2001/10/01 Caterpillar

Improved Troubleshooting Procedures for EMCPII, EMCPII+, and EMCPII+P Annunciators {4490}

Usage:

3304 02B

Engine: 3116 DI T (S/N: 1NJ1-UP) 3208 DI T (S/N: 30A1-UP) 3208 DI STDBY T (S/N: 5YF1-UP) 3304 DI (S/N: 83Z1-UP) 3304B DI RENTL T (S/N: 9HK1-UP) 3306 DI T (S/N: 85Z1-UP) 3306B DI STDBY T (S/N: 2AJ1-UP) 3306B DI RENTL TA (S/N: 8JJ1-UP) 3306B (S/N: 8NS1-UP) 3306B ATAAC (S/N: 9NR1-UP) 3406 DI T (S/N: 75Z1-UP) 3406 DI PC T (S/N: 90U1-UP) 3406B (S/N: 2WB1-UP; 4JK1-UP; 4RG1-UP) 3406C (S/N: 1LS1-UP; 4ZR1-UP; 9ES1-UP) 3406E (S/N: 8AZ1-UP; 8FZ1-UP; 1MZ1-UP) 3408 (S/N: 67U1-UP; 78Z1-UP) 3412 (S/N: 38S1-UP; 81Z1-UP; 2WJ1-UP; 4BZ1-UP; 1EZ1-UP; 3FZ1-UP) 3412C (S/N: 9EP1-UP; BCW1-UP) 3456 (S/N: BGA1-UP; CBX1-UP; CCB1-UP) 3508 (S/N: 1ZF1-UP; 23Z1-UP; 3LS1-UP; 5PW1-UP; 5XM1-UP; 70Z1-UP; CAW1-UP; CNF1-UP; 1JZ1-UP) 3508B (S/N: 2HW1-UP; 4GM1-UP; 5KW1-UP; 6PN1-UP; BGX1-UP; CNB1-UP; 1FZ1-UP) 3512 (S/N: 24Z1-UP; 3MS1-UP; 3YF1-UP; 67Z1-UP; 6PM1-UP; 6WW1-UP; CMJ1-UP; FDR1-UP; 1KZ1-UP) 3512B (S/N: 2EZ1-UP; 4AW1-UP; 5AW1-UP; 6GW1-UP; 6WN1-UP; 8RM1-UP; BLF1-UP; BRK1-UP; CMC1-UP; 1GZ1-UP) 3516 (S/N: 25Z1-UP; 3NS1-UP; 4XF1-UP; 5SJ1-UP; 73Z1-UP; 7KM1-UP; 8TW1-UP; CAL1-UP; CMD1-UP; 1LZ1-UP) 3516B (S/N: 1NW1-UP; 6HN1-UP; 7RN1-UP; 8NW1-UP; BMB1-UP; BPJ1-UP; CPA1-UP; FDN1-UP; 1HZ1-UP) C-12 (S/N: BEL1-UP) D330C (S/N: 02B1-UP; 04B1-UP) D333C PC TA (S/N: 62M1-UP) D333C (S/N: 66D1-UP; 70R1-UP) D379A (S/N: 68B1-UP) D379B PC TA (S/N: 34Z1-UP) D398A (S/N: 66B1-UP) D398B PC TA (S/N: 35Z1-UP) D399 PC TA (S/N: 35B1-UP; 36Z1-UP) G3306 (S/N: 07Y1-UP) G3406 SI TA (S/N: 4FD1-UP) G3408 SI TA (S/N: 6NB1-UP) G3408 (S/N: 6RJ1-UP) G3408C (S/N: 3WR1-UP) G3412 SI (S/N: 3NK1-UP) G3412 SI TA (S/N: 7DB1-UP) G3412C (S/N: 6ZM1-UP) G3508 (S/N: 2JF1-UP; 4WD1-UP; 9TG1-UP) G3512 (S/N: 4KC1-UP; 5JD1-UP; 7NJ1-UP) G3516 (S/N: 3RC1-UP; 4EK1-UP; 8LD1-UP) G3524 (S/N: 7SZ1-UP) G379 NA SI (S/N: 72B1-UP) G398 NA SI (S/N: 73B1-UP) G399 SI TA (S/N: 49C1-UP)

