Electronic Modular Control Panel II+ (EMCP II+) Caterpillar

Illustration 1	g00792603
Display Area Of The Generator Set Control+ (GSC+) (1) Dedicated Shutdown Indicators (2) Spare Fault Indicators (3) Fault Shutdown Indicator (4) Fault Alarm Indicator (5) Upper Display (6) Lower Display (7) Keypad (8) Exit Key (9) Service Mode Key (10) Power Meter Key And Scroll Right Key (11) AC Meter Key And Scroll Up Key (12) Engine Meter Key And Scroll Down Key (13) Lamp Test Key And Select Key (14) Alarm Codes Key and Enter Key

The main component of the EMCP II+ system is the generator set control + (GSC+). The GSC+ is designed to operate when the GSC+ is powered by 24 DCV or 32 DCV. The GSC+ monitors the functions of the generator. Also, the GSC+ controls the functions of the generator. The functions and features of the GSC+ are listed below.

• The GSC+ provides the generator AC output information. The information includes the metering of power. The GSC+ controls starting and stopping of the engine.

• The GSC+ shows engine conditions and generator output information on two displays.

• The displays show the fault codes. The displays also show the information for programming that is used by the GSC+.

• The GSC+ monitors the system for faults. A fault alarm annunciation is provided by the GSC+ after a fault occurs. When a fault occurs the GSC+ may also perform a controlled fault shutdown. The GSC+ uses indicators and displays in order to describe the fault to the operator or the service technician.

• The GSC+ contains programmable features for certain applications. The programmable features are also used by the GSC+ in order to meet the requirements of the customers.

Note: Setting P023 to 0 ensures proper operation on MUI engines. SetP023 to 1 for Gas engines. Set P023 to 2 for EUI engines. Failure to set setpoint P023 can result in improper engine operation, incorrect display of engine parameters, and logging an erroneous CID 590 diagnostic code. For more information on the setpoints for the GSC+, refer to Systems Operation,, "Engine-Generator Programming OP5-0".

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Part Number of the GSC +

Illustration 2	g00310244
Location Of the Part Number for the GSC + Rear View Of GSC+

The part number is stamped into the rear housing of every GSC+ above the harness connector. When the GSC+ is updated internally, the part number also changes. The part number can be used to identify the effectivity of any changes.

Serial Number for the GSC +

Illustration 3	g00394402
Location of the serial number for the GSC+. Rear View Of GSC+

The serial number of the GSC+ is a ten digit number which is unique for each GSC+. The preceding illustration shows the location of the serial number on the back of the GSC+. The serial number is also shown to service personnel when the GSC+ is in option OP2-2. The serial number which is shown on the display and the actual serial number will always match. See Systems Operation, "AC Factory Calibration Setpoint Viewing OP2-2".

Fault Indicators

The ten fault indicators are used in order to show a fault that is present. The ten fault indicators are also used to describe a fault that is present. The fault indicators are divided into four groups. The four groups are the fault alarm indicator (4), the spare fault indicators (2), the fault shutdown indicator (3) and the dedicated shutdown indicators (1) .

The yellow fault alarm indicator (4) FLASHES when the GSC+ detects a fault that is an alarm fault. The alarm fault does not cause the engine status to change. The engine is able to start. The engine will continue operating, only if the engine is running at the time of the alarm fault. Fault alarm indicator (4) is accompanied by an alarm fault code. The code is then shown on the upper display (5) when the alarm codes key is pressed.

The red fault shutdown indicator (3) FLASHES when the GSC+ detects a fault that is a shutdown fault. The engine is shutdown if the engine is running and the engine is not allowed to start. Fault shutdown indicator (3) is accompanied by a fault code that is immediately shown on the upper display (5) .

The yellow spare fault indicators (2) FLASH when the conditions that are associated with that spare fault are active. The three spare faults can be programmed to show coolant loss, oil temperature, spare fault condition or no assignment. The spare fault condition may be a customer generated switch input. See Systems Operation, "SP Fault Codes" for more information. The yellow fault alarm indicator (4) or the red fault shutdown indicator (3) will accompany the spare fault indicators (2). The spare fault indicators will tell whether the spare fault input is programmed to be an alarm condition or a shutdown condition.

