Installation of the Generator and Control Panel Components for Dynamic Gas Blending Retrofits on Certain 3500 Engines{4490, 7451} Caterpillar

Electric Power Generation:

3512B GENSET (S/N: ZAH1-UP; 1GZ1-UP)

3516B GEN SET (S/N: ZAP1-UP)

Engine:

3512B (S/N: PTF1-UP; PTM1-UP; YAM1-UP; 4AW1-UP; CTB1-UP; 1GZ1-UP)

3512C (S/N: RMS1-UP)

3516B (S/N: YAP1-UP; YAT1-UP; YBT1-UP)

Petroleum Engine:

3512C PETROLEUM (S/N: LLA1-UP)

Introduction

This Special Instruction contains information for the installation of the upgrade fuel kit for dynamic gas blending. The installation applies to the 3516B and 3512B Diesel Engines. The information in this publication focuses on removing the old components, installing the new components, and engine components. Some engine components may not be original components.

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Table 1

Related Publications for Reference
Media Number	Publication Type
REHS7487	Special Instruction
UENR1210	Systems Operation Troubleshooting Testing and Adjusting
LEBE0007	Application and Installation Guide
SEBU9019	Operation and Maintenance Manual (for drilling)
KENR9744	Troubleshooting (for Drilling)

Note: The EMCP panel does not come with a mounting bracket. A mounting bracket must be fabricated. Refer to the ECMP publication Application and Installation Guide, LEBE0007 for best mounting practices. Modifying the old mounting location brackets is not acceptable for mounting of the new panel.

Note: The following instructions will allow the EMCP to be configured properly if the following configuration is true. The engine must be configured for remote start and stop as described in the ""Remote Start" " section of this publication. If the configuration is not the same as described, refer to the Application and Installation Guide, LEBE0007 to ensure the proper configuration.

Use the latest version of Cat ET. The current version of Cat ET is "2014B".

Illustration 1	g03581530

Typical example of a unit

Illustration 2	g03581527

Typical example of a unit

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Power source must be disconnected before working on equipment. Failure to disconnect power source could result in injury or death.

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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures.

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Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls "DO NOT OPERATE".

Common Parts for All Applications

Table 2 provides information that is related to all applications. Table 7, 8, 9, 10, and 11 contain information for specific applications.

Note: The part numbers listed in the following tables may not be the same part numbers that are used in your application. That is, the part numbers may be different due to the kV rating of the application.

Table 2

Qty	Part Number	Part Name	Description
	4B-4274	Washer
	5M-5845	Screw 10-32
2	9Y-8419	Fuse (12 Amp)	There are two fuses per panel on the DC side.
	109-3038	Wire end 16 gauge wire
	110-8714	Wire end for 18 gauge wire
	115-1322	Terminal Block (1)	314-9101 End Bracket , 3E-5503 Fixed Bridge Bar , 325-1788 Terminal Cover
	125-9969	Rail
	175-4998	mA to PWM converter
	272-5835	Fuse (0.5 Amp)	There are three fuses per panel on the AC side.
1	275-2081	Coolant Temperature Gauge Gp
1	275-2096	Engine Oil Pressure Gauge Gp
1	275-2098	Oil Temperature Gauge Gp
1	275-2100	Engine Percent Load Gauge Gp
1	275-2110	Voltmeter Gp
	314-9098	Terminal Block (2)	314-9101 End Bracket , 314-9100 Fixed Bridge Bar , and 314-9099 Terminal Cover
1	363-8626	Gauge
1	382-1791	Instrument Panel Box Gp	Contains an EMCP 4.4 and gages
	383-8563 (3)	Engine Wiring Gp	Engine to panel short harness. The harness is a 70 pin to a 70 pin interface harness.
	383-8565 (4)	Engine Wiring Gp	Generator short harness. The harness is a 40 pin to 40 pin and a 14 pin MS connector to bare wire harness.
	386-4896 (5)	Engine Wiring Gp	Longer version of the 383-8563 Engine Wiring Gp engine interconnect harness. Contains the 386-4897 Wiring Harness . Refer to Illustration 3 for a picture of the harness.
	386-4901 (6)	Generator Wiring Gp	Contains the 386-4904 Generator Interconnect Harness As . Refer to Illustration 3 for a picture of the harness.

