Power Module Switchgear (Low Voltage and Medium Voltage) Caterpillar

Illustration 1	g00860924
Display Area Of The Generator Set Control+ (GSC+) (1) Dedicated shutdown indicators (2) Upper display (3) Indicator for "LOW OIL PRESSURE" (4) Indicator for "EMERGENCY STOP" (5) Indicator for "HIGH WATER TEMP" (6) Lower display (7) Indicator for "ENGINE OVERSPEED" (8) Indicator for "OVERCRANK" (9) Indicators for spare faults (10) Keypad (11) "EXIT" key (12) "SERVICE MODE" key (13) Indicator for "FAULT SHUTDOWN" (14) Indicator for "FAULT ALARM" (15) "POWER METER" key and "SCROLL RIGHT" key (16) "AC METER" key and "SCROLL UP" key (17) "ENGINE METER" key and "SCROLL DOWN" key (18) "LAMP TEST" key and "SELECT" key (19) "ALARM CODES" Key and "ENTER" key

The GSC+ is powered by 24 DCV. The GSC+ is used in order to monitor the functions of the generator and the GSC+ is used in order to control the functions of the generator. The functions and features of the GSC+ are listed below:

• The GSC+ monitors the generator AC output. The information includes the power metering. The GSC+ controls starting and stopping of the engine.

• The GSC+ shows engine conditions and generator output information on two displays.

• The displays show the fault codes. The displays also show the information for programming that is used by the GSC+.

• The GSC+ monitors the system for faults. An annunciation for a fault alarm is provided by the GSC+ after a fault occurs. When a fault occurs the GSC+ may also perform a controlled fault shutdown. The GSC+ uses indicators and displays in order to describe the fault to the operator or the service technician.

• The GSC+ contains programmable features for certain applications. The programmable features are also used by the GSC+ in order to meet the requirements of the customers.

Note: Set P023 to 1 for gas engines. Set P023 to 2 for EUI engines. Failure to set setpoint P023 can result in improper engine operation, incorrect display of engine parameters, and logging an erroneous CID 590 diagnostic code.

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Part Number of the GSC +

Illustration 2	g00310244
Location Of the Part Number for the GSC + Rear View Of GSC+

The part number is stamped into the rear housing of every GSC+ above the harness connector. When the GSC+ is updated internally, the part number also changes. The part number can be used to identify the effectivity of any changes.

Serial Number for the GSC +

Illustration 3	g00394402
Location of the serial number for the GSC+ Rear View Of GSC+

The serial number of the GSC+ is a ten digit number which is unique for each GSC+. Illustration 3 shows the location of the serial number on the back of the GSC+. The serial number is also shown to service personnel when the GSC+ is in option OP2-2. The serial number which is shown on the display and the actual serial number will always match.

Fault Indicators

The ten fault indicators 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 four groups are the indicator for "FAULT ALARM" (14), the indicators for "SPARE" faults (9), the indicator for "FAULT SHUTDOWN" (13) and the dedicated shutdown indicators (1) .

The yellow indicator for "FAULT ALARM" (14) FLASHES when the GSC+ detects an alarm that is an alarm fault. The alarm fault does not cause the engine status to change. The engine is able to start. The engine will continue operating, only if the engine is running at the time of the alarm fault. The indicator for "FAULT ALARM" (14) is accompanied by an alarm fault code. When the "ALARM CODES" key (19) is pressed the code is shown on the upper display (2) .

The red indicator for "FAULT SHUTDOWN" (13) FLASHES when the GSC+ detects a shutdown fault. If the engine is running, the engine will shut down. If the engine is not running, the engine will not be allowed to start. The indicator for "FAULT SHUTDOWN" (13) is accompanied by a fault code that is immediately shown on the upper display (2) .

The yellow indicators for "SPARE" faults (9) FLASH when the conditions that are associated with those spare faults are active. Three faults can be programmed to show coolant loss, oil temperature, spare fault condition or no assignment. The spare fault condition may be a switch input that is generated by the customer. The yellow indicator for "FAULT ALARM" (14) or the red indicator for "FAULT SHUTDOWN" (13) will accompany the indicators for spare faults (9). The spare fault indicators will indicate whether the spare fault input is programmed to be an alarm condition or a shutdown condition.

