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| Illustration 1 | g00591520 |
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Typical EMCP II (1) Generator Set Control + (2) Alarm module (option) (3) Custom alarm module (option) (4) Control panel (operation) (5) Caterpillar Monitoring System | |
Each component of the EMCP II+ is described below. The components and the control panel operation is comparable for the EMCP II.
The Generator Set Control + (GSC+) is the main component of the EMCP II+. The control is powered by a battery system with 24 VDC or 32 VDC. The control has several functions and features.
The GSC+ controls normal starting and stopping of the engine. When a signal is received to start the engine, the fuel and the starting motor are activated. When the engine speed reaches the crank terminate speed, the starting motor is disengaged. When a signal is received to stop the engine, the fuel is shut off to the injectors.
The control system is designed to remove power from the GSC+ when the Engine Control Switch is in the "OFF/RESET" position.
However, the GSC+ will not permit power to be removed until the crank termination relay and the fuel control relay are OFF for approximately 70 seconds.
Note: A jumper wire may be installed between terminal 6 and terminal 9 of the Engine Control Switch. The wire will allow the GSC+ to remain powered while the Engine Control Switch is in the "OFF/RESET" position. This can be used by service technicians to troubleshoot a shutdown fault that is ACTIVE.
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| Illustration 2 | g00591650 |
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(1) Indicators
(2) Upper display (3) Lower display (4) Keypad | |
The GSC+ activates the indicators (1) for alarm conditions and for shutdown conditions. The GSC+ can transmit signals that represent the conditions to alarm modules in order to activate annunciation. The GSC+ controls shutdowns that are caused by events or by diagnostics from a failed component. For a description of the indicators, see the "Alarm Mode" and "Shutdown Mode" topics below.
The GSC+ monitors the status of engine operation and generator operation. Displays (2) and (3) show the following items: status of engine operation, status of generator operation, event codes, diagnostic codes and programmed information.
Keypad (4) is used for changing displays (2) and (3). The keypad is also used for programming certain features. For example, the crank cycle and the cooldown timer can be programmed.
Note: To ensure proper operation with EUI systems, the "P023" setpoint of the GSC+ must be programmed to a value of "2". Otherwise, the engine will not operate properly. Also, an erroneous component identifier ("CID 590") will be LOGGED. For information on programming, see the EMCP II Service Manual.
The GSC+ has connectors for an optional Customer Communication Module (CCM). The CCM allows the generator set to be controlled and monitored from a remote location. Remote communications can be established with any personal computer or other RS-232C communications device.
The GSC+ has these four modes of operation: normal, alarm, shutdown and service.
The GSC+ is in normal mode during normal operation. None of the indicators are illuminated. The upper display does NOT show "SERV".
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| Illustration 3 | g00591848 |
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Keypad (1) "POWER METER" (2) "AC METER" (3) "ENGINE METER" (4) "LAMP TEST" (5) "ALARM CODES" (6) "EXIT" (7) "SERVICE MODE" | |
Note: Keys (1), (2), (3), (4), and (5) function differently when the GSC+ is in the service mode.
The upper display shows the status of the following parameters for the generator: AC voltage, current and frequency. To view the following information individually, press the "AC METER" key (2) (Illustration 3):
- Average voltage, frequency of the generator, and total current
- Line-to-line voltage, frequency of the generator, and line current for any phase
- Line-to-line voltage for all three phases
- Line current for all three phases
- Line to neutral voltage for all three phases
Note: When the total current increases to more than 9999 amperes, the current is displayed in kA.
Note: For the delta generator set, the line to neutral voltage is not shown when the "P032" setpoint is programmed to "1".
The lower display shows values for these items:
- Power output of the generator
- Status of engine parameters
- Status of the relays
The left side of the lower display serves as a power meter for the generator set. The following parameters scroll automatically: total real power (kW), total reactive power (kVAR), percentage of rated power (% kW), average power and total output of energy (kW/h).
In order to display a particular parameter continuously, press "POWER METER" key (1) (Illustration 3) for less than five seconds.
If the "POWER METER" key is pressed for more than five seconds and then released, these additional parameters scroll on the display: total real power (kW), real power of each phase, total apparent power (kVA), total reactive power (kVAR), percentage of rated power (% kW), average power, power factor of each phase, total output of energy (kW/h) and total reactive power output (kVAR/h).
Note: All of the real values for power are identified with a positive "+" sign or a negative "-" sign. A negative sign indicates reverse power.
Note: For the delta generator set, the real power and the power factor for all three phases are not displayed when the "P032" setpoint is programmed to "1".
The right side of the lower display shows the value of the following engine parameters:
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Exhaust temperature (option) |
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Engine oil temperature (option) |
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System battery voltage |
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Engine hours |
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Engine speed (rpm) |
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Engine oil pressure |
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Engine coolant temperature |
The value of a parameter is displayed for two seconds before the value of the next parameter is displayed. A pointer above the symbol identifies the corresponding parameter. See Illustration 4.