( 1 )	115-1322 must be used with the parts listed in the description field for 115-1322. 314-9098 or 115-1322 can be used for this application.
( 2 )	314-9098 must be used with the parts listed in the description field for 314-9098. Either 314-9098 or 115-1322 can be used for this application.
( 3 )	Refer to Table 3 for individual parts.
( 4 )	Refer to Table 4 for individual parts.
( 5 )	Refer to table 5 for individual parts.
( 6 )	Refer to table 6 for individual parts.

Table 3

383-8563 Engine Wiring Gp Parts
Part Number	Description
0L-1351	Bolt
6V-5839	Washer - hard
7K-1181	Strap - cable
132-5789	Clip - ladder
383-8564	Harness assembly - wiring

Table 4

383-8565 Engine Wiring Gp
Part Number	Description
0L-1351	Bolt
5P-6264	GROMMET
6V-5839	Washer - hard
7K-1181	Strap - cable
132-5789	Clip - ladder
383-8566	Harness assembly - wiring

Table 5

386-4896 Engine Wiring Gp
Part Number	Description
0L-1351	Bolt
6V-5839	Washer - hard
7K-1181	Strap - cable
132-5789	Clip - ladder
386-4897	Harness assembly - wiring

Table 6

386-4901 Engine Wiring Gp
Part Number	Description
0L-1351	Bolt
6V-5839	Washer - hard
7K-1181	Strap - cable
132-5789	Clip - ladder
386-4904	Harness assembly - wiring

Table 7

3516B Production (50Hz, 1500rpm, 2290hp, 1640eKw, 0.8pf, 400v, 826 frame (3))
Qty	Part Number	Description
1	361-6978	Terminal Strip Gp
1	361-7009	Harness AS
3	128-0115	Current Transformer As
3	361-7027	Transformer AS
3	5P-0537	Hard washer (for mounting PTs)
3	2A-4781	Bolt (for mounting PTs)
3	198-4776	Hard washer (for mounting PTs)
3	9S-8750	Nut-full (for mounting PTs)
4	030-9613	Screw-forming (for mounting Block AS)
4	9X-8486	Screw (for mounting 40 pin connector)
4	3B-4501	Lock washer (for mounting 40 pin connector)
4	4B-2043	Nut (for mounting 40 pin connector)
4	4B-4863	Washer (for mounting 40 pin connector)
1	361-7002	Harness AS
1	361-6974	Terminal Strip Gp

( 3 )

All frame numbers in this publication are only for Caterpillar reference purposes.

Table 8

3512B Drilling (50Hz, 1500rpm, 1757hp, 1240eKw, 0.7pf, 600v, 826 frame (3))
Qty	Part Number	Description
1	361-6978	Terminal strip group
1	361-7009	Harness assembly
3	122-6588	Current Transformer assembly
3	154-3488	Transformer assembly
3	5P-0537	Hard washer (for mounting PT)
3	2A-4781	Bolt (for mounting PT)
3	198-4776	Hard washer (for mounting PT)
3	9S-8750	Nut-full (for mounting PT)
4	030-9613	Screw-forming (for mounting block assembly)
4	9X-8486	Screw (for mounting 40 pin connector)
4	3B-4501	Lock washer (for mounting 40 pin connector)
4	4B-2043	Nut (for mounting 40 pin connector)
4	4B-4863	Washer (for mounting 40 pin connector)
1	361-7002	Harness assembly
1	361-6974	Terminal strip group