The red dedicated shutdown indicators (1) represent the following shutdown faults: low oil pressure, emergency stop, high water temperature, engine overspeed and engine overcrank. When the GSC+ detects a fault in one of these areas, the dedicated shutdown indicator that corresponds to the fault FLASHES. If the engine is running, the engine will shut down. If the engine is not running, the engine will not be allowed to start. No fault codes are associated with the dedicated shutdown indicators because each indicator has a descriptive label.

Many of the dedicated shutdown faults depend on certain setpoints in the GSC+.

The conditions that are required to activate the dedicated fault shutdowns are in the following list:

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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. One setpoint is used when the engine is at idle speed. The other setpoint is used when the engine is at rated speed. When a low oil pressure fault occurs, the indicator for "LOW OIL PRESSURE" (3) FLASHES, and the engine will shut down. The engine is not allowed to start.

Emergency stop - The operator presses the emergency stop push button (ESPB) on the front panel. When an emergency stop condition occurs, the emergency stop indicator FLASHES and the engine is shut down. The engine is not allowed to start.

High water temperature - The engine coolant temperature rises above the setpoint for high water temperature shutdown that is programmed into the GSC+. When the high water temperature fault occurs, the indicator for "HIGH WATER TEMP" (5) FLASHES. The engine is shut down and the engine is not allowed to start.

Engine overspeed - The engine speed exceeds the setpoint for engine overspeed that is programmed into the GSC+. The indicator for "ENGINE OVERSPEED" (7) will FLASH when the fault for engine overspeed occurs. If the engine is running, the engine will shut down. If the engine is not running, the engine will not be allowed to start.

Overcrank - The engine does not start within the setpoint for total cycle crank time that is programmed into the GSC+. When the overcrank fault occurs, the indicator for "OVERCRANK" (8) FLASHES. The engine will shut down. The engine will not be allowed to start.

Note: The GSC+ can be programmed to override the shutdown for low oil pressure and high water temperature faults. When the operator overrides the shutdown faults, the GSC+ responds to the faults as though the faults are alarm faults. The corresponding dedicated shutdown indicator is ON CONTINUOUSLY. The corresponding dedicated shutdown indicator will not be flashing. The engine continues to run and the engine continues to start instead of shutting down. When the dedicated shutdown indicator is ON CONTINUOUSLY, the setpoint for shutdown has been exceeded, but the GSC+ is programmed to override the shutdown fault. The GSC+ does not treat the shutdown fault as a shutdown fault. The GSC+ treats the shutdown fault as an alarm fault. At the factory, the GSC+ is programmed to treat a low oil pressure fault and a high water temperature fault as shutdown faults. The operator or the service technician must decide to override these shutdown faults. The operator or the service technician may program the GSC+ in order to recognize the shutdown faults as alarm faults.

Upper Display

Illustration 4	g00521435
Upper Display (2) With All Segments

The primary function of the upper display (2) is showing the following output information: AC voltage, current and frequency. Several options are available on the upper display (2) for AC metering. These options can be individually viewed by pressing the "AC METER" key (16) on the keypad. The options are listed below:

• Average voltage, generator frequency, and total current

• Line-to-line voltage, generator frequency, and line current for any one phase

• Line-to-line voltage for all three phases at the same time

• Line current for all three phases at the same time

• Line to neutral voltage for all three phases at the same time

Note: When total current increases above "9999A", the GSC+ will show current in "kA" units.

Note: Line to neutral voltages are not shown when setpoint "P032"is set to 1 (delta generator sets).

Upper display (2) is also used to show the various fault codes for system faults.

Illustration 5	g00527264
The upper display (2) shows the following items: The average line to line voltage of all three phases is 480 volts. The generator frequency is 60 Hz. The total line current of all three phases is 3000 amperes.

Illustration 6	g00527266
The upper display (2) shows the following items: The line to line voltage of phase A to phase B is 480 volts. The generator frequency is 60 Hz. The total line current of phase A is 1000 amperes.

Illustration 7	g00394497
The upper display (2) shows the following items: The line to line voltage of phase A-B is 480 volts. The line to line voltage of phase B-C is 480 volts. The line to line voltage of phase C-A is 480 volts.

Illustration 8	g00394503
The upper display (2) shows the following items: The line current of phase A is 1000 Amperes. The line current of phase B is 1000 Amperes. The line current of phase C is 1000 Amperes.