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| Illustration 4 | g00591851 |
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Engine oil pressure of 64 psi | |
When "ENGINE METER" key (3) (Illustration 3) is pressed, the value for one parameter is displayed continuously. The pointer flashes above the symbol for the parameter.
For more information on the engine parameters, see this Operation and Maintenance Manual, "Gauges and Indicators" topic.
The status of the relays are displayed on the bottom of the lower display. When a relay is activated, the corresponding relay is shown. The relays are represented by "K1", "K2", etc.
Note: An alarm will activate if a setpoint that is programmed into the monitoring system for a parameter is reached. For information on the setpoints, see this Operation and Maintenance Manual, "Monitoring System" topic (Operation Section).
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"FAULT ALARM" |
An alarm indicates a serious condition that requires immediate attention. If an alarm condition occurs, the yellow "FAULT ALARM" indicator flashes.
If the panel has an optional alarm module, an indicator on the module will also flash and the horn will annunciate. See the "Alarm Module" topic below.
To determine the cause of the alarm, press "ALARM CODE" key (5) (Illustration 3). The event code will appear on the upper display. For descriptions of the codes, refer to the EMCP II Service Manual, or refer to the film that is on the door of the control panel.
To test the operation of the indicators, press "LAMP TEST" key (4) (Illustration 3). The ten indicators will illuminate continuously and every segment of the upper display and the lower display will be ON. If the alarm module (option) is included, all of the indicators will be ON and the horn will annunciate. If the "LAMP TEST" key is pressed for more than ten seconds, the lamp test is deactivated.
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"FAULT SHUTDOWN" |
If a shutdown occurs, the red "FAULT SHUTDOWN" indicator flashes. The engine is shut down immediately. If the event is caused by a condition that is associated with one of the five dedicated shutdown indicators, the indicator will also flash.
Spare indicators - In addition to the dedicated shutdown indicators, three spare indicators are included. The spare indicators are programmable. Two of the indicators may be used to indicate "COOLANT LOSS" and "HIGH OIL TEMPERATURE". The third indicator can be programmed according to the requirements of the system.
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"LOW OIL PRESSURE" |
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"EMERGENCY STOP" |
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"HIGH WATER TEMP" |
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"ENGINE OVERSPEED" |
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"OVERCRANK" |
Note: The GSC+ can be programmed to override the shutdowns for "LOW OIL PRESSURE" and "HIGH WATER TEMP". These conditions are programmed at the factory as shutdowns. When these conditions are overridden, the events will be treated as alarm conditions. Rather than flash, the indicators will illuminate continuously. The engine can be started and operated even if the alarm condition is present.
If the shutdown condition is NOT associated with one of the five dedicated shutdown indicators, an event code will be immediately shown on the upper display. For descriptions of the codes, refer to the EMCP II Service Manual, or refer to the film that is on the door of the control panel.
After a shutdown, the engine will not be allowed to start until the condition is corrected. Before the engine can be started, the Engine Control Switch must be turned to the "OFF/RESET" position.
The air shutoff (if equipped) is activated if the shutdown is caused by one of these occurrences: emergency stop, engine overspeed and failure of the speed sensor. In addition to the Engine Control Switch, the air shutoff must be reset before the engine can be restarted.
Keys (1), (2), (3), (4), and (5) function differently when the GSC+ is in the service mode. Illustration 5 shows the functions of the keypad when the GSC+ is in the service mode. The film on the door of the control panel also shows the functions.
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| Illustration 5 | g00591853 |
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Functions of the keypad during service mode (1) "SCROLL RIGHT" (2) "SCROLL UP" (3) "SCROLL DOWN" (4) "SELECT" (5) "ENTER" (6) "EXIT" (7) "SERVICE MODE" | |
"SCROLL RIGHT" key (1) - This key is used for viewing of information and for scrolling of information. This key represents the number 1 when the password is entered.
"SCROLL UP" key (2) - This key is used for scrolling up through information and for increasing the value of setpoint information. This key represents the number 2 when the password is entered.
"SCROLL DOWN" key (3) - This key is used for scrolling down through information and for decreasing the value of setpoint information. This key represents the number 3 when the password is entered.
"SELECT" key (4) - This key is used to select the information for viewing or for changing. This key is also used for starting and for stopping the automatic scroll.
"ENTER" key (5) - This key is used to enter information into the memory of the GSC+.
"EXIT" key (6) - This key only functions when the GSC+ is in the service mode. Press this key in order to exit the service mode.
"SERVICE MODE" key (7) - Press this key in order to activate the service mode. The upper display will flash "SERV".
The service mode cannot be activated under the following conditions:
- A shutdown condition is ACTIVE. To temporarily deactivate a shutdown condition, turn the Engine Control Switch to the "OFF/RESET" position.
- The Engine Control Switch is in the "AUTO" position.
Note: If a jumper wire from terminal 6 to terminal 9 is NOT installed on the Engine Control Switch, the GSC+ does not power up when the switch is in the "OFF/RESET" position. Any ACTIVE shutdown condition must be corrected before the service mode can be activated.
