EMCP and controls excitation current to control generator voltage.
Discrete Input/Output Module
Electronic Modular Control Panel 4. This is the Cat generator set control panel, consisting of a generator set control (GSC).
Electronic Control Module. This is a general term and can refer to any microprocessor-based module that is part of a control system. The engine ECM is an ECM dedicated to the task of engine timing and air/fuel control.
Engine Control Switch
Engine Control Unit. Another name for an ECM (Electronic Control
Module).
Excitation Module. This is the excitation power converter component required for use with the Integrated Voltage Regulator (IVR).
Electronic Unit Injector. A type of Fuel Injector.
Failure Mode Indicator. The CAN term for a failure code associated with a particular Suspect Parameter Number. For a complete list of FMI codes, refer to the Systems Operation Troubleshooting Testing and
Adjusting guide.
Fault Protection Timer. A time delay that suppresses some events for a configurable amount of time after the generator set starts to allow values to settle before taking action on the event.
Generator Set Controller. This is the module responsible for the overall generator protection and control functions. It is the master module on the generator set, interfacing with the user as well as the engine ECM and any other accessory modules.
Integrated Voltage Regulator. This is a voltage regulating system integrated into EMCP controls. Requires an Excitation Module component.
Mechanical Unit Injector. A type of fuel injector.
National Fire Protection Association. A n American standards body responsible for creation of various codes.
Programmable Cycle Timer. A timer which supports starting a generator set for exercise on a 7 day basis.
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Glossary of Terms
RMS
RPM
RPM
RS-232
RS-485
RTD
RTU
SCR
SCADA
SPN
A mathematical approach of representing a useful average for varying quantities; this is useful to indicate AC quantities.
Revolutions per minute
Reduced Power Mode. A mode to reduce the power consumption of an
EMCP controller when a battery charger is not fitted to the generator set.
Recommended Standard 232, maintained by the Electronics Industries
Alliance (EIA). Also known as EIA-232.
Recommended Standard 485, maintained by the Electronics Industries
Alliance (EIA). Also known as EIA-485.
Resistive Temperature Device. A temperature sensor that changes resistance based on temperature.
Remote Transmitter Unit. This term refers to a Slave device in a
MODBUS network that merely responds to requests from the Master.
The EMCP 4.2 can function as an RTU on a SCADA system via the RS-
485 SCADA port.
Selective Catalyst Reduction. This is a form of emission treatment.
Supervisory Control And Data Acquisition. This term represents any computing system designed to perform high-level control and monitoring over various subsystems. On the EMCP 4, we provide a MODBUS interface to allow any SCADA systems to connect and collect data about the operations of the control and the generator set(s).
Suspect Parameter Number. The CAN term for any parameter whose data is transmitted over a CAN network, such as the EMCP 4 primary or accessory data link. For a complete list of SPNs supported by the EMCP
4, refer to the Diagnostic Trouble Code List in the Systems Operation
Troubleshooting Testing and Adjusting guide.
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All rights reserved.
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Table of contents
- 24 Connecting to the EMCP 4 to Configure Setpoints
- 26 Supported Parameters
- 26 Engine Overview
- 30 AC Overview
- 32 Setting The Preferences Using The EMCP 4 Display
- 34 Changing The EMCP 4 Contrast When the Display is Unreadable
- 34 Changing The EMCP 4 Display to Technician English
- 35 Changing The EMCP 4 Display to the Primary Language
- 35 Setting the Preferences Using the Service Tool
- 36 Changing The Time/Date
- 38 Changing Date Format
- 39 Generator Output Voltage
- 39 Engine Speed
- 40 Idle/Rated
- 41 Engine Sensor Versus Data link
- 43 Engine Oil Pressure
- 46 Engine Coolant Temperature
- 48 Starting The Engine
- 49 EMCP 4 Remote Start
- 49 Stopping The Engine
- 51 Emergency Stop
- 53 Procedure For Overspeed Verification