Table 9

3512B Production (60Hz, 1800rpm, 1910hp, 1360eKw, 0.8pf, 480v, 824 frame (3))
Qty	Part Number	Description
1	361-6978	Terminal Strip Gp
1	361-7009	Harness As
3	122-6589	Current Transformer As
3	154-3488	Transformer As
3	5P-0537	Hard washer (for mounting PTs)
3	2A-4781	Bolt (for mounting PTs)
3	198-4776	Hard washer (for mounting PTs)
3	9S-8750	Nut-full (for mounting PTs)
4	030-9613	Screw (for mounting Block As)
4	9X-8486	Screw (for mounting 40 pin connector)
4	3B-4501	Lockwasher (for mounting 40 pin connector)
4	4B-2043	Nut (for mounting 40 pin connector)
4	4B-4863	Washer (for mounting 40 pin connector)
1	361-7002	Harness As
1	361-6974	Terminal Strip Gp

Table 10

3512B Drilling (60Hz, 1200rpm, 1477hp, 1750eKW, 0.7pf, 600v, 867 frame (3))
Qty	Part Number	Description
1	361-6978	Terminal Strip Gp
1	361-7009	Harness AS
3	122-6589	Current Transformer As
3	154-3488	Transformer As
3	5P-0537	Hard washer (for mounting PTs)
3	2A-4781	Bolt (for mounting PTs)
3	198-4776	Hard washer (for mounting PTs)
3	9S-8750	Nut-full (for mounting PTs)
4	030-9613	Screw (for mounting Block AS)
4	9X-8486	Screw (for mounting 40 pin connector)
4	3B-4501	Lockwasher (for mounting 40 pin connector)
4	4B-2043	Nut (for mounting 40 pin connector)
4	4B-4863	Washer (for mounting 40 pin connector)
1	361-7002	Harness As
1	361-6974	Terminal Strip Gp

Table 11

3512C Drilling (60Hz, 1200rpm, 1477hp, 1750eKW, 0.7pf, 600v, 867 frame (3))
Qty	Part Number	Description
1	361-6978	Terminal Strip Gp
1	361-7009	Harness As
3	122-6588	Current Transformer As
3	154-3488	Transformer As
3	5P-0537	Hard washer (for mounting PTs)
3	2A-4781	Bolt (for mounting PTs)
3	198-4776	Hard washer (for mounting PTs)
3	9S-8750	Nut-full (for mounting PTs)
4	030-9613	Screw (for mounting Block AS)
4	9X-8486	Screw (for mounting 40 pin connector)
4	3B-4501	Lockwasher (for mounting 40 pin connector)
4	4B-2043	Nut (for mounting 40 pin connector)
4	4B-4863	Washer (for mounting 40 pin connector)
1	361-7002	Harness As
1	361-6974	Terminal Strip Gp

Illustration 3	g03556680
386-4897 Engine Interconnect Wiring Harness 386-4904 Generator Interconnect Harness as

Illustration 4	g03315957
386-4904 Generator Interconnect Harness AC Connector As 14 pin connector

Table 12

386-4904 Generator AC 14 pin connector
Connector	Description
A	Generator Voltage Phase A
B	Generator Voltage Phase B
C	Generator Voltage Phase C
D
E
F
G	Generator Voltage Neutral
H	Generator Current Phase A
I	Generator Current Phase B
J	Generator Current Phase C
K	Generator Current Return
L	Droop CT+
M	Droop CT-
N	Ground

Note: The control panel assembly is shipped without a stand.

Illustration 5	g03317298
DGB control panel

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210 for more information about the operation of the EMCP 4.4.

Note: The information in UENR1210 is related to a generator application, but not specifically to the application in this publication for dynamic gas blending.

