XQ2000 Power Module Caterpillar

Electronic Modular Control Panel 4 (EMCP 4)

Usage:

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Illustration 1	g03645228
(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) Alarms acknowledge 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

EMCP 4.3/4.4

The EMCP 4 performs generator voltage regulation, generator temperature monitoring, generator AC metering, and engine monitoring.

The main component of the Electronic Modular Control Panel 4.3/4.4 ( EMCP 4.3/4.4) is the electronic control module (ECM). This section discusses the display, keys, and indicators on the control system panel of the ECM. The EMCP 4.3/4.4 panel is used for monitoring and controlling many of the generator set functions. Some of the functions include:

Sending start and stop signals to the engine
Providing visual and audible indications when warning or shutdown events occur
Displaying engine information and AC generator set information
Displaying Suspect Parameter Number (SPN) and Failure Mode Identifier (FMI) information for events
Programming set points for the standard EMCP 4.3/4.4 (The set points for optional modules are set with the use of Cat ET.)
Annunciator configuration is done within the EMCP 4.3/4.4

ECM Front Panel Components

The following components can be found on the front panel of the ECM:

Information Display
Alarm Indicators
Alarm Acknowledge/Silence Key
Event Reset Key
Function Keys
Navigation Keys
System Overview Keys

Information Display

(1) Display Screen - Information from the EMCP 4 is displayed on the display screen. This screen is used for the following programming and display functions.

Displaying AC parameter information of the generator set
Displaying engine parameter information of the generator set
Programming set points for the generator
Displaying engine event information
Displaying event codes from other modules
Programming the display preferences of the EMCP 4.3/4.4
Changing password levels of the EMCP 4.3/4.4

Alarm Acknowledge/Silence Key

(11) Alarm Acknowledge/Silence Key - Pressing the alarm acknowledge/silence key will cause the horn relay output to turn off and silence the horn. Pressing the key will also make yellow or red flashing lights turn off or 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 J1939 Data Link to silence horns on annunciators. However, other modules must be configured in order to listen to the global acknowledge.

Event Reset Key

(13) Event Reset Key - The event reset button will clear all inactive fault conditions.

Alarm Indicators

Yellow Warning Light - The yellow warning light (10) is located directly above the alarm acknowledge/silence key (11). A flashing yellow light indicates that there are unacknowledged active warnings. A solid yellow light indicates that there are acknowledged warnings active. If there are any active warnings, the yellow light will change from flashing yellow to solid yellow after the alarm acknowledge/silence key is pressed. If there are no longer any active warnings, the yellow light will turn off after the alarm acknowledge/silence key is pressed.

Red Shutdown Light - The red shutdown (12) light is located directly above the event reset key (13). 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 is pressed. Any condition that has caused a shutdown event must be manually reset. If there are no longer any active shutdown events, the red light will turn off.

Function Keys

(2) F4 - Pressing the F4 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.

(3) F3 - Pressing the F3 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.

(4) F2 - Pressing the F2 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.

(5) F1 - Pressing the F1 key will enable the function that is described on the screen directly above this key. When this key is defined on screen to scroll up or down, the Scroll Up and Scroll Down keys will also function the same.

(15) RUN - Pressing the "RUN" key causes the EMCP 4.3/4.4 to enter the run mode.

(16) AUTO - Pressing the "AUTO" key causes the EMCP 4.3/4.4 to enter the auto mode.

(17) STOP - Pressing the "STOP" key causes the EMCP 4.3/4.4 to enter the stop mode or the cool down mode.

(18) Escape Key - The escape key is used during menu navigation in order to navigate up through the menu/submenu structure. Each key press causes the user to move backward (upward) through the menus. The escape key is also used in order to cancel of data entry screens during set point programming. If the escape key is pressed during set point programming, then none of the changes displayed on the screen will be saved to memory.

(21) OK Key - The OK key is used during menu navigation in order to move forward (downward) through the menu/submenu structure. The key is also used during set point programming in order to save set points changes. Pressing the OK key during set point programming causes set point changes to be saved to memory.

