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| Illustration 1 | g00793163 |
Typical EMCP II (1) Generator Set Control (2) Alarm module (3) Custom alarm module (4) Optional speed potentiometer (SP) or optional governor switch (GS) (5) Panel lights (PL) (6) Control panel (operation) (7) Caterpillar Monitoring System (CMS) (8) Voltage adjust rheostat (9) Engine control switch (ESC) (10) Panel light switch (PLS) (11) Emergency stop push button (ESPB) | |
Generator set control (GSC) (1) - The left side of the control panel contains the Generator Set Control (GSC). This is the main component of the system. The GSC displays generator output, fault conditions, and key engine parameters.
Alarm Module (2) - The alarm module provides a warning of engine conditions. This warning is given before conditions become so severe that the engine shuts down or conditions become severe enough to prevent the engine from starting.
Custom Alarm Module (3) - This alarm module is an optional feature.
Speed Potentiometer (4) - The engine is equipped with an electronic governor. A speed potentiometer is mounted in this location.
Panel Lights (5) - The panel lights are controlled by the Panel Light Switch (10) .
Control panel (6) - The control panel controls the operation of the generator set.
Caterpillar Monitoring System (CMS) (7) - The main display module continuously monitors all generator set systems.
Voltage Adjust Rheostat (8) - The voltage adjust rheostat is used to adjust the generator output voltage to the desired level.
Engine Control Switch (9) - The engine control switch determines the status of the control panel. In the AUTO position (3 o'clock), the engine will start automatically whenever a remote start/stop initiate contact is closed. The engine will stop after the initiate contact opens and after an adjustable cooldown period has elapsed. A cooldown period can be programmed. This cooldown period (0 to 30 minutes) will allow the engine to dissipate heat before the engine shuts down.
Panel Light Switch (10) - The panel light switch operates the panel lights (5) .
Emergency Stop Push Button (11) - The emergency stop push button is used to shut down the engine during an emergency situation. The engine is shut down by shutting off the fuel supply. Do not use the emergency stop push button to shut down the engine under normal circumstances.
Generator Set Control (GSC)
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| Illustration 2 | g00591650 |
(1) Indicators (2) Upper display (3) Lower display (4) Keypad | |
The left side of the control panel contains the Generator Set Control (GSC). This is the main component of the system. The GSC also displays the following information:
- generator output
- generator set functions
- fault conditions
- key engine parameters
The GSC accepts information from the following sources: operator, magnetic pickup, oil pressure sensor, water temperature sensor and optional remote sources This information is used to determine the on/off state of the engine's air, fuel, and starter.
Under basic operating conditions, the GSC receives a signal in order to run the generator set. The GSC turns on the engine's fuel and the engine's starter. When the engine speed reaches the crank termination speed, the starter is disengaged. When the GSC receives an engine stop signal, the GSC shuts off the fuel.
GSC Features and Functions
The GSC is in normal mode during normal operation. None of the indicators are illuminated. The upper display does NOT show "SERV".
The GSC has the following features and functions:
- The GSC controls the starting and the stopping of the engine (normal conditions).
- The GSC shows the engine conditions and generator output information (on two displays). The displays also show fault codes and GSC programming information.
- The GSC monitors the system for faults. If a fault occurs, the GSC performs a controlled fault shutdown or the GSC provides a fault alarm annunciation. The GSC uses indicators and displays to describe the fault.
- The GSC contains programmable features for certain applications or customers' requirements.
Cycle Crank - The GSC can be programmed to alternate between cranking and resting for adjustable time periods. Refer to Systems Operation / Testing and Adjusting, SENR5828 for programming instructions.
2301A Control - When the engine oil pressure is increased beyond the low oil pressure setpoint, the GSC will inform the governor that the engine speed should be increased from IDLE to RATED rpm.
Cool Down - When the GSC receives a signal to perform a shutdown, the GSC hesitates for a period of time. This period of time is preprogrammed. The engine is shut down via the fuel control.
Automatic Operation - While the GSC is in the automatic mode, a remote start signal (contact closure) will start the GSC. Upon loss of the signal (contact opening), the GSC will perform a normal shutdown.
Alarm Module Communication - The GSC can transmit fault conditions and alarm conditions to an alarm module.
Power Down - The Electronic Modular Control Panel II (EMCP II) is designed to remove power from the GSC when the following conditions are met:
- The GSC is in the Off/Reset mode.
- The proper jumper wire is removed.
The GSC will not be powered down until the crank termination relay is OFF and the fuel control relay is OFF. Both relays must be OFF for approximately 70 seconds. The GSC will not be powered down unless the wire is removed.