Reference: Service Manual, RENR1200, "Electronic Modular Control Panel II+ (EMCPII+) For EUI Engines (Packaged in Mossville, IL and Lafayette, IN)"

Service Manual, RENR1254, "Electronic Modular Control Panel II+ (EMCPII+) For PEEC Engines (Packaged in Mossville, IL and Lafayette, IN)"

Service Manual, RENR2483, "Electronic Modular Control Panel II (EMCPII) (3306B, 3406C, 3406E, 3412, 3508, 3508B, 3512, 3512B, 3516, and 3516B Engines - Packaged in Larne, Northern Ireland)"

Systems Operation, Troubleshooting, Testing and Adjusting, RENR2484, "Electronic Modular Control Panel II+ (EMCPII+) (3306B, 3406C, 3406E, 3412, 3508, 3508B, 3512, 3512B, 3516, and 3516B Engines - Packaged in Larne, Northern Ireland)"

Service Manual, RENR2486, "Electronic Modular Control Panel II+ (EMCPII+) (For Generator Sets Packaged in Griffin Georgia, USA)"

Systems Operations, Testing and Adjusting, Schematics & Wiring Diagrams, SENR5394, "Electronic Modular Control Panel II (EMCPII) For Gas Engines (Packaged in Mossville, IL and Lafayette, IN)"

Systems Operations, Testing and Adjusting, SENR5398, "3508, 3508B, 3512, 3512B, 3516, and 3516B Engines EMCPII Basic (Packaged in Mossville, IL and Lafayette, IN)"

Service Manual, SENR5809, "Electronic Modular Control Panel II (EMCPII) For MUI Engines (Packaged in Mossville, IL and Lafayette, IN)"

Service Manual, SENR5827, "Electronic Modular Control Panel II (EMCPII) For Electronically Controlled Engines (PEEC Engines) (Packaged in Mossville, IL and Lafayette, IN)"

Service Manual, SENR5828, "Electronic Modular Control Panel II (EMCPII) For Rental Generator Sets (Packaged in Mossville, IL and Lafayette, IN)"

Service Manual, SENR5832, "Electronic Modular Control Panel II+ (EMCPII+) For MUI Engines (Packaged in Mossville, IL and Lafayette, IN)"

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Illustration 1	g00530281

Note: The following Annunciator troubleshooting procedures are also included in the publications that are listed above. These procedures have been consolidated in this article to aid annunciator troubleshooting.

The optional Alarm Module (ALM) may be mounted on the front panel or placed at a distance from the control panel as a remote annunciator. The ALM satisfies the National Fire Protection Association (NFPA) requirements for annunciating the presence of a diagnostic code.

The ALM communicates with the GSC+ by a serial data link. When the data link malfunctions, all of the indicators on the ALM that are controlled by the data link flash at a rate of .5 Hz.

Note: The maximum number of alarm modules or Customer Interface Modules (CIM) that may be connected to the serial data link is three. The maximum distance between a module and the GSC+ is 305 m (1000 ft). If these specifications are not met, the alarm module indicators may begin to flash. Also, the GSC+ may show a CID 0333 FMI 03 or a CID 0333 FMI 04. If the setup is not in compliance with these specifications, reduce the number of modules and/or shorten the distance to the modules.

Note: If the harness connector is disconnected from the GSC+ during these troubleshooting procedures, diagnostic codes are created. Clear these created diagnostic codes after the particular problem is corrected.

The following troubleshooting procedures are included in this article:

Indicators of Alarm Module or Remote Annunciator Are Constantly Flashing
GSC CID 0333 - FMI 03
GSC CID 0333 - FMI 04

Indicators of Alarm Module or Remote Annunciator Are Constantly Flashing

Note: In older publications, this procedure is titled "Alarm Module or Remote Annunciator - Troubleshoot".