Navigation Keys

(6) Control Key - The control key will navigate the display to the screen that allows the user to monitor and/or adjust various special control features.

(9) Main Menu Key - The main menu will navigate the display to the main menu directly without having to navigate out of menus.

(14) Event Log - The event log button will navigate the display to the event log.

(19) Up Key - The up key is used in order to navigate up through the various menus or monitoring screens. The key is also used during set point entry. During numeric data entry, the key is used in order to increment the digits (0-9). If the set point requires selection from a list, then the key is used to navigate up through the list.

(20) Right Key - The right key is used during set point adjustment. During numeric data entry, the key is used in order to choose which digit is being edited. The key is also used during certain set point adjustments in order to select a check box or to deselect a check box. If a box has a check mark inside, then pressing the key will cause the check mark to disappear. If the box does not have a check mark inside, then pressing the key will cause a check mark to appear inside.

(22) Down Key - The down key is used in order to navigate down through the various menus or monitoring screens. The key is also used during set point entry. During numeric data entry, the key is used in order to decrement the digits (0-9). If the set point requires selection from a list, then the key is used to navigate down through the list.

(23) Left Key - The left key is used during set point adjustment. During numeric data entry, the key is used in order to choose which digit is being edited. The key is also used during certain set point adjustments in order to select a check box or to deselect a check box. If a box has a check mark inside, then pressing the key will cause the check mark to disappear. If the box does not have a check mark inside, then pressing the key will cause a check mark to appear inside.

System Overview Keys

(7) AC Overview - Pressing the AC overview key displays the first screen of AC information for the generator set. This initial information page contains various AC parameters that summarize the electrical operation of the generator set. Additional AC parameters can be viewed by pressing the down key multiple times.

(8) Engine Overview - Pressing the engine overview key displays the first screen of engine information. This initial information page contains various engine parameters that summarize the operation of the engine. Additional engine parameters can be viewed by pressing the down key multiple times.

Genset Controls

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Illustration 2	g03645301
(24) Emergency stop button (25) CAN 1 Connector

Emergency stop button (24) - The emergency stop button is used to shut down the engine during an emergency situation.

CAN1 Connector (25) - Connection for Cat service tool on the CAN1 network (used for the Engine ECM and EMCP).

Inside of the Control Panel

Generator Circuit Breaker

The generator circuit breaker is a 100% rated universal power circuit breaker. The generator circuit breaker is designed to protect electrical systems from damage caused by overloads, short circuits, and equipment ground faults. The circuit breaker is designed to open and close a circuit electrically. The circuit breaker is designed to open the circuit automatically at a predetermined over current setting.

The generator circuit breaker is operated via a stored energy mechanism. The stored energy mechanism can be charged manually or charged by using a motor. The closing time is less than five cycles.

Note: Breaker closing and opening operations are initiated by electrical signals from the automatic generator set controller (AGC) controller. Use operator controls on the AGC controller to close and open the breaker. Do not use the open and close buttons on the front of the breaker for operation.

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Arc Flash Hazard And Electric Shock Hazard: To reduce the risk of arc flash and electrical shock injury to personnel, always comply with NFPA 70E, OSHA, and all other applicable electrical safety regulations when servicing any Caterpillar UPS equipment. Prior to performing service that requires opening a tool, access door, or removing a dead front panel, this equipment must be isolated from all sources of power.

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Illustration 3	g03582622
(14) Cradle rejection kit (15) Lifting tab (16) Trip unit connection to over current trip switch (17) Auxiliary control connection (18) Shunt trip (MX2) or under voltage trip device (MN) (19) Arc chamber (20) Shunt trip (MX1) (21) Auxiliary contact connection (22) Additional switches (OF) or combined connected/closed switches (EF) (23) Auxiliary form "C" contacts (24) Shunt close (XF) (25) Ready-to-close contact (PF) (26) Charging handle (27) Spring charging motor (MCH) (28) Close breaker push button (29) Open breaker push button (30) Operation counter (31) Trip unit (32) Over current trip switch (SDE1) (33) Circuit breaker communication module (34) Over current trip switch (SDE2) or electric reset (35) Face plate (36) Charge/discharged indicator (37) Open/close indicator (38) Push-to-reset fault trip button

Over Current Fault Trip Indicator

If the generator circuit breaker experiences an overcurrent event, the circuit breaker will automatically open and the reset button (39) will extend. The circuit breaker will not be operational until the reset button (39) is pushed into the normal operating position.