Illustration 9	g00394505
The upper display (2) shows the following items: The line to neutral voltage of phase A is 277 Volts. The line to neutral voltage of phase B is 277 Volts. The line to neutral voltage of phase C is 277 Volts.

Note: Line to neutral voltages are not shown when the setpoint P032 is set to 1 for generator sets with the delta configuration.

Lower Display

Illustration 10	g00394557
Lower Display (6) With All Segments

The lower display (6) 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. The following functions will scroll automatically:

• Total real power (kW)

• Total reactive power (KVAR)

• Percentage of rated power (%kW)

• Power factor (average)

• Total energy output (kW/h)

The display will stop scrolling when the operator presses the power meter key for less than five seconds. The display will show a particular parameter continuously. Additional power meter functions will scroll, if the power meter key is held for more than five seconds and then released. The additional functions are shown below:

• Total real power (kW)

• Real power of phase A (kW)

• Real power of phase B (kW)

• Real power of phase C (kW)

• Total apparent power (kVA)

• Total reactive power (KVAR)

• Percentage of rated power (%kW)

• Power factor (average)

• Power factor of phase A

• Power factor of phase B

• Power factor of phase C

• Total energy output (kW/h)

• Total reactive energy output (kVARHr)

Note: All real power values are signed with a "+" or a "-". A negative value indicates reverse power.

Note: Real power of phases A, B, and C and the power factor of phases A, B, and C are not shown when setpoint P032 is set to 1 for generator sets with the delta configuration.

Illustration 11	g00394559
Lower Display Showing: The total real power of generator output is 691 kW.

Illustration 12	g00394561
Lower Display Showing: The real power of phase A is 230 kW.

Note: The phase B and the phase C can be viewed in a similar manner.

Illustration 13	g00394562
Lower Display Showing: The total apparent power is 831 kVA.

Illustration 14	g00394563
Lower Display Showing: The total reactive power of the generator output is 462 KVAR.

Illustration 15	g00394565
Lower Display Showing: The percentage of rated power of the generator output is 80 %kW.

Illustration 16	g00394566
Lower Display Showing: The average power factor of generator output is .83.

Note: You may view the power factor for the individual phases in a similar manner.

Illustration 17	g00394567
Lower Display Showing: The total energy of the generator output is 1000 kW/h.

Note: Total energy output that is greater than 999,999 kW/h will be shown as MW/h in two steps in order to maintain a resolution of 1 kW/h. The first step will show MW/h as a whole number up to six places. The second step will show MW/h as a decimal to three places. For example, 1,000,001 kW/h will be shown as 1000 MW/h in the first step. The second step will show .001 MW/h.

Illustration 18	g00579439
Lower Display Showing: The engine oil pressure is 64 psi.

The right side of lower display (6) shows the value of certain engine parameters. The parameters are listed below:

• Left side exhaust temperature (option)

• Right side exhaust temperature (option)

• Engine oil temperature (option)

• System battery voltage

• Engine hours

• Engine speed

• Engine oil pressure

• Engine coolant temperature

Note: If the GSC+ displays dashes (---) for oil pressure, coolant temperature, or engine oil temperature, this indicates that the GSC+ is receiving invalid data from the sensor. The upper display (2) will be showing a corresponding diagnostic code for the sensor.

The value for one of these conditions is shown on the display for two seconds. The display then 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, the lower display (6) stops scrolling. The lower display continuously shows one particular value. The pointer flashes above the value that is showing on the display.

Illustration 19	g00394569
Lower Display Showing: K1, K3 and K5 are active. K2, K4, K6, K7 and K8 are not active.

The relay status indicators are on the bottom of the lower display (6). When a relay in the GSC+ is activated, the corresponding indicator (K1 through K8) is shown on lower display (6). When a relay is not activated, the corresponding indicator (K1 through K8) is not shown.

Keypad

Illustration 20	g00395398
Keypad (10) for the Control Panel for the EMCP II +

Keypad (10) is used to control the information that is shown on upper display (2) and lower display (6). The seven keys have two sets of functions, normal functions and service functions. The normal functions of the keys are described in the following paragraphs.

"AC METER" Key (16) - The AC meter key controls the viewing of the AC parameters on the upper display (2). Pressing the key causes the display to show a different set of parameters.