The following data link controlled devices flash every two seconds (0.5 Hz):

the fault indicators on the remote annunciator
the fault indicators on the control panel alarm module

There are several possible reasons that the alarm module indicators are flashing. Before performing the test procedure, perform the following checks on the alarm module.

Check the GSC+ for diagnostic codes. If a CID 333 FMI 03 or CID 333 FMI 04 diagnostic code is active or if the codes are contained in the fault log, perform those procedures first.
Verify the number of modules. A maximum of three modules can be connected to the GSC+ data link for the alarms.
Verify that all remote modules are powered. If multiple modules are connected to a GSC+, ALL of the modules must be powered up. If a module is not powered and the +battery wire is disconnected, the wire on Terminal 2 must also be disconnected. If a module is not powered and the ground wire is disconnected, the wire on Terminal 2 must also be disconnected.
Verify the length of the wire. The maximum length of the wires between the GSC+ and a remote annunciator is 304 m (997.4 ft). The actual length of the wire can be considerably longer than the physical distance between the two modules.
Check the type of wire or cable on the remote modules. On remote installations, three separate wires are required for the following connections: B+, B- and data for the alarm. For the switched inputs on a remote annunciator, the application may require additional wires. The wire size that is used on the remote modules must be 16 AWG. Ensure that the wire that is used on the remote modules is NOT shielded. Also ensure that the cables that are used on the remote modules do not have twisted conductors. Twisted conductor cable is not appropriate for this application. Twisted conductor cables usually have more capacitance than separate wires. This additional capacitance can corrupt the data from the GSC+.
Verify the methods of wiring. There must be a separate set of three wires between the remote annunciator and the GSC+. Do NOT connect any wires directly between the remote annunciators. The wires should NOT be in the same conduit as AC voltage wires or other high voltage signals.

Test Step 1 - Check the Data Circuit Wire for an Open Circuit

Clear the GSC+ Fault Log. Refer to Systems Operation, "Fault Log Clearing OP4".

Turn the Engine Control Switch (ECS) to "OFF/RESET".

For approximately three seconds, connect alarm module Terminal 1 to alarm module Terminal 2.

For approximately three seconds, connect alarm module Terminal 7 to alarm module Terminal 2.

Expected Result:

The CID 333 FMI 03 and CID 333 FMI 04 diagnostic codes should be temporarily active while the faults are occurring. The CID 333 FMI 03 and CID 333 FMI 04 diagnostic codes should be contained in the GSC+ fault log.

Results:

OK - The diagnostic codes occur and the codes are contained in the GSC+ fault log. The GSC+ and the wire for the alarm (data) have not failed. Proceed to "Test Step 2 - Check the Alarm Module for Faults".
NOT OK - The diagnostic codes DO NOT occur and the codes are not in the GSC+ fault log. The wire from GSC+ Contact 35 to alarm module Terminal 2 is open or the wire has failed. Also, the GSC+ may have failed. Proceed to "Test Step 3 - Check the GSC+ for Diagnostic Codes".

Test Step 2 - Check the Alarm Module for Faults

The indicators on the alarm module remain flashing.

Disconnect the wire on alarm module Terminal 2.

Measure the DC voltage from alarm module Terminal 2 to alarm module Terminal 7.

Expected Result:

The voltage should be 10.5 DCV ± 1.0 DCV.

Results:

OK - The voltage is 10.5 DCV ± 1.0 DCV. The requirements for the alarm module that were listed at the beginning of this procedure may not have been met.

Repair: Review the list of requirements at the beginning of this procedure. If all requirements are being met, replace the alarm module. If replacing the alarm module does not solve the problem, replace the GSC+. Refer to Testing and Adjusting, "EMCP Electronic Control (Generator Set) - Replace". STOP.

NOT OK - The voltage is NOT 10.5 DCV ± 1.0 DCV. The alarm module has failed.

Repair: Replace the alarm module. STOP.

Test Step 3 - Check the GSC+ for Diagnostic Codes

Install a cable probe on Pin 35 of the GSC+ 40-pin connector. Ensure that the cable probe is fully seated.