- 53 Procedure For Low Oil Pressure Verification
- 54 Procedure For High Coolant Temperature Verification
- 55 Updating Engine Operating Hours
- 66 Not in Auto Warning
- 66 Service Maintenance Interval (EMCP 4.2 Only)
- 78 Setpoint Categories
- 83 Viewing the Current Digital Input Status
- 84 Configuring Digital Inputs for Status Parameters
- 86 Digital Input Command/STatus Descriptions
- 89 Configuring Digital Inputs for System Events
- 92 Configuring Digital Inputs for SCADA Data link
- 93 Disabling Digital Inputs
- 95 Configuring Digital Inputs for Status Parameter
- 96 Configuring Digital Inputs for System Events
- 100 Configuring Digital Inputs for SCADA Data link
- 100 Disabling Digital Inputs
- 103 Viewing the Current Analog Input Status
- 104 Configuring Analog Inputs for Resistive Mode
- 106 Configuring Analog Inputs for Voltage Mode
- 108 Disabling Analog Inputs
- 110 Configuring Analog Inputs for Resistive Mode
- 113 Configuring Analog Inputs for Voltage Mode
- 116 Disabling Analog Inputs
- 127 Warnings and Shutdowns
- 127 Unsupported Analog Input Sensor Ranges
- 127 Sensor Range is Smaller than Setpoint Options
- 129 Sensor Range is Larger than Setpoint Options, But Usable Range is Not
- 130 Sensor Range is Larger than Setpoint Options, And Usable Range is Larger Than Setpoint Options
- 132 Viewing the Current Output Status
- 133 Configuring Outputs for Status Parameters
- 135 Digital/relay Output Command/STatus Descriptions
- 138 Configuring Outputs for System Events
- 142 Digital/relay Output SYSTEM EVENT DESCRIPTIONS
- 145 Configuring Outputs for SCADA Data link
- 146 Disabling Outputs
- 147 Configuring Outputs for Status Parameters
- 149 Configuring Outputs for System Events
- 150 Configuring Outputs for SCADA Data link
- 151 Disabling Outputs
- 158 Fleet Configuration Option
- 158 ECM Replacement Option
- 178 Primary CAN Wiring
- 178 Network Topology
- 180 Accessory CAN Wiring
- 180 Network Topology
- 184 CAN Annunciator Features
- 184 Annunciator Specifications
- 185 Annunciator Wiring
- 186 LED Colors
- 187 CAN Annunciator Software Configuration
- 187 Global Acknowledge
- 187 ECU Instance Number
- 187 Configuring Annunciator LED Behavior
- 190 Trigger Condition
- 191 Severity Level
- 192 Suspect Parameter Number
- 193 Annunciator Features
- 193 Annunciator Specifications
- 194 RS-485 Annunciator Wiring
- 195 LED Colors
- 196 Lamp Test Function
- 196 Alarm Acknowledge
- 197 RS-485 ANNUNCIATOR ALARM GROUPS
- 197 Alarm Group Selection Mode (AGSM)
- 198 Entering AGSM
- 198 Re-configuring/Selecting Alarm Group Address
- 199 Exiting AGSM
- 199 RS-485 Annunciator Custom Alarm Group Configuration
- 199 CUSTOM ALARM GROUP SELECTION
- 200 Severity Level
- 200 Suspect Parameter Number
- 202 Alarm Groups
- 206 Configuring Custom Alarm Groups using Cat Service Tool
- 213 Thermocouple Features
- 214 Thermocouple Specifications
- 215 Thermocouple Wiring
- 216 Thermocouple Physical Layout
- 216 Thermocouple Module – Configuration
- 218 Configuring Thermocouple Inputs
- 219 RTD Features
- 220 RTD Specifications
- 221 RTD Wiring
- 222 RTD Physical Layout
- 222 RTD Module – Configuration
- 223 Configuring RTD Inputs
- 224 Discrete I/O Features
- 225 Discrete I/O Specifications
- 226 Discrete I/O Wiring
- 227 Discrete I/O Physical Layout
- 227 Discrete I/O Software Configuration
- 229 Configuring Digital Inputs
- 230 Configuring Relay Outputs
- 233 Configuring The SCADA Data Link Using The Display
- 235 Configuring The SCADA Data Link Using The Cat Service Tool
- 239 EMCP IVR Connections
- 239 IVR Excitation Module
- 240 IVR Excitation Module Physical Layout
- 241 IVR Excitation Module Connections
- 242 IVR Excitation Module Over-Excitation Protection
- 243 IVR Excitation Module Fusing
- 245 Voltage Regulator Control Source Configuration
- 246 Starting Profile
- 249 IVR PID Gain Setpoints
- 250 Under-Frequency Roll-Off (Loading) Profile
- 251 Voltage Regulator Load Compensation Type Configuration
- 251 Line Loss (IR) Compensation
- 252 Reactive Droop Compensation
- 254 Voltage Regulator Lockout Configuration
- 254 Loss of Sensing Shutdown Event
- 255 Over Excitation Shutdown Event
- 256 Digital Inputs
- 256 Voltage/Hz Control (EMCP Display)
- 256 SCADA Modbus (EMCP 4.2 Only)
- 257 Analog Inputs