Note: For the wiring diagram and jumper wire locations, refer to Systems Operation / Testing and Adjusting, SENR5828.
Fuel Solenoid Type - The GSC can be programmed for an energized-to-run fuel system or an energized-to-shutdown fuel system.
Fault Indicators
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| Illustration 3 | g00793303 |
The ten fault indicators are used to show that a fault is present. The fault indicators describe the fault. The fault indicators are divided into three groups: fault alarm indicator (3), fault shutdown indicator (2) and dedicated shutdown indicators (1).
The yellow fault alarm indicator (3) FLASHES when the GSC detects an alarm fault. The alarm fault does not cause the engine status to change. The engine will be able to start. Fault alarm indicator (3) is accompanied by a fault code that is shown on upper display (4) when the alarm code key is pressed.
The red fault shutdown indicator (2) FLASHES when the GSC detects a fault that is a shutdown fault. When a fault is detected, the engine is shut down. The engine is not allowed to start. Fault shutdown indicator (2) is accompanied by a fault code that is immediately shown on upper display (4) .
The red dedicated shutdown indicators (1) represent the following shutdown faults: low oil pressure, emergency stop, high water temperature, engine overspeed, and engine overcrank. When the GSC detects a fault in one of these areas, the corresponding shutdown indicator FLASHES. If the engine is running, the engine is shut down and the engine is not allowed to start. There are no fault codes that are associated with the dedicated shutdown indicators. Each indicator has a descriptive label.
The conditions that are required for each dedicated fault are in the following list. The results of each dedicated fault are also in the following list.
Low Oil Pressure - The engine oil pressure drops below the setpoints for low oil pressure shutdown that are programmed into the GSC. There are two low oil pressure setpoints: engine at idle speed and engine at rated speed. When this fault occurs, the low oil pressure indicator FLASHES. The engine is shut down. The engine is not allowed to start until the fault is corrected.
Emergency Stop - The operator presses the emergency stop push button (ESPB) on the instrument panel. When this condition occurs, the emergency stop indicator FLASHES. The engine is shut down. The engine is not allowed to start until the condition is corrected.
High Water Temperature - The engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSC. When this fault occurs, the high water temperature indicator FLASHES. The engine is shut down. The engine is not allowed to start until the fault is corrected.
Engine Overspeed - The engine speed exceeds the setpoint for engine overspeed that is programmed into the GSC. When this fault occurs, the engine overspeed indicator FLASHES. The engine is shut down. The engine is not allowed to start until the fault is corrected.
Overcrank - The engine does not start within the setpoint for total cycle crank time that is programmed into the GSC. When this fault occurs, the overcrank indicator FLASHES. The engine is not allowed to start until the fault is corrected.
Note: The GSC can be programmed to override the following shutdowns: low oil pressure, high water temperature and low coolant level. When the shutdown faults are overridden, the faults are treated as alarm faults. The corresponding dedicated shutdown indicator is ON CONTINUOUSLY. The engine continues to run instead of shutting down. This dedicated shutdown indicator means that the setpoint for shutdown has been exceeded. The GSC is programmed to override the shutdown fault. The GSC will treat the fault as an alarm fault. The factory programs the GSC to treat low oil pressure, high water temperature and low coolant level as shutdowns. The operator must decide if these shutdown faults can be overridden.
Display
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| Illustration 4 | g00793330 |
The upper display (1) and lower display (2) of the GSC provide information about the generator set.
Upper display (1) shows AC voltage, current and frequency of one phase of the generator output. Each phase can be viewed one at a time by pushing the phase select key. Upper display (1) is also used to show the various fault codes for system faults. For more information on fault codes, refer to Systems Operation / Testing and Adjusting, SENR5828 for fault descriptions.
Lower display (2) shows left exhaust temperature, right exhaust temperature, system battery voltage, engine hours, engine speed, engine oil pressure, and engine coolant temperature. The value for one of these conditions is shown for two seconds. The display scrolls to the value for the next condition. A small pointer identifies the engine condition that corresponds to the value that is showing. When the engine meter key is pressed, lower display (2) stops scrolling. The lower display continuously shows one particular value. The pointer flashes above the condition with the value that is showing.
The relay status indicator is on the lower display. The corresponding indicator such as K1 or K2 is shown on lower display (2) when a GSC relay is activated. No indicators are shown when a GSC relay is not activated.
In the service mode, both displays are used for programming functions. For more information, refer to the appropriate service manual module for service modes.