Illustration 6	g03163320
EMCP 4 Control System Panel (1) Display screen (2) F4 Soft key (3) F3 Soft key (4) F2 Soft key (5) F1 Soft key (6) Control key (7) AC overview key (8) Engine overview key (9) Main menu (10) Warning Indicator lamp (yellow) (11) Acknowledge alarm key and silence key (12) Shutdown Indicator lamp (red) (13) Event reset key (14) Event log key (15) Run key (16) Auto key (17) Stop key (18) Escape key (19) Up key (20) Right key (21) OK key (22) Down key (23) Left key

Illustration 7	g03163216
(24) 275-2098 Oil Temperature Gauge Gp (25) 275-2100 Engine Percent Load Gauge Gp (26) 275-2096 Engine Oil Pressure Gauge Gp (27) 275-2081 Coolant Temperature Gauge Gp (28) 363-8626 Gauge (29) 275-2110 Voltmeter Gp (35) Gauges (36) EMCP 4 (37) Emergency stop (38) Generator AC inputs (39) Generator interface connector (40) Service port connector (41) Engine interface connector (42) Radio connector

Illustration 8	g03587224
(50) Potential transformer (51) Current Transformer As (52) Dot to indicate positive terminal (53) Dot to indicate CT polarity

The yellow dot (52) on the top of the current transformer is a reference to determine which post of the CT is positive or negative. The installer must confirm which post is positive or negative when the CT is correctly oriented. The yellow dot (53) on the side of the CT is used for polarity, the current flow direction, and orientation when installing the CT.

Shutting Down The Unit

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Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from any utility and/or other generators that can provide power service), and either lock out or tag as "DO NOT OPERATE". Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.

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NOTICE
Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of engine components. Excessive temperatures in the turbocharger centerhousing will cause oil coking problems. Excessive temperatures in the turbocharger centerhousing may damage the turbocharger bearing/shaft system and significantly shorten the life of the turbocharger. Allow the engine to gradually cool before stopping the engine

1. Open the main circuit breaker in order to disengage the driven equipment.

2. Turn the engine control switch to the "OFF/RESET" position. The engine will immediately shut off.

3. Press the red "STOP" button on the controller. If the set point for the duration of the cool down period is set to a value that is greater than zero, the engine will operate for a programmed period before the engine stops. Otherwise, the engine will immediately shut off.

4. All power to the unit must be disconnected and locked out. All gas, fuel, hydraulic, and air must be blocked and/or locked out that is used for the unit. Some applications may require air or hydraulic accumulators to have the pressure relieved.

Remove Original Components

Remove Original Control Panel

Illustration 9	g03233297
Earlier control panel (60) Connections

The original control panels can vary in the configuration of the unit. As shown in Illustration 9, the control panel is mounted on the engine. Other units may have the control panel mounted in another location such as on the terminal box.

1. Disconnect any cables (60) to the original control panel.

2. Remove the control panel mounting bolts.

3. Use an appropriate lifting device to remove the original control panel.

4. Remove the control panel mounting brackets and discard.

Remove Access Panels

Illustration 10	g03701070
Examples of other access panel installations

Illustration 11	g03163681
Typical example of access panel for customer connections. (54) Access hole for wiring harness (plug removed) (55) Large access cover (56) Smaller access covers

Note: There are multiple types of enclosures. Refer to Illustration 10 and 11 for two typical examples.

Remove access panel (55) to access the customer connections.

Note: Removal of the access covers (56) is not required for all applications.

Illustration 12	g03702009
Access covers removed.

Installation Procedure

Install Potential Transformers

Use the following steps to install the potential transformers.

Note: Due to the various types of enclosures or terminal boxes, the required location of components will vary. The illustrations in the following procedure show different mounting locations for the potential transformers.

1. Verify that the correct PT has been shipped. Check to make sure the part numbers of the PT are correct.

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Illustration 13	g03702163
PT location (60) Access hole (61) PT location

2. Examples for potential transformer location are shown in Illustrations 13 and 14. Place marks on the enclosure where the holes for the mounting bolts of the transformers are to be located.

3. Drill the mounting holes for the transformers.

4. Select the correct transformer wires that are to be used. Insulate the unused wires. Ensure that the correct mounting bolt and proper washers are used. Make sure that no wires from the PT are being pinched.

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Illustration 14	g03164044
Typical example of transformers installed (67) Potential transformer (68) Mounting bolt and washer (69) Transformer leads

5. Install the transformers (67). Ensure that the transformers leads are routed correctly so the leads will not be pinched during the install process. Refer to Illustration 14.

Install Current Transformers

Use the following steps to install the current transformers.

