3500B and 3500B High Displacement Generator Set Engines Caterpillar

Illustration 1	g00800583
EMCP II+ (1) Generator set control+ (GSC+) (2) Upper display (3) Lower display (4) Alarm module (ALM) (5) Custom Alarm module (CAM) (6) Speed potentiometer (7) Start Aid switch (8) Voltage adjust rheostat (9) Caterpillar monitoring system control (10) Scroll switch (11) Display mode (12) Fault alarm indicators (13) Keypad (14) Emergency stop push button (ESPB) (15) Panel lights (16) Engine control switch (ECS) (17) "LH/RH switch"

Illustration 2	g00800584
EMS II (1) Display mode (2) Scroll switch (3) Display module (4) Engine oil pressure (5) Engine coolant temperature (6) Engine intake manifold pressure (7) Engine exhaust temperature (8) Reset push button (9) "LH/RH switch" (10) Battery monitor (11) Engine oil temperature (12) Engine inlet air temperature (13) Fuel pressure (14) Emergency stop push button (ESPB) (15) Engine control switch (ECS)

EMCP II+

The EMCP II+ consists of the following components: Generator Set Control+ (GSC+), Instrument Panel, Alarm Module and Synchronizing Light Module. Refer to Illustration 1.

Generator Set Control+ (GSC+)

The main component of the EMCP II+ system is the generator set control+ (GSC+) (1). The GSC+ is designed to operate when the GSC+ is powered by 24 VDC or 32 VDC. The GSC+ monitors the generator set. The GSC+ controls many of the functions of the generator set. The GSC+ has four main components: fault indicators, upper display, lower display and keypad.

Fault Indicators

The ten fault indicators (12) 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, the spare fault indicators, the fault shutdown indicator and the dedicated shutdown indicators.

Upper Display

The primary function of the upper display (2) 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.

Lower Display

The lower display (3) 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.

Keypad

The keypad (13) is used to control the information that is shown on upper display (2) and lower display (3). 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 indicating that the scrolling is 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 (2) and lower display (3) are ON. On the optional alarm module, all of the indicators are ON and the horn sounds. The lamp test function automatically turns off when the key is held on for more than ten seconds.

Alarm Code Key - If fault alarm indicator is FLASHING, pressing this key causes the upper display (2) to show the corresponding alarm fault code. If the alarm code key is pressed again the upper display reverts to the previous display. If fault alarm indicator 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.

Instrument Panel

The engine control switch (ECS) (16) determines the status of the control panel. If the ECS is in the AUTO position the generator can be remotely controlled and remotely monitored with a Customer Communication Module. See Systems Operation, "Customer Communication Module". The GSC+ allows the engine to start whenever the remote initiating contact is closed. The engine starts and the engine runs while the ECS is in the MANUAL START position. If the ECS is placed in the COOLDOWN/STOP position the engine shuts down after a cooldown period. If the ECS is placed in the OFF/RESET position the engine shuts down immediately and any fault indicators are reset. If the ESPB is pushed in the dedicated emergency stop indicator will not be reset.

If the red emergency stop push button (ESPB) (14) is pressed, the fuel is shut off. The operator must turn the ESPB clockwise until the ESPB releases in order to restart the engine. Next turn the ECS to OFF/RESET and then turn the ECS to the MANUAL START.

The voltage adjust rheostat (VAR) (8) connects to the voltage regulator and the VAR is used to adjust generator voltage to the desired level. The VAR is used in place of the voltage level rheostat. The voltage level rheostat is located on the assembly for the generator voltage regulator.

The optional speed adjust potentiometer (SP) (6) is used to raise the engine speed. The optional speed adjust potentiometer is used to lower the engine speed when an electronic governor is used. An optional governor is mounted in this location if a governor with a speed adjust motor is used.