Turn the ECS to the "STOP" position.

For approximately three seconds, connect GSC+ Pin 35 to "B+".

For approximately three seconds, connect GSC+ Pin 35 to "B-".

Expected Result:

The CID 333 FMI 03 and CID 333 FMI 04 diagnostic codes will temporarily be active on the GSC+ display while the diagnostic codes are occurring.

Results:

OK - The diagnostic codes occur. The GSC+ has not failed. The wire from GSC+ Pin 35 to alarm module Terminal 2 is open or the wire has failed.

Repair: Repair the wire or replace the wire.

NOT OK - The diagnostic codes do not occur. The GSC+ may have failed. STOP.

Repair: The GSC+ may have failed. Exit this procedure and perform this entire procedure again. During the procedure, ensure that all cable probes are fully seated and ensure that the probes are making contact with the GSC+ pins. If the result is repeated, replace the GSC+. Refer to Testing and Adjusting, "EMCP Electronic Control (Generator Set) - Replace". STOP.

GSC CID 0333 - FMI 03

A possible cause of a CID 0333 FMI 03 diagnostic code is a short to "B+".

The GSC+ treats a CID 0333 FMI 03 as an alarm fault. Clear the diagnostic code from the fault log after troubleshooting is complete.

Note: If a CID 0333 FMI 03 is active on the upper display and no alarm module is installed, check the terminal strips on the subpanel for a short. Perform the check from the signal wire to "B+". Also, check the customer connection box for a short from the alarm data signal wire to "B+".

Test Step 1 - Check if the Diagnostic Code Is Active

Turn the engine control switch (ECS) to the "OFF/RESET" position and then turn the ECS to the "STOP" position.

Press the "Alarm Codes" key.

Observe the upper display for a "CID 0333 FMI 03". The diagnostic code is active if the upper display shows a "CID 0333 FMI 03".

If the diagnostic code is not showing, enter the service mode and view the fault log. Check the upper display if the diagnostic code is active.

Expected Result:

A "CID 0333 FMI 03" is active.

Results:

OK - A CID 0333 FMI 03 is active. Proceed to "Test Step 2 - Check for Shorted Data Link Wire".

NOT OK - A CID 0333 FMI 03 has not occurred. The diagnostic code is NOT active. STOP.

Test Step 2 - Check for Shorted Data Link Wire

Disconnect the cable on the "B-" terminal of the battery or open the optional battery disconnect switch.

Disconnect both ends of the data link wire: GSC+ Pin 35 and Alarm Module Terminal 2.

Measure the resistance from the data link wire to the GSC+ battery positive terminal.

Expected Result:

The resistance should be greater than 5000 ohms.

Results:

OK - The resistance is correct. Proceed to "Test Step 3 - Check the Alarm Module".

NOT OK - The resistance is NOT greater than 5000 ohms. The data link wire is faulty.

Repair: See the system schematic in order to troubleshoot and repair the harness wiring that has failed between the ALM and the GSC+. Refer to Testing and Adjusting, "Schematics and Wiring Diagrams". STOP.

Test Step 3 - Check the Alarm Module

The cable on the "B-" terminal remains disconnected or the optional battery disconnect switch is open.

Measure the resistance from Alarm Module Terminal 2 to "B+".

Expected Result:

The resistance should be greater than 5000 ohms.

Results:

OK - The resistance is greater than 5000 ohms. Proceed to "Test Step 4 - Check the GSC+".

NOT OK - The resistance is NOT greater than 5000 ohms. The Alarm Module has failed.

Repair: Replace the Alarm module. STOP.

Test Step 4 - Check the GSC+

Ensure that the data link wire remains disconnected.

Connect the cable on the "B-" terminal of the battery or close the optional battery disconnect switch.

Turn the ECS switch to the "STOP" position.

Check for an active CID 333 FMI 03 diagnostic code on the GSC+.

Expected Result:

The diagnostic code is no longer active.

Results:

YES - The diagnostic code is not active. The diagnostic code does not exist at this time.

Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Check the wiring for problems and resume normal operation. Watch for a recurrence of the problem. STOP.

NO - The diagnostic code has not been corrected. The GSC+ may have failed.

Repair: Exit this procedure and perform this procedure again. Also, recheck if the diagnostic code is active. If the cause of the diagnostic code is not found, replace the GSC+. Refer to Testing and Adjusting, "EMCP Electronic Control (Generator Set) - Replace" STOP.

GSC CID 0333 - FMI 04

A possible cause of a CID 0333 FMI 04 diagnostic code is a short to "B-".

The GSC+ treats a CID 0333 FMI 04 as an alarm fault. Clear the diagnostic code from the fault log after troubleshooting is complete.

Note: If a CID 0333 FMI 04 is active on the upper display and no alarm module is installed, check the terminal strips on the subpanel for a short. Perform the check from the signal wire to "B-". Also, check the customer connection box for a short from the alarm data signal wire to "B-".

Test Step 1 - Check if the Diagnostic Code Is Active

Turn the engine control switch (ECS) to the "OFF/RESET" position and then turn the ECS to the "STOP" position.

Press the "Alarm Codes" key.

Observe the upper display for a CID 0333 FMI 04. The diagnostic code is active if the upper display shows a CID 0333 FMI 04.

If the diagnostic code is not showing, enter the service mode and view the fault log. Check the upper display if the diagnostic code is active.

Expected Result:

A CID 0333 FMI 04 is active.

Results:

OK - A CID 0333 FMI 04 is active. Proceed to "Test Step 2 - Check the GSC+".

NOT OK - A CID 0333 FMI 04 has not occurred. The diagnostic code is NOT active. STOP.

Test Step 2 - Check the GSC+

Disconnect the cable on the "B-" terminal of the battery or open the optional battery disconnect switch.

Disconnect the data link wire from GSC+ Pin 35.

Reconnect the cable on the "B-" terminal of the battery or close the optional battery disconnect switch.

Turn the Engine Control Switch (ECS) to the "STOP" position.

Expected Result:

The CID 0333 FMI 04 is inactive.

Results:

OK - The CID 0333 FMI 04 is inactive. Proceed to "Test Step 3 - Check the Alarm and Data Link Wire".

NOT OK - The CID 0333 FMI 04 remains active. The GSC+ may have failed.

Repair: The GSC+ may have failed. Exit this procedure and perform this procedure again. If the procedure result is the same, replace the GSC+. Refer to Testing and Adjusting, "EMCP Electronic Control (Generator Set) - Replace".

Test Step 3 - Check the Alarm and Data Link Wire

Ensure that the data link wire remains disconnected from the GSC+.

Disconnect the cable on the "B-" terminal of the battery or open the optional battery disconnect switch.

Disconnect the data link wire from Alarm module Terminal 2.

Measure the resistance from the data link wire to GSC+ battery negative.

Expected Result:

The resistance should be greater than 5000 ohms.

Results:

OK - The resistance is greater than 5000 ohms. Proceed to "Test Step 4 - Check the Alarm Module".

NOT OK - The resistance is NOT greater than 5000 ohms. The data link wiring is faulty.

Repair: Use the system schematic to troubleshoot and repair the harness wiring that has failed between the ALM and the GSC+. Refer to Testing and Adjusting, "Schematics and Wiring Diagrams". STOP.

Test Step 4 - Check the Alarm Module

Ensure that the cable on the "B-" terminal remains disconnected or that the optional battery disconnect switch is open.

Ensure that the data link wire remains disconnected.

Measure the resistance from Alarm Module Terminal 2 to battery negative.

Expected Result:

The resistance should be greater than 5000 ohms.

Results:

OK - The resistance is greater than 5000 ohms. The problem may be intermittent.

Use the System Schematic and examine the wiring between the GSC+ and the Alarm Module for nicks, abrasion, or other damage. Refer to Testing And Adjusting, "Schematics and Wiring Diagrams". STOP.

NOT OK - The resistance is NOT greater than 5000 ohms. The Alarm Module has failed.