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Illustration 15	g03359941

1. Disconnect output cables (75) .

   Note: Ensure that the cables are appropriately labeled in order to ensure that the cables are installed correctly after the current transformer (CT) is installed.

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Illustration 16	g03587259
Typical example of a CT. (76) Dot to indicate positive terminal (77) Dot to indicate CT polarity

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Illustration 17	g03587261
Typical example of the CTs installed on output cables.

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Illustration 18	g03703300
Another example of a typical installation of customer connections

2. Install one CT on each group of output cables.

   Note: Ensure that the polarity dot (77) is facing the drive end of the generator.

3. Secure each CT with cable ties in the correct location. Cut off the excess length of the cable ties.

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Illustration 19	g03587263
Another example of a typical installation (78) Signal (sensing) lines (79) Dot to indicate CT polarity (80) CT connections

4. Connect the red signal (sensing) wires (78) .

   Note: Ensure the length for signal (sensing) wires and CT connections will long enough to reach the terminal strips.

5. Connect the wiring (80) for each CT. Refer to Illustration 19.

   Note: Remove any used CT. If the CT is not removed, the CT must be shorted.

6. Install all of the output cables on the correct bus bars.

Install Terminal Strip and 40 Pin Connector

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Illustration 20	g03164037
Another example of a typical installation (85) DIN rail installed

1. Install the DIN rail (85) in an appropriate location. The DIN rail (85) must be long enough to accommodate the terminal strip and PWM module.

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Illustration 21	g03166877
Typical installation example (86) Location for 40 pin connector (87) Installed connector

2. A hole (86) will need to be cut in the enclosure to allow installation the 40 pin connector (87) in an appropriate location.

   Note: Ensure that hole (86), for the 40 pin connector (87), is in a location that will not interfere with the terminal strip on the inside of the enclosure.

   Illustration 21 shows the location of the hole that is needed and the connector installed.

3. Prior to mounting the terminal strip, the area must be cleaned of any metal shavings and debris.

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Illustration 22	g03587536
Typical installation example (87) Installed connector (88) Terminal strip (89) Wire harness (90) PWM converter (91) Filter for direct rack module (optional)

4. Mount terminal strip (88), PWM converter (90), and filter (91).

5. Wire the CTs, PTs, and PWM (90) .

   Note: Refer to Special Instruction, REHS7328, "Wiring Diagrams" for wiring schematics information.

6. Feed the wire harness (89) through the enclosure and connect to the terminal strip (88) .

7. After wiring is completed, install all covers and access panels.

Install EMCP 4 Control Panel

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210 for EMCP 4 concerns.

Note: The installation kit included the EMCP 4.4 control panel, however, the EMCP 4.4 was flashed with EMCP 4.3 software.

Refer to Application and Installation Guide, LEBE0007 for information related to the differences between the EMCP 4.3 and EMCP 4.4.

Install the EMCP 4 control panel in the appropriate location. The location of the panel is to be determined by the need of the customer. A stand for the control panel is NOT included with the DGB kits.

Caterpillar does offer a stand for certain applications. However, for most applications, a stand will need to be fabricated.

The stand that is available by Caterpillar is 389-0244 Instrument Panel Mounting Gp .

Control Panel Stand

An example of a stand for the control panel is shown below. Refer to Special Instruction, REHS7328, "Panel Dimensions" section for control panel dimensions.

EMCP4 Control Installed

Illustration 23	g03176709

Caterpillar does offer a stand. However, the stand may not be appropriate for your installation. The part information for the stand that Caterpillar has available is listed in Table 13.

Table 13

EMCP Stand 389-0244 Instrument Panel Mounting Gp
Part Number	Description
389-0242	Bracket Assembly
389-0243	Bracket Assembly

Harness Connector

1. Remove the cap (95) that is on the wiring harness. Connect the wire harness connector (96) to the connector that was installed on the enclosure.

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Illustration 24	g03168218
Typical example of 40 pin and harness installation

Note: Ensure that the cable (89) has some type of protection, like a rubber grommet, where the cable enters the enclosure.