The optional start aid switch (SAS) (7) is present only on required generator sets. The starting aid system is a metered shot type of system. When the SAS is placed and the SAS is held in the ON position (momentary contact), the metered shot start aid system is activated. A specific amount of ether is metered into a holding chamber. When the SAS is released a solenoid allows ether to flow to the engine. The metered shot starting aid system deactivates when the following conditions are present.

• The contacts of the run relay (RR) open.

• The engine coolant temperature is sufficient to open the start aid temperature switch (SATS).

• The SAS is released to the OFF position.

Alarm Modules

The alarm module (ALM) (4) is an attachment. The ALM is located on the instrument panel. Red indicators and amber indicators are the visual indicators. The Horn is the audible indicator. A 24 VDC battery system or a 32 VDC battery system powers the ALM.

An alarm fault develops while the generator set is running and when the engine control switch (ECS) is in the COOLDOWN/STOP position or in the AUTO position. An alarm fault develops when the generator set is not running and when the engine control switch (ECS) is in the COOLDOWN/STOP position or in the AUTO position.

The ALM gives a warning of conditions that are becoming a problem. The warning occurs before conditions are severe enough to shut down the engine.

The custom alarm module (CAM) (5) is an attachment. The optional alarm module is used to display faults, alarms, and other conditions that are generated by customer supplied inputs.

Caterpillar Monitoring System Control

The Caterpillar monitoring system control (9) is used for accessing information on the engine and related engine components. See the Operation Section, "Caterpillar Monitoring System" for more information.

Switches

The scroll switch (10) is used to scroll through the various parameters that are available in a single mode. The main display module will scroll through the parameter display information that is available in the selected mode, when the scroll switch is held in the up position. If a continuous display of a parameter is desired, hold the scroll switch in the up position until the desired parameter information is displayed. Then, release the scroll switch. The parameter information will remain displayed until the main display module receives another switch signal.

The clear/mode switch (11) is used to move between five available modes of operation. This switch is also used to clear the information which is displayed on the main display module. The main display module will cycle through the five different modes of operation when the clear/mode switch is held down in the MODE position. When the desired mode is reached, release the clear/mode switch. The main display module will remain in that mode of operation until the clear/mode switch (11) is held down again. Information that is being displayed can be removed from the display by holding the clear/mode switch in the UP position for approximately one second. This will also remove the information from memory.

The "LH/RH" switch (17) is used to display both the right and left side parameter information for a group of sensors on a single gauge. For example, the left and right exhaust temperatures on an engine can be displayed if the "LH/RH" switch is toggled. The display area shows the value for one sensor at a time.

Engine Monitoring System (EMS II)

The EMS II consists of the following components: Main Display Module, Gauge Cluster Modules and Switches. Refer to Illustration 2.

Main Display Module

The main display module (3) is the "heart" of the system. The main display module receives information from the switches, sensors and other electronic controls on the engine by using the CAT data link. The main display module processes the information. The main display module outputs the information to the gauge clusters, display or the action alarm. The display components show the condition of engine systems and system diagnostic information.

There could be up to ten alert indicators on the main display module. Eight of these indicators are defined below. The other two indicators can be defined by the customer.

Emergency Stop Indicator or Engine Overspeed Indicator - This indicator is red. Emergency stop indicator or engine overspeed indicator FLASHES when the system has determined that the engine speed has exceeded the overspeed setpoint. This indicator also flashes when the system has determined that the emergency stop push button (ESPB) has been pressed.

Overcrank Indicator - This indicator is red. The overcrank indicator illuminates after the system has determined that the engine has not started within the preprogrammed amount of time. the crank cycle time has timed out. If the engine fails to start within the preprogrammed amount of time, the system will turn off the starting sequence. In this case, the overcrank indicator will flash. Another attempt to start the engine cannot be made until the engine control switch (ECS) is placed in the OFF/RESET position.

High Coolant Temperature Indicator - This indicator is red. The high coolant temperature indicator FLASHES when the engine coolant temperature is high.