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 dedicated shutdown indicator (that corresponds to the fault) FLASHES. The engine is shutdown if the engine is running, and the engine is not allowed to start. No fault codes are associated with the dedicated shutdown indicators because each indicator has a descriptive label.

Many of the dedicated shutdown faults depend on certain setpoints in the GSC+. See Systems Operation, "Setpoint Programming OP5" for more information. To restart the engine after a shutdown, see Systems Operation, "Shutdown Mode".

The conditions that are required to activate the dedicated fault shutdowns are in the following list. The results of each dedicated fault are in the following list.

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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. One setpoint is used when the engine is at idle speed. The other setpoint is used when the engine is at rated speed. When a low oil pressure fault occurs, the low oil pressure indicator FLASHES, and 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 front panel. When an emergency stop condition occurs, the emergency stop indicator FLASHES and 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 the high water temperature fault occurs, the high water temperature indicator FLASHES. The engine is shutdown and 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+. The engine overspeed indicator will FLASH when the engine overspeed fault occurs. The engine is shutdown and 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 the overcrank 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 shutdown for low oil pressure and high water temperature faults. When the operator overrides the shutdown faults, the GSC+ responds to the faults as though the faults are alarm faults. The corresponding dedicated shutdown indicator is ON CONTINUOUSLY. The corresponding dedicated shutdown indicator will not be flashing. The engine continues to run and the engine continues to start instead of shutting down. When the dedicated shutdown indicator is ON CONTINUOUSLY, the setpoint for shutdown has been exceeded, but the GSC+ is programmed to override the shutdown fault. The GSC+ does not treat the shutdown fault as a shutdown fault. The GSC+ treats the shutdown fault as an alarm fault. At the factory, the GSC+ is programmed to treat a low oil pressure fault and a high water temperature fault as shutdown faults. The operator or the service technician must decide to override these shutdown faults. The operator or the service technician may program the GSC+ in order to recognize the shutdown faults as alarm faults.

Upper Display

Illustration 4	g00521435
Upper Display (5) With All Segments

The primary function of the upper display (5) is showing the following information of the generator output: AC voltage, current and frequency. Several options are available on the upper display for AC metering. These options can be viewed one at a time by pressing the AC Meter key on the keypad. The options are listed below.

• Voltage (average), generator frequency, current (total)

• Voltage (line), generator frequency, current (line) for any one phase

• Line voltage for all three phases

• Line Current for all three phases

Note: When total current increases above "9999A", the GSC+ will show current in "kA" units.

• Line to neutral voltage for all three phases

Note: Line to neutral voltages are not shown when setpoint "P032" is set to 1 (delta generator sets).

Upper display (5) is also used to show the various fault codes for system faults. For more information on fault codes, see Systems Operation, "Fault Description".

Illustration 5	g00527264
The upper Display: 480 volts is the average line to line voltage of all three phases 60 hertz, generator frequency 3000 amperes, total line current of all three phases

Illustration 6	g00527266
Upper Display Showing: 480 volts, line to line voltage of phase A to phase B 60 hertz, generator frequency 1000 amperes, total line current of phase A

Illustration 7	g00394497
Upper Display Is Showing: 480 volts, line to line voltage of phase A-B 480 volts, line to line voltage of phase B-C 480 volts, line to line voltage of phase C-A

Illustration 8	g00394503
Upper Display Is Showing: 1000 Amperes, line current of phase A 1000 Amperes, line current of phase B 1000 Amperes, line current of phase C

Illustration 9	g00394505
Upper Display Is Showing: 277 Volts, line to neutral voltage of phase A 277 Volts, line to neutral voltage of phase B 277 Volts, line to neutral voltage of phase C

Note: Line to neutral voltages are not shown when the setpoint P032 is set to 1 for delta generator sets.

Lower Display

Illustration 10	g00394557
Lower Display (6) With All Segments

The lower display (6) shows values for power metering, engine parameters and the relay status. The left side of the lower display serves as a power meter for the generator set. The following functions will scroll automatically.

• Total real power (kW)

• Total reactive power (KVAR)

• Percentage of rated power (%kW)

• Power factor (average)

• Total energy output (kW/h)

The display will stop scrolling when the operator presses the power meter key for less than five seconds. The display will show a particular parameter continuously. Additional power meter functions will scroll, if the power meter key is held for more than five seconds and then released. The additional functions are shown below.