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Illustration 25	g03703376
Another typical example of installation (98) Access hole for connector assembly (99) Connector assembly installed

2. Route the wiring harness (89) to the EMCP panel.

   Note: Ensure that the harness wiring is the appropriate length to allow connections to the terminal strip.

3. Connect the wiring harness to the control panel.

   Note: Refer to Special Instruction, REHS7328, "Wiring Diagrams" for wiring schematics information.

Wiring Diagrams

Control Panel - Wiring of Earlier Version

Illustration 26	g03164078
Earlier Version of the electronic instrument panel (100) Wire 060-YL (101) Wire 998-BR

Use the following steps to make necessary wiring changes.

Note: The following is the recommended configuration. If the current installation is different, refer to Application and Installation Guide, LEBE0007.

Note: The following example applies to a unit that uses the three position remote start/run, cool/stop, and stop switch. The three position switch is used in the earlier version of the control panel.

1. A wire 060-YL must be routed from the remote switch to the EMCP 4 control panel terminal strip. The 060-YL wire is connected to terminal 8 of the remote switch.

2. Connect wire 060-YL to the "START" terminal block on the terminal strip that is in the EMCP 4 control panel.

3. Connect 998-BR to the "BATT-" terminal block on the terminal strip that is in the EMCP 4 control panel. Wire 060-YL is connected to contact 5 of remote switch.

   Note: All other contacts and wires must be removed from the 40 pin connector.

When the remote switch is in "STOP" or "COOL/STOP" position, the EMCP will send the stop request signal to the engine controller. When the remote switch is in "START/RUN" position, the EMCP will send the start request signal to the engine controller.

Note: The engine will always go through a cool down cycle when using the remote start/stop.

Remote Start

The EMCP4 can accept a remote start signal. If the 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.

The remote start will become active when "START" is pulled to "BATT-". For more information, refer to the Application and Installation Guide, LEBE0007.

Illustration 27	g03172277
EMCP panel terminal strip

EMCP 4 Control Panel Connections

Illustration 28	g03171396
(105) E-stop, Start, and Batt- terminal block location (106) Blue jumper wire (107) CAN 1 terminator resistor (108) CAN 2 terminator resistor

E-Stop Connections

Perform the following steps to use a remote E-stop switch.

1. Remove the blue jumper wire (106). Refer to Illustration 28 and Illustration 29.

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Illustration 29	g03171736
Removal of jumper wire and installation of external E-stop switch wiring. (106) Blue jumper wire

2. Connect the E-stop leads to the E-stop terminal and the Batt- terminal. Refer to Illustration 29.

PT and CT Connections

Illustration 30	g03703355
Schematic is for reference only.

The application will determine the PTs and CTs that will be needed. That is, for example, if the generator output is wired for 240 V, the PT output will be 240 V. The black and white wire of the input must be used for the one to one ratio.

The following is another example. The output of the PT will be 240 V if the following configuration is used:

• The generator is wired for 600 V output

• The generator is wired to the black and red input wires of the PT

Note: The PT uses a 2.5 to 1 ratio for this configuration.

Refer to Illustration 31.

Illustration 31	g03171820
Schematic is for reference only. The voltage rating for the installation will determine which connections are correct. For example, installations that use 240 V will use the black and white wires. For installations that use 380 V, the black and green wires are to be used.

Illustration 32	g03320208

Direct Rack Connections

Illustration 33	g03172222

Refer to Special Instruction, REHS0848, "3500 Direct Fuel Control Modification" for related information.

If direct rack is used, a CAN 1 termination resistor must be used. If the Cat Digital Voltage Regulator (CDVR) is used, the CAN 1 termination resistor must be removed if there is a CAN termination resistor at the CDVR. Refer to Illustration 28 for the location of the CAN 1 termination resistor inside the panel.

Programmable Discrete Input Connections

Illustration 34	g03172302
Programmable discrete inputs for the EMCP4.