"ALARM CODES" Key (19) - If the indicator for "FAULT ALARM" (14) is FLASHING, pressing this key causes upper display (2) to show the corresponding alarm fault code. Press this key again in order to resume the display of the information on AC output for the generator on the upper display (2). If the indicator for "FAULT ALARM" (14) is OFF, this key has no function.

"ENGINE METER" Key (17) - This key controls the viewing of engine parameters on the lower display (6). Pressing the key stops the scrolling of engine conditions. The value for one particular engine condition will show continuously. The pointer flashes in order to indicate that the scrolling has stopped. The scrolling of the engine conditions will resume when the engine meter key is pressed again.

"EXIT" Key (11) - This key only functions when the GSC+ is in service mode. Press this key in order to exit the service mode.

"LAMP TEST" Key (18) - Pressing this key performs a lamp test on the GSC+ and the optional alarm module. On the GSC+, the ten fault indicators are ILLUMINATED CONTINUOUSLY. Every segment of upper display (2) and lower display (6) is ON. The lamp test function is automatically turned OFF if the lamp test key is pressed and held for more than ten seconds.

"POWER METER" Key (15) - 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.

"SERVICE MODE" Key (12) - Pressing this key causes the GSC+ to enter service mode. See Systems Operation, "Service Mode" for more information.

Relays

Illustration 21	g00521482
Relay Module On Rear Of GSC+

Illustration 22	g00861599
Relays In Relay Module (20) Jumper Block

The relays are located in the relay module on the rear of the GSC+. The relays are permanently attached within the relay module. The relays are not removable. The entire relay module is replaced if a relay has failed.

Some of the contacts of the relays are internally connected to the terminals of the relay module. The contacts are available for the customer's use. The voltage specifications and the current specifications for each terminal of the relay are listed in table 1.

Note: Jumper block (20) is used to select the voltage range of the voltmeter of the GSC+. Jumper block (20) is installed for systems with 700 volts full scale AC inputs. Jumper block (20) is NOT installed for systems with 150 volts full scale AC inputs or for any unit with external potential transformers. The jumper block (20) is installed in the relay module at the factory.

The relays and the functions are listed below.

K1 - Electronic governor relay (EGR)

On EUI engines, this relay enables the engine ECM to begin fuel injection.

• When the relay is active the normally open contacts close.

• The relay has no normally closed contacts.

K2 - Generator fault relay (GFR)

The GSC+ uses the generator fault relay (GFR) to activate the shunt trip coil of the optional circuit breaker during a shutdown fault. The optional circuit breaker is located in the generator housing.

• When the relay is active the normally open contacts close. This trips the optional circuit breaker when a shutdown fault occurs.

• The relay has no normally closed contacts.

K3 - Crank Termination Relay (CTR)

The CTR is used to indicate that the engine is beginning to run without cranking. The GSC+ activates the CTR when the engine speed is greater than the crank terminate setpoint and the starting motor relay has been deactivated. The crank terminate setpoint is 400 RPM. The crank terminate setpoint is P011. The CTR deactivates when the engine RPM reaches 0.

When the relay is active the normally open contacts close. When these contacts are closed the following functions are performed:

• The generator running relay (GRR) is activated.

• The governor switch is enabled.

• The governor synchronizing motor is enabled.

• The generator running relay (GRR) is located in the customer connection box. The governor switch (GS) is located on the front panel.

• When the relay is inactive the normally closed contacts close.

K4 - Starting motor relay (SMR)

• When the relay is active the normally open contacts close. This activates the starting motor magnetic switch.

• When the relay is inactive the normally closed contacts close.

K5 - Run relay (RR)

• When the relay is active the normally open contacts close. This provides power to the optional start aid switch (SAS) and the crank relay (CR).

• When the relay is inactive the normally closed contacts close. These contacts are for the customer's use.

K6 - Air shutoff relay (ASR)

• When the relay is active, the normally open contacts close. This activates an optional air shutoff solenoid during fault shutdowns.

• When the relay is inactive, the normally closed contacts close.

K7 - Fuel control relay (FCR)

• When the relay is active, the normally open contacts close. This activates the fuel control solenoid via the fuel control relay in the junction box. Also, power is supplied to the optional electronic governor.

• The relay has no normally closed contacts.

K8 - Programmable spare relay (PSR)

This relay is for the customer's use. Activation of this relay is programmable for several conditions.