• Total real power (kW)

• Real power phase A (kW)

• Real power phase B (kW)

• Real power phase C (kW)

• Total apparent power (kVA)

• Total reactive power (KVAR)

• Percentage of rated power (%kW)

• Power factor (average)

• Power factor phase A

• Power factor phase B

• Power factor phase C

• Total energy output (kW/h)

• Total reactive energy output (kVARHr)

Note: All real power values are signed with a "+" or a "-". A negative value indicates reverse power.

Note: Real power phase A, B, and C as well as power factor phase A, B, and C are not shown when setpoint P032 is set to 1 for delta generator sets.

Illustration 11	g00394559
Lower Display Showing: 691 kW, total real power of generator output

Illustration 12	g00394561
Lower Display Showing: 230 kW, real power of phase A

Note: Phase B and Phase C can be viewed in a similar manner.

Illustration 13	g00394562
Lower Display Showing: 831 kVA, total apparent power.

Illustration 14	g00394563
Lower Display Showing: 462 KVAR, total reactive power of generator output.

Illustration 15	g00394565
Lower Display Showing: 80 %kW, percentage of rated power of generator output

Illustration 16	g00394566
Lower Display Showing: .83 PF, average power factor of generator output

Note: You may view the power factor for the individual phases in a similar manner.

Illustration 17	g00394567
Lower Display Showing: 1000 kW/h, total energy of generator output.

Note: Total energy output that is greater than 999,999 kW/h will be shown as MW/h in two steps in order to maintain a resolution of 1 kW/h. The first step will show MW/h as a whole number up to six places. The second step will show MW/h as a decimal to three places. For example: 1,000,001 kW/h will be shown as 1000 MW/h (first step), followed by .001 MW/h (second step).

Illustration 18	g00579439
Lower Display Showing: 64 psi engine oil pressure.

The right side of lower display (6) shows the value of certain engine parameters. The parameters are listed below.

• Left side exhaust temperature (optional)

• Right side exhaust temperature (optional)

• Engine oil temperature (optional)

• System battery voltage

• Engine hours

• Engine speed

• Engine oil pressure

• Engine coolant temperature

Note: If the GSC+ displays dashes (---) for oil pressure, coolant temperature, or engine oil temperature, this indicates that the GSC+ is receiving invalid data from the sensor. The upper display will be showing a corresponding diagnostic code for the sensor. Refer to the appropriate procedure in Troubleshooting, "Troubleshooting Diagnostic Codes".

The value for one of these conditions is shown on the display for two seconds. The display then 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, the lower display (6) stops scrolling. The lower display continuously shows one particular value. The pointer flashes above the value that is showing on the display.

Illustration 19	g00394569
Lower Display Showing: K1, K3 and K5 are active. K2, K4, K6, K7 and K8 are not active.

The relay status indicators are on the bottom of the lower display. When a GSC+ relay is activated, the corresponding indicator (K1, K2, etc) is shown on lower display (6). When a relay is not activated, the corresponding indicator (K1, K2, etc) is not shown.

Keypad

Illustration 20	g00395398
Keypad (7) for the EMCP II+ Control Panel

Keypad (7) is used to control the information that is shown on upper display (5) and lower display (6). The seven keys have two sets of functions, normal functions and service functions. See the topic Systems Operation, "Service Mode" for a description of the service functions of the keys. The normal functions of the keys are described in the following paragraphs.

Power Meter Key - This key controls the viewing of power meter information. This information is shown on the lower display. Pressing the key for at least five seconds causes all the power meter data to scroll once. The default power meter data then resumes scrolling. Briefly pressing this key (for less than five seconds) will stop the scrolling of the power meter functions until the key is pressed again.

AC Meter Key - The AC meter key controls the viewing of the AC parameters on the upper display. Pressing the key causes the display to show a different set of parameters.

Engine Meter Key - This key controls the viewing of engine parameters on the lower display. Pressing the key stops the scrolling of engine conditions. The value for one particular engine condition will show continuously. The pointer flashes in order to indicate that the scrolling has stopped. The scrolling of the engine conditions will resume when the engine meter key is pressed again.