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Illustration 4	g03582651
(39) reset button

Micrologic Trip Unit

The Micrologic trip unit is one component of the generator circuit breaker assembly. Micrologic trip units protect power circuits and provide current measurements, overload protection, and short-circuit protection.

Note: Equipment ground faults protection would require the user to install a separate CT kit which is not included in the power module.

Protection thresholds and delays are set using the rotary switches. The selected values are momentarily displayed in amperes and in seconds. A full-range of long-time settings are available via field-installable rating plug.

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Illustration 5	g03582637
(40) Test lamp, and reset (41) Trip cause indicator (42) Digital display (43) Three-phase bar graph and ammeter (44) Navigation buttons (45) Overload signal (46) Long-time rating screw (47) Long-time current setting and tripping delay (48) Short-time pickup and tripping delay (49) Instantaneous pickup (50) Electronic push-to-trip (51) Ground fault pickup and tripping delay (52) Test connector

AGC

The AGC is the primary means of starting and operating the unit. If started via the EMCP, the variable frequency drive (VFD) will not run in Remote/Auto mode. The VFD must be turned ON in local mode to operate the cooling fans if the unit is started via EMCP.

The AGC has two displays. The upper display is for primary operator control to start/stop the engine and open/close the generator breaker. The lower display is for secondary operator control buttons, and status indicators.

Upper AGC Display

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Illustration 6	g03607851
(32) Alarm lamp (33) View button (34) Yellow alarm indicator (35) Red alarm indicator (36) Log button (37) Power indicator (38) Self check OK indicator (39) PM CAN indicator (40) Select/arrow buttons (41) Back button (42) Local button/indicator (43) Remote button/indicator (44) Bus voltage indicator (45) Close generator circuit breaker button (46) Breaker closed indicator (47) Generator voltage indicator (48) Generator running indicator (49) Stop button (50) Start button (51) Jump button (52) Info button

Alarm lamp (32) - this indicator is illuminated when any active alarms are present. The indicator flashes for new alarms.

View button (33) - this button allows the user to select views on the display screen.

Yellow alarm indicator (34) - this indicator will illuminate when the engine ECM has transmitted an alarm condition over the J1939 CAN1 bus.

Red alarm indicator (35) - this indicator will illuminate when the engine ECM has transmitted a shutdown condition over the J1939 CAN1 bus.

Log button (36) - this button displays the events that have occurred and recorded in the history.

Power indicator (37) - this indicator will illuminate when the AGC4 power supply input is within tolerance.

Self check OK indicator (38) - this indicator will illuminate when AGC4 hardware and software are functioning correctly.

PM CAN indicator (39) - this indicator will illuminate when the AGC4 is connected to plant management CAN bus.

Select/arrow buttons (40) - these buttons are used to navigate through the user menus and screens.

Back button (41) - this button returns the screen to the previous selection.

Local button/indicator (42) - this button initiates the "LOCAL" mode of the controller. The indicator is lit when "LOCAL" mode is selected.

Remote button/indicator (43) - this button initiates the "REMOTE" mode of the controller. The indicator is lit when "REMOTE" mode is selected.

Bus voltage indicator (44) - this indicator will illuminate when bus voltage, and frequency are within limits.

Close generator circuit breaker button (45) - this button closes the generator circuit breaker when pressed. A second press on this button will open the generator circuit breaker.

Breaker closed indicator (46) - this indicator will illuminate when the generator breaker is closed.

