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| Illustration 1 | g00789627 |
Electric Modular Control Panel II (EMCPII) (1) Generator set control (GSC) (2) Engine control switch (ECS) (3) Start aid switch (SAS) (4) Panel lights (5) Alarm module - optional (6) Synchronizing lights module - optional (7) Speed potentiometer (8) Voltage adjust rheostat (9) Emergency stop push button (ESPB) (10) Panel lights switch | |
The Electronic Modular Control Panel II (EMCP II) is located on top of the generator regulator housing. The control panel consists of a main panel with indicators, meters, and control switches. This control panel either has one empty slot or two empty slots. Control panels with one empty slot may be configured in one of the following ways:
- no module
- contain an alarm module.
- contain a synchronizing lights module.
Control panels with two empty slots may be configured in one of the following ways:
- no modules (two blank slots)
- one alarm module (one blank slot)
- one synchronizing lights module (one blank slot)
- one alarm module and one synchronizing lights module (zero blank slots)
The left side of the control panel contains the Generator Set Control (GSC). This is the main component of the system. The GSC (1) also displays generator output, fault conditions, and key engine parameters.
Main Control Panel
The main control panel may not contain all of the components that are shown below. Some components are optional. These components may not be required for your particular application.
Panel Lights (4) - The panel lights are controlled by the Panel Light Switch (10) .
Voltage Adjust Rheostat (8) - The voltage adjust rheostat is used to adjust the generator output voltage to the desired level.
Optional Governor Switch or Speed Potentiometer (7) - If the governor is equipped with a speed adjusting motor, the governor switch is used to adjust the engine speed. If the engine is equipped with an electric governor, a speed potentiometer is mounted in this location.
Starting Aid Switch (3) - The starting aid switch is used to inject ether into the engine for starting in cold weather conditions. After being turned to the ON position, the starting aid switch meters a specific amount of ether into a holding chamber. When the switch is released, the solenoid releases the ether into the engine.
Emergency Stop Push Button (9) - The emergency stop push button is used to shut down the engine during an emergency situation. In order to shut down the engine, the emergency stop push button shuts off the fuel. The emergency stop push button also activates the optional air shutoff (if equipped).
Engine Control Switch (2) - The engine control switch determines the status of the control panel. In the Automatic 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.
In the Manual Run position (6 o'clock), the engine will start and the engine will run. In order for the engine to continue to run, the ECS must remain in the Manual Run position.
In the Stop position (9 o'clock), the fuel solenoid stops the engine. This shutdown occurs after a programmable cooldown period.
In the Off/Reset position (12 o'clock), the fault lights are reset and the engine shuts down immediately.
Generator Set Control (GSC)
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, engine speed sensor, 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 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 the appropriate Service Manual Module 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 the appropriate Service Manual Module.
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 2 | g00604607 |
Display Area Of Generator Set Control (GSC) (1) Dedicated shutdown indicators. (2) Fault shutdown indicator. (3) Fault alarm indicator. (4) Upper display. (5) Lower display. (6) Keypad. | |
The eight 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. This fault code is shown on upper display (4) when the alarm codes 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, low coolant level, 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.
Low Coolant Level - The engine coolant level drops below the coolant loss sensor's probe. This probe is optional. When this fault occurs, the engine coolant level indicator lamp 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 3 | g00604607 |
Display Area Of Generator Set Control (GSC) (1) Dedicated shutdown indicators. (2) Fault shutdown indicator. (3) Fault alarm indicator. (4) Upper display. (5) Lower display. (6) Keypad. | |
The upper display (4) and lower display (5) of the GSC provide information about the generator set.
Upper display (4) 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 (4) is also used to show the various fault codes for system faults. For more information on fault codes, refer to the appropriate service manual module for fault descriptions.
Lower display (5) 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 (5) 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. When a GSC relay is activated, the corresponding indicator (K1, K2, etc) is shown on lower display (5). When a relay is not activated, the corresponding indicator (K1, K2, etc) is not shown.
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
Keypad (6) is used to control the information that is shown on upper display (4) and lower display (5). 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 the appropriate Service Manual Module. 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 (5). 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 (4) and lower display (5) is ON. On the optional alarm module, all of the indicators are ON and the horn will sound.
Alarm Codes Key - If fault alarm indicator (3) is FLASHING, pressing this key causes upper display (4) to show the corresponding fault code. Pressing this key again resumes the showing of generator output information on upper display (4). If fault alarm indicator (3) is OFF, this key has no function. See Systems Operation, "Fault Description" for more information on fault codes.
Exit Key - This key only functions when the GSC is in service mode. See Systems Operation, "Service Mode" for more information.
Service Mode Key - Pressing this key causes the GSC to enter service mode. See Systems Operation, "Service Mode" for more information.
Synchronizing Lights Module (If Equipped)
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| Illustration 4 | g00633434 |
Synchronizing Lights Module | |
The optional synchronizing lights module is mounted on the right side of the control panel. This module is not used when the control panel is equipped with the 2301A governor.
Synchronizing lights are used as an aid in paralleling units at no load and under load. Two lights are in the module. Each light is connected to the side with the load of the generator output circuit breaker. The lights are used to indicate when the voltages are in-phase. Close the circuit breaker in order to connect the generator with the load.
Note: Refer to Operation Section, "Parallel Operation" for information regarding the paralleling of two generators.
Refer to the appropriate Service Manual Module for all wiring and installation information.
Synchronizing Lights Module With Reverse Power Relay (If Equipped)
When a reverse power relay is added to a synchronizing lights module, the original synchronizing lights module will change in the following ways:
- The reverse power relay is mounted on the control panel interior.
- A reverse power fault is indicated by the Fault Shutdown Indicator on the front of the GSC.
The reverse power relay is a single phase protective relay. This relay is energized by power in only one direction. In a reverse power fault, the relay contacts close and the engine shuts down. This will take the generator off the line. The reverse power relay is equipped with a test switch and adjustments.
For additional information, refer to the appropriate Service Manual Module.
Alarm Module (If Equipped)
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| Illustration 5 | g00604696 |
Alarm Module | |
The optional alarm module is located on the right side of the control panel. 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.
One basic alarm module is used to satisfy the following requirements:
- Standby NFPA 99 alarm module
- Standby NFPA 110 alarm module
- NFPA 99 remote annunciator panel
- Prime power alarm
Several signals can be input to the module. Different decals on the front of the module indicate alarms or shutdown conditions.
Refer to the appropriate Service Manual Module for the following information:
- Wiring information
- Installation information
- Indicators that meet the requirements of NFPA
- Alarm functions that meet the requirements of NFPA
The front of the alarm module consists of four AMBER Light Emitting Diodes (LED). Relative to the configuration, these light emitting diodes can indicate various warnings:
- High Coolant Temperature
- Low Coolant Temperature
- Low Coolant Level
- Low Oil Pressure
- Generator On Load
- Charger Malfunction
- Low Oil Level
- Low Fuel Level
There are four RED light emitting diodes that can indicate the following conditions:
- Not-in AUTO condition
- Low DC Voltage
- Closed Air Damper
- Low Oil Pressure Shutdown
- Overcrank Shutdown
- High Coolant Temperature Shutdown
- Overspeed Shutdown
The front of the alarm module consists of an alarm horn and an Acknowledge/Silence Switch. For more information, refer to the appropriate Service Manual Module.