Low Oil Pressure Indicator - This indicator is red. The low oil pressure indicator FLASHES when the engine oil pressure is low.

Low Coolant Level Indicator - This indicator is red. The low coolant level indicator FLASHES when the engine coolant level is low. This condition occurs when the customer supplied engine coolant level sensor is no longer submerged in the coolant.

Not In AUTO Indicator - This indicator is yellow. The not in AUTO indicator FLASHES when the ECS is not in the AUTO position. Remote starting of the engine is only possible when the ECS is in the AUTO position.

Low Coolant Temperature Indicator - This indicator is yellow. The low coolant temperature indicator FLASHES when the engine coolant temperature is low.

Local Control Enable Indicator - This indicator is yellow. The local control enable indicator FLASHES when the ECS is in the LOCAL/START position.

Spare Alert Indicators - There are two spare alert indicators. These indicators are defined by the customer.

Display Area - The display area has a row of six digits and two decimal points. The type of information which is shown on the display depends on the display mode. This information is received from sensors or senders or through the CAT data link.

Gauge Cluster Modules

The Gauge cluster modules display information that is received from sensors, senders, or the CAT data link. The information is used to drive the gauge needles to the appropriate position. Under normal operating conditions, the needles will point straight up. Use the "LH/RH" switch in order to display both the right and left side parameter information on a single gauge. The "LH/RH" switch is located next to the main display module.

The left Gauge cluster module displays the following items.

• engine oil pressure (4)

• engine coolant temperature (5)

• system voltage (10)

• engine oil temperature (11)

The right Gauge cluster module displays the following items.

• inlet air pressure (boost) (6)

• right side and left side exhaust temperature (7)

• inlet air temperature (12)

• fuel pressure (13)

Gauge cluster module (7) displays exhaust temperatures for both right side and left side values for the respective exhaust temperature sensors. The "LH/RH" switch can be toggled back and forth so that the left or right sensor information can be displayed individually.

Switches

Scroll Switch (2) - The scroll switch is used to scroll through the various parameters that are available in a single mode. The main display module will scroll through the parameter display information that is available in the selected mode, when the scroll switch is held in the up position. If a continuous display of a parameter is desired, hold the scroll switch in the up position until the desired parameter information is displayed. Then, release the scroll switch. The parameter information will remain displayed until the main display module receives another switch signal.

Clear/Mode Switch (1) - The clear/mode switch is used to move between five available modes of operation. This switch is also used to clear the information which is displayed on the main display module. The main display module will cycle through the five different modes of operation when the clear/mode switch is held down in the MODE position. When the desired mode is reached, release the clear/mode switch. The main display module will remain in that mode of operation until the clear/mode switch is held down again. Information that is being displayed can be removed from the display by holding the clear/mode switch in the UP position for approximately one second. This will also remove the information from memory.

"LH/RH" Switch (9) - The "LH/RH" switch is used to display both the right and left side parameter information for a group of sensors on a single gauge. For example, the left and right exhaust temperatures on an engine can be displayed if the "LH/RH" switch is toggled. The display area shows the value for one sensor at a time.

Emergency Stop Switch (14) - The emergency stop push button (ESPB) is used to shut down the engine during an emergency situation. The fuel to the engine is shut off and the air shutoff system will activate.

Reset Push Button (8) - The reset push button is used to reset alarm faults.

Engine Control Switch (ECS) (15) - The engine control switch is a four-position switch. OFF/RESET, REMOTE, LOCAL and SERVICE. When the ECS is turned to the OFF/RESET position the ECM is not powered. When the ECS is in the OFF/RESET position the engine will shut down. When the ECS is turned to the REMOTE position the ECM is powered. When the ECS is placed in the REMOTE position and the remote start/stop switch is closed, the engine start sequence will begin. When the ECS is turned to the LOCAL position the ECM will begin the engine start sequence. When the ECS is in the SERVICE position the ECM is powered.