Generator voltage indicator (47) - this indicator will illuminate when the generator voltage, and frequency are within limits.

Generator running indicator (48) - this indicator will illuminate when the generator is running.

Stop button (49) - this button stops the generator set when the EMCP is in AUTO.

Start button (50) - this button starts the generator set when the EMCP is in AUTO.

Jump button (51) - this button allows the user to scroll to specific parameters with the use of the scroll buttons.

Info button (52) - this button gives the user a more detailed description of alarms that are present.

Lower AGC Display

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Illustration 7	g03615779
(53) "GEN AVAILABLE" lamp (54) "OVERCURRENT" lamp (55) "EXT FAULT" lamp (56) "BATT ALARM" lamp (57) "DELTA AIR FILTER" lamp (58) "DELTA FUEL FILTER" lamp (59) "METHANE DET." lamp (60) "OIL ALARM" lamp (61) "EMCP NOT AUTO" lamp (62) "EMCP ALARM" lamp (63) "VFD ALARM" lamp (64) "VPS ALARM" lamp (65) "RDTR ALARM" lamp (66) "COOLANT ALARM" lamp (67) "FIXED POWER" lamp (68) "MANUAL" lamp (69) "RESET" button (70) "DATA VIEW" button (71) "RPM UP" button (72) "RPM DOWN" button (73) "VOLTAGE UP" button (74) "VOLTAGE DOWN" button (75) "FIXED POWER ON/OFF" button (76) "MANUAL ON/OFF" button

"GEN AVAILABLE" lamp (53) - If the lamp is illuminated green, the generator is ready to run.

"OVERCURRENT" lamp (54) - If illuminated, there is a generator trip on overcurrent.

"EXT FAULT" lamp (55) - If illuminated, there is a plant trip, or remote emergency stop trip.

"BATT ALARM" lamp (56) - If illuminated, there is a battery charger alarm/fault.

"DELTA AIR FILTER" lamp (57) - Delta pressure across the generator terminal box air filter is high.

"DELTA FUEL FILTER" lamp (58) - Delta pressure across the primary fuel water separator filter on the fuel tank.

"METHANE DET." lamp (59) - If illuminated, methane has been detected in the container.

"OIL ALARM" lamp (60) - Make-up oil tank low-level alarm.

"EMCP NOT AUTO" lamp (61) - If illuminated, the EMCP is not in "AUTO" mode.

"EMCP ALARM" lamp (62) - If illuminated, the EMCP has an alarm/fault.

"VFD ALARM" lamp (63) - If illuminated, the variable frequency drive (VFD) has an alarm/fault.

"VPS ALARM" lamp (64) - If illuminated, the gas train system has an alarm/fault.

"RDTR ALARM" lamp (65) - Activates in the event one of the following occurs: radiator breaker trip, auto lube pump failure and VFD failure.

"COOLANT ALARM" lamp (66) - Activates in the event one of the following occurs: coolant level is low and coolant temperature is high.

"FIXED POWER" lamp (67) - If illuminated, the unit is in "FIXED POWER" mode. Speed/KW, and voltage/KVar can be manually controlled by the operator.

"MANUAL" lamp (68) - If illuminated, the unit is in "MANUAL" control mode. Speed/KW, and voltage/KVar can be manually controlled by the operator.

"RESET" button (69) - Press to acknowledge AGC4 alarms/shutdown, or to reset VFD fault.

"DATA VIEW" button (70) - Press to jump to "VIEW 1".

"RPM UP" button (71) - Press to increase generator speed when breaker is open, and "MANUAL" mode is on. Push to increase KW when breaker is closed, and "MANUAL" mode is on.

"RPM DOWN" button (72) - Press to decrease generator speed when breaker is open, and "MANUAL" mode is on. Push to decrease KW when breaker is closed, and "MANUAL" mode is on.

"VOLTAGE UP" button (73) - Press to increase generator voltage when breaker is open, and "MANUAL" mode is on. Push to increase KVar when breaker is closed, and "MANUAL" mode is on.