Keypad
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| Illustration 5 | g00793332 |
Keypad (3) is used to control the information that is shown on upper display and lower display. The seven keys have two sets of functions, normal functions and service functions. For a description of the service functions of the keys, refer to Systems Operation / Testing and Adjusting, SENR5828. The normal functions of the keys are in the following list.
Leftmost Key - This key only functions when the GSC is in service mode.
Phase Select Key - This key selects the phase of the generator output that is shown on the GSC. Pressing this key allows the operator to check the voltage, current, and frequency of each phase one at a time.
Engine Meter Key - This key stops the scrolling of engine conditions on lower display (2). The display continuously shows the value for one particular engine condition. The pointer flashes in order to indicate that scrolling is stopped. Pressing the key again resumes the scrolling of engine conditions.
Lamp Test Key - This key performs a lamp test on the GSC and the optional alarm module. The eight fault indicators are ON CONTINUOUSLY. Every segment of upper display (1) and lower display (2) is ON. On the optional alarm module, all of the indicators are ON and the horn will sound.
Alarm Code Key - Press the fault alarm indicator (4) in order to show the corresponding fault code. Pressing this key again resumes the showing of generator output information on upper display (1). If fault alarm indicator (4) is OFF, this key has no function. Refer to Systems Operation / Testing and Adjusting, SENR5828 for more information on fault codes.
Exit Key - This key only functions when the GSC is in service mode. Refer to Systems Operation / Testing and Adjusting, SENR5828 for more information.
Service Mode Key - Pressing this key causes the GSC to enter service mode. Refer to Systems Operation / Testing and Adjusting, SENR5828 for more information.
Alarm Module
An alarm condition will not shut down the engine. However, an alarm may precede a shutdown. An alarm indicates a serious condition that requires immediate attention. If an alarm condition occurs, the alarm module uses an indicator and a horn to inform the operator.
There are several different types of alarm modules that are available. Alarm modules are optional. The features of the alarm module are identified in Illustration 6.
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| Illustration 6 | g00792430 |
National Fire Protection Association (NFPA) 110 Alarm Module (1) "HIGH COOLANT TEMP" (2) "LOW COOLANT TEMP" (3) "LOW OIL PRESSURE" (4) "LOW FUEL LEVEL" (5) "SYSTEM NOT IN AUTO" (6) "LOW BATTERY VOLTAGE" (7) "RUPTURE BASIN TANK" (8) "HIGH FUEL LEVEL" (9) "ALARM SILENCE" button | |
| "HIGH COOLANT TEMP" (1) |
| "LOW COOLANT TEMP" (2) |
| "LOW OIL PRESSURE" (3) |
| "LOW FUEL LEVEL" (4) |
| "SYSTEM NOT IN AUTO" (5) |
| "LOW BATTERY VOLTAGE" (6) |
| "RUPTURE BASIN TANK" (7) |
| "HIGH FUEL LEVEL" (8) |
Note: These other indicators are available as options: "GENERATOR ON LOAD", "CHARGER MALFUNCTION", "LOW OIL LEVEL", "LOW COOLANT LEVEL", "LOW OIL PRESSURE SHUTDOWN", "OVERCRANK SHUTDOWN", "HIGH COOLANT TEMP SHUTDOWN" and "OVERSPEED SHUTDOWN".
| "ALARM SILENCE" (9) |
To silence the horn, press "ALARM SILENCE" button (9) .
The following six versions of the basic alarm module are available. The only differences are the films on the fronts of the modules and the wiring.
- An alarm module that is used for standby applications is available. This alarm module also meets the requirements of NFPA 99.
- A remote annunciator panel that is used with the alarm module that was previously mentioned (NFPA 99) is available.
- An alarm module that is used for standby applications is available. This alarm module also meets the requirements of NFPA 110.
- An alarm module for single engines in prime power applications is available.
- An alarm module for multiple engines in prime power applications is available.
- A remote annunciator panel for the EMCP II is also available.
Custom alarm modules are also available for use in the control panel or in remote locations. The conditions that activate the custom alarm modules are determined by the customer. Labels can be provided for the custom alarm modules.
For the following information on alarm modules, refer to the control panel's Service Manual: Installation, Wiring and Requirements of the NFPA.
Caterpillar Monitoring System
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| Illustration 7 | g00297407 |
Main Display Module (1) Alert Indicators. (2) Display area. | |
The main display module continuously monitors all generator set systems. The main display module makes decisions that are based upon the input from the systems or other electronic control modules. The main display module sends information to other electronic controls that are on the generator set. The input and output of this information takes place over the CAT data link. The outputs on the main display module notify the operator and the service technician of the status of the generator set systems. For more information, refer to Operation and Maintenance Manual, SEBU6918, "SR4B Generators and Control Panels".