The "BATT-" must be used as reference. Refer to Illustration 34 for the terminal blocks used for programmable discrete inputs.

For more information, refer to the Application and Installation Guide, LEBE0007.

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210 or Application and Installation Guide, LEBE0007 for the following information:

• Analog inputs

• Digital inputs

• Analog output

• Digital output

Low Idle Request

Refer to Illustration 34 for the terminal blocks used for the digital ground reference and the low idle request input.

The low idle request is initiated by completing the circuit between PW02- (the digital ground reference) and the low idle request terminal L972.

Normal operation is allowed when an open connection exists between PW02- (the digital ground reference) and the low idle request terminal L972.

Modbus Connections

Illustration 35	g03320722

Refer to Illustration 35 for connections related to the Modbus.

Refer to Systems Operation, Troubleshooting, Testing and Adjusting, UENR1210 and Application and Installation, LEBE0010 for EMCP 4 SCADA data link related information.

Caterpillar Electronic Technician Changes (Cat ET)

The retrofit process will require that changes be made with the use of Cat ET.

Use the latest version of Cat ET. The current version of Cat ET is "2013C".

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Illustration 36	g03588267

1. Use Cat ET to navigate to the "Analog PWM Outputs" screen. Refer to Illustration 36.

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Illustration 37	g03174178

2. The maximum data range is the same as the generator rated power. Refer to the Systems Operation Troubleshooting Testing and Adjusting, UENR1210 EMCP manual.

Use the generator AC monitor to change the "Generator Rated Frequency" and the "Generator Rated Voltage" settings to match the generator configuration. Refer to Illustration 37. Refer to the generator manufacturer specifications.

Note: The values that are used for "Generator AC Monitor" parameters will be dependent on the type of CTs and PTs that were installed.

Not in Reduced Power Mode

The EMCP controls the engine key switch and the generator. The EMCP must be set to "Not in Reduced Power Mode". If the EMCP is set to reduced power mode, the key switch to the engine ecm will be turned off.

Note: If the batteries are on chargers, there is no reason to run in reduced power mode.

Illustration 38	g03316496

Refer to the Systems Operation Troubleshooting Testing and Adjusting, UENR1210 manual for any further EMCP concerns.

CDVR Equipped Installations

For installations that use the CDVR, refer to Specifications, Systems Operation, Testing and Adjusting, RENR7941.

EMCP 4.4 Gas Blending Control

Use the EMCP 4.4 to access control gas blending. The gas blending control can be accessed by two different methods. The control screen can be accessed by pressing the "Contol" button (6) on the EMCP 4.4 or by using the following steps.

Note: If needed, refer to Illustration 6 for information about the EMCP 4.4 control panel.

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Illustration 39	g03255396

1. If the main menu is not shown, press the "Main Menu" button on the front of the EMCP 4.4. At the main menu screen, select "Control". The following screen will appear.

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Illustration 40	g03255397

2. Select "Dynamic Gas Blend". The following screen will appear.

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Illustration 41	g03703382

3. Use the soft keys to turn the gas blending control on, off, raise the maximum percent, or to lower the maximum percent.

4. Press the "Main Menu" button on the front of the EMCP 4.4 to return to the "Main Menu" screen.

Engine Overview Gas Blending

Note: If the EMCP 4.3/4.4 detects a DGB engine, a selection for "Engine Overview" will become available.

1. There are two methods to access the engine overview.

   1. Press the "Engine" push button, call out (8), shown in Illustration 6 that is located on the front panel of the EMCP.

   2. Press the "Main Menu", call out (9), shown in Illustration 6 that is located on the front panel of the EMCP. Select "View". Press "OK". Select "Engine Overview".

2. At the "Engine Overview" screen, click on the "Gas Blending" selection.

3. The screen that is shown in Illustration 42 will appear.

Illustration 42	g03335536
Engine overview screen

Startup and Operation

Startup and operation process.

For more information, refer to the Application and Installation Guide, LEBE0007 for the EMCP4.3 and EMCP4.4 control.

Panel Dimensions

Illustration 43	g03320228