"VOLTAGE DOWN" button (74) - Press to decrease generator voltage when breaker is open, and "MANUAL" mode is on. Push to decrease KVar when breaker is closed, and "MANUAL" mode is on.

"FIXED POWER ON/OFF" button (75) - Press to turn "FIXED POWER" mode on or off.

"MANUAL ON/OFF" button (76) - Press to turn "MANUAL" mode on or off.

AGC Display Navigation

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Illustration 8	g03790614

To go to a menu, press the "JUMP" button on the AGC upper display, and then enter the desired menu number using the arrow keys, and "ENTER" key. When prompted, enter the password "2002".

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Illustration 9	g03635404
AGC display screen showing "Menu group number 1000" (77) SP (menu 1001) set point (78) DEL (menu 1002) delay (79) OA (menu 1003) output A (80) OB (menu 1004) output B (81) ENA (menu 1005) enable (82) FC (menu 1006) fail class

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Illustration 10	g03635428
(83) Minimum setting (84) Actual setting (85) Maximum setting

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Illustration 11	g03635446
(86) Cursor (underlined text)

The left and right arrow keys change the cursor position. The "SEL" key is used to make a selection, and the up and down arrow keys are used to change settings.

Modes of Operation

Local or Remote Control

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Illustration 12	g03634476

The AGC can be set for the operator to control the unit manually ("LOCAL" mode). The AGC can alternately be set for the plant control system to control the unit automatically ("REMOTE" mode). The mode can be selected by pressing either the "LOCAL", or "REMOTE" buttons on the AGC display. Mode indicators located next to the buttons illuminate depending on which mode is active.

In "LOCAL" mode, the following operations are affected:

Engine can be started/stopped by pressing the "START" button on the upper AGC display, if the EMCP is in "AUTO" mode
Generator breaker can be opened/closed by pressing the breaker symbol on the upper AGC display
Engine start/stop and generator breaker operation by remote means, such as digital inputs, or commands via communications, are disabled.

In "REMOTE" mode, the following operations are affected:

Engine cannot be started/stopped using the upper AGC display
Generator breaker cannot be opened/closed using the upper AGC display
Engine start/stop and generator breaker operation by remote means, such as digital inputs, or commands via communications, are enabled. The EMCP must be in "AUTO" mode for remote means to work.

Manual Mode

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Illustration 13	g03635092

A button is provided on the lower AGC display to enable/disable certain local operator functions, in "MANUAL" mode.

When "MANUAL" mode is activated, the generator set can be controlled from the display and with digital inputs. The following operations are affected:

Engine speed can be adjusted up/down using the lower AGC display
Generator Kw output can be adjusted up/down using the lower AGC display (when paralleled to the utility)
Generator voltage can be adjusted up/down using the lower AGC display
Generator Kvar output can be adjusted up/down using the lower AGC display
Synchronization failure alarm is disabled

To enter and exit "MANUAL" mode, use the following procedure:

Ensure that the unit is in power management mode.
Press fixed power button (the unit will go into fixed power mode).
Press manual button (the unit will go into manual mode in fixed power mode).
Use up/down buttons to control generator output manually.
Press manual button to exit manual mode.
Press fixed power button to exit fixed power mode (the unit will return to power management mode).

Fixed Power Mode

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Illustration 14	g03634838

Fixed power mode is used when a single unit is base loading to the utility in which the generator output is controlled by setpoints contained within the controller and nothing controlled over CAN communications.

A button is provided on the lower AGC display to enable/disable fixed power (or base load) mode.

In fixed power/base load (remote mode), the user starts the unit and synchronizes to the utility when the remote "auto start"/"auto stop" signal is activated. After the generator breaker closure, the unit ramps up the load to the setpoint level. When the signal is deactivated, the unit is unloaded and stopped after the cooling period.

When the generator breaker is closed, the generator power output continues to rise in ramp up steps, determined by the number of steps in menu 2615. For example, if the delay point is set to 20%, and the number of load steps is set to 3, the unit will ramp to 20%, wait the configured delay time, ramp to 40%, ramp to 60%, wait, and then ramp to the present power setpoint.