After the service mode is activated, the keypad can be used for the options that are listed in Table 1.
| Options of the Keypad During Service Mode | |
| Option | Description |
| OP1 (1) | View LOGGED diagnostic information. |
| OP2-0 (1) | View the setpoints for the engine and/or the generator. |
| OP2-1 (1) | View the setpoints of the protective relays. |
| OP2-2 (2) | View the setpoints for the calibration that was programmed at the factory. |
| OP3 (2) | Enter the password. |
| OP4 (2) | Clear LOGGED diagnostic information. |
| OP5-0 (2) | Program the engine and/or the generator. |
| OP5-1 (2) | Program the protective relays. |
| OP6 (2) | Program the spare input/output circuits. |
| OP8 (2) | Program the voltmeter and/or the ammeter. |
| OP9 (2) | Verify the setpoints for the engine. |
| OP10 (2) | Adjust the offset of the AC. |
| (1) | A password is NOT required. |
| (2) | A password IS required. |
For a complete description of the service mode, refer to the control panel's Service Manual.
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| Illustration 6 | g00591867 |
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(1) "STARTING AID" switch
(2) Engine Control Switch (3) Frequency adjustment (4) Voltage adjustment (5) "PANEL LIGHTS" switch (6) "EMERGENCY STOP" button | |
"STARTING AID" switch (1) - This optional switch can be used to manually inject ether during start-up. The "AUT" position will allow the Engine Control Module (ECM) to control the automatic ether injection system. The operator should utilize the functionality of this feature according to the strategy that is described in this Operation and Maintenance Manual, "Cold Weather Starting" topic (Operation Section).
Engine Control Switch (2) - This switch is used to control the engine operation. The switch has these four positions: "AUTO", "MAN. START", "COOLDOWN/STOP" and "STOP/RESET".
"AUTO" - This position (3 o'clock) enables the operator to control the engine from a remote location via a Customer Communication Module. The engine will start when the remote start/stop initiate contact is closed. The engine will shut down after the remote start/stop initiate contact opens. However, if the cooldown feature is programmed the engine will operate for the cooldown period before stopping.
"MAN. START" - When the switch is turned to this position (6 o'clock), the engine will immediately begin an engine start sequence. The engine will continue to run until the GSC+ receives a shut down signal or the switch is moved from this position.
"COOLDOWN/STOP" - This position (9 o'clock) is used for manual stopping. If the cooldown feature is programmed, the engine will operate for a cool down period when the switch is turned to this position. After the cooldown, the fuel injection is terminated in order to stop the engine. If the cooldown feature is not programmed, the engine will stop immediately. The power to the control panel is maintained when the switch is in this position. The cooldown can be programmed from 0 to 30 minutes. The default cooldown is 5 minutes.
"STOP/RESET" - When the switch is turned to this position (12 o'clock), power is removed from the control panel unless a jumper is installed between terminal 6 and terminal 9 of the Engine Control Switch. This position will also reset the diagnostic indicators if any events have occurred. If the engine is operating, the engine is immediately shut off.
Frequency adjustment (3) - This momentary contact switch is used to control the engine speed and the output frequency of the generator.
Voltage adjustment (4) - This rheostat is used to adjust generator voltage to the desired level. This control is used instead of the rheostat that is located on the voltage regulator of the generator.
"PANEL LIGHTS" switch (5) - This switch turns the panel lights on and off.
"EMERGENCY STOP" button (6) - This button is used to stop the engine quickly in an emergency situation. When this button is pressed, the fuel injection is disabled and the air shutoffs (if equipped) are activated.
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 7.
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| Illustration 7 | g00579773 |
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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) "BATTERY CHARGER FAILURE" (8) "AIR DAMPER CLOSED" (9) "ALARM SILENCE" button | |
The following four indicators are yellow:
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"HIGH COOLANT TEMP" (1) |
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" LOW COOLANT TEMP" (2) |
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" LOW OIL PRESSURE" (3) |
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" LOW FUEL LEVEL" (4) |
Note: These other yellow indicators are available as options: "GENERATOR ON LOAD", "CHARGER MALFUNCTION", "LOW OIL LEVEL" and "LOW COOLANT LEVEL".
The following four indicators are red:
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"SYSTEM NOT IN AUTO" (5) |
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" LOW BATTERY VOLTAGE" (6) |
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" BATTERY CHARGER FAILURE" (7) |
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" AIR DAMPER CLOSED" (8) |
Note: These other red indicators are available as options: "LOW OIL PRESSURE SHUTDOWN", "OVERCRANK SHUTDOWN", "HIGH COOLANT TEMP SHUTDOWN" and "OVERSPEED SHUTDOWN".
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"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 used for standby applications and that meet the requirements of NFPA 99 is available.
- A remote annunciator panel that is used with the alarm module that was previously mentioned (NFPA 99) is available.
- An alarm module used for standby applications and that meet the requirements of NFPA 110 is available.
- 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.
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| Illustration 8 | g00297407 |
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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, SEBU7050, "SR4B Generators and Control Panels".