Lamp Test Key - Pressing this key performs a lamp test on the GSC+ and the optional alarm module. On the GSC+, the ten fault indicators are ON CONTINUOUSLY. Every segment of upper display (5) and lower display (6) are ON. On the optional alarm module, all of the indicators are ON and the horn sounds. The lamp test function automatically turns off if an operator presses the key and holds the key for longer than ten seconds.

Alarm Codes Key - If fault alarm indicator (4) is FLASHING, pressing this key causes upper display (5) to show the corresponding alarm fault code. Pressing this key again will resume the showing of generator AC output information on the upper display (5). If fault alarm indicator (4) is OFF, this key has no function. For more information on alarm fault codes, see Systems Operation, "Fault Description".

Exit Key - This key only functions when the GSC+ is in Service Mode. See Systems Operation, "Service Mode".

Service Mode Key - Pressing this key causes the GSC+ to enter service mode. See Systems Operation, "Service Mode" for more information.

Relays

Illustration 21	g00521482
Relay Module On Rear Of GSC+

Illustration 22	g00436699
Relays In Relay Module (1) Jumper block

The relays are located in the relay module on the rear of the GSC+. The relays are permanently attached within the relay module. The relays are not removable. The entire relay module is replaced if a relay has failed. For more information, see Schematics And Wiring Diagrams, "Generator Set Wiring Diagram".

Some of the contacts of the relays are internally connected to the terminals of the relay module. The contacts are available for the customer's use. The voltage specifications and the current specifications for each terminal of the relay are listed in the following chart.

Note: Jumper block (1) is used to select the voltage range of the voltmeter of the GSC+. Jumper block (1) is installed for systems with 700 volts full scale AC inputs. Jumper block (1) is NOT installed for systems with 150 volts full scale AC inputs or for any unit with external potential transformers. The relay module comes factory equipped with the jumper block (1) installed. See Testing And Adjusting, "AC Voltage Range Selection".

The relays and the functions are listed below.

K1 - Electronic Governor Relay (EGR)

On MUI engines this relay signals the optional 2301A Electronic Governor to accelerate the engine to the rated speed.

On EUI engines, this relay enables the engine ECM to begin fuel injection.

On PEEC engines, this relay signals the engine to go to rated speed immediately after starting.

• When the relay is active the normally open contacts close.

• The relay has no normally closed contacts.

K2 - Generator Fault Relay (GFR)

The GSC+ uses the generator fault relay (GFR) to activate the shunt trip coil of the optional circuit breaker during a shutdown fault. The optional circuit breaker is located in the generator housing.

• When the relay is active the normally open contacts close. This trips the optional circuit breaker when a shutdown fault occurs.

• The relay has no normally closed contacts.

K3 - Crank Termination Relay (CTR)

The CTR is used to indicate that the engine is beginning to run without cranking. The GSC+ activates the CTR when the engine speed is greater than the crank terminate setpoint (400 RPM, setpoint P011) and the starting motor relay has been deactivated. The CTR deactivates when the engine RPM reaches 0.

• When the relay is active the normally open contacts close. This activates the optional generator running relay (GRR) and enables an optional governor switch (GS) and the governor synchronizing motor. The GRR is located in the customer connection box. The GS is located on the front panel.

• When the relay is inactive the normally closed contacts close.

K4 - Starting Motor Relay (SMR)

• When the relay is active the normally open contacts close. This activates the starting motor magnetic switch.

• When the relay is inactive the normally closed contacts close.

K5 - Run Relay (RR)

• When the relay is active the normally open contacts close. This provides power to the optional start aid switch (SAS) and the crank relay (CR).

• When the relay is inactive the normally closed contacts close. This contacts are for customer use.

K6 - Air Shutoff Relay (ASR)

• When the relay is active the normally open contacts close. This activates an optional air shutoff solenoid during fault shutdowns.

• When the relay is inactive the normally closed contacts close.

K7 - Fuel Control Relay (FCR)

• When the relay is active the normally open contacts close. This activates the fuel control solenoid via the fuel control relay in the junction box. Also, power is supplied to the optional electronic governor.

• The relay has no normally closed contacts.

K8 - Programmable Spare Relay (PSR)

This relay is for customer use. It is programmable to activate for a variety of conditions.

• When the relay is active, the normally open contacts close.

• When the relay is inactive, the normally closed contacts close.