Note: For the load steps to be active, menu 2614 ENABLE must be set to "ON".

Island Mode

Island mode is used when paralleling multiple units on a common bus, powering an isolated load, or for a single unit powering an isolated load. In this mode, load sharing is performed via analog signals shared among all units and nothing controlled over CAN communications.

In island mode (manual mode), ensure that each unit is set to "LOCAL" mode. Start one unit, and close the breaker for that unit to the dead bus. If paralleling multiple units, go to each of the other units. Start the units, and parallel the units to the live bus. As load is applied, the real and reactive power is automatically shared proportionally among all paralleled units via analog load share signals, shared among all paralleled units.

Power Management Mode

Power management mode is used when two or more units communicate to each other or to a plant control system over CAN communications.

In island applications, power management mode enables CAN communications among other units. In utility applications, power management mode enables CAN communications with the plant control system.

Operation Procedures

The following describes how to start the unit, control the generator breaker, paralleling, and generator load control based on different operation scenarios.

The following table contains the relevant settings that must be made prior to startup depending on application:

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Table 1
Application	AGC Configurations
	Menu 9160	Menu 6070	Menu 7531	Menu 7051 and 7052
Island Mode/Single Unit	A1	Island Mode	N/A	N/A
Island Mode/Multi- Units	A2	Power Management Mode	Assign unique number to each unit	N/A
Utility Mode/Base Load	A3	Fixed Power Mode	N/A	Set desired % load (7051) and power factor (7052)

A1 (menu 9160) used for any of the following applications:

Single unit, prime power
Multiple units paralleling in island mode using analog load share lines
Commissioned unit in a typical IPP plant system (AGC software must be customized as per the plant configuration)

A2 (menu 9160) used for the following application:

Two units (max) paralleling in island mode with CAN communications from AGC-to-AGC

Note: The unit is configured for two generator sets (ID1 and ID2). For more than two generator sets, the AGC software must be customized.

A3 (menu 9160) used for the following application:

Single unit, base load (fixed power). Non-typical plant application.

Island Mode/Single Unit

Manual Control Startup Procedure

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Illustration 15	g03643830

Press the "AUTO" button (16) on the EMCP to put the EMCP into auto mode.
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Illustration 16 g03643840
Verify "LOCAL" mode is active. If "LOCAL" mode is inactive, press the "LOCAL" button (42) on the AGC upper display. The unit is now ready to start.
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Illustration 17 g03643848
Press the "START" button (50) on the AGC upper display to start the engine.
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Illustration 18 g03643808
Press the breaker symbol (45) on the AGC upper display in order to close the generator breaker after the two indicators, (47) and (48) illuminate.
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Illustration 19 g03643853
When the generator breaker closes, indicators (44) and (46) will illuminate. The unit is now powering the load.

Manual Control Shutdown Procedure

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Illustration 20	g03643948

Press the "STOP" button (49) on the AGC upper display to open the generator breaker immediately, and put the engine in cooldown/stop mode.

Note: Always use the AGC upper display to start/stop the engine when using manual control. Using the EMCP for startup or shutdown will result in improper equipment operation.

Island Mode/Single Unit

Automatic Control Startup Procedure

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Illustration 21	g03643830

Press the "AUTO" button (16) on the EMCP to put the EMCP into auto mode.
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Illustration 22 g03643818
Verify "REMOTE" mode is active. If "REMOTE" mode is inactive, press the "REMOTE" button on the AGC upper display. The unit is now ready to start.
Close the remote start contact to activate the AGC digital input. The engine will start, the generator will build up voltage, and the generator breaker will close automatically.
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Illustration 23 g03643853
When the generator breaker closes, indicators (44) and (46) will illuminate. The unit is now powering the load.

Automatic Control Shutdown Procedure

Open the remote start contact to open the generator breaker immediately, and put the engine in cooldown/stop mode.