100-200 kW Tactical Quiet Generators (TQG) EMCP2 Plus Caterpillar

Illustration 1	g00481725
Block Diagram Of AC Voltage Display In the EMCP II+

Illustration 2	g00583168
System Schematic For AC Transformer Box + (ATB+) Schematic For Wye Connected Generator On 3306B And 3406C

Illustration 3	g00444304
System Schematic For AC Transformer Box + (ATB+) Schematic For A Wye Connected Generator For All Models Covered By This Manual Except 3306B And 3406C

Note: For related information, see Testing And Adjusting, "AC Voltage Range - Adjust".

The P020 setpoint determines the proper AC voltage range and the internal multipliers that are used by the GSC+ for calculating AC voltage. If the external potential transformers are present, the GSC+ uses the internal multipliers to compensate for the ratio of turns of the external potential transformers. This must take place in order to ensure accurate calculations by the GSC+ for AC voltage .

A jumper block is located in the relay module. The jumper block connects a circuit which will divide the AC voltage by five. The circuit reduces the AC voltage to an acceptable level for the GSC+ when P020 is 700. When setpoint P020 is 700, a multiplier of five is needed to compensate for the presence of the circuit even though no external potential transformer is present.

Note: The jumper block should NOT be installed when P020 is NOT programmed to a value of 700. This will prevent voltage readings that are calculated incorrectly by the GSC+. The other values (150 through 30000) are used with an external potential transformer. These values result in input voltages from 0 to 150 ACV at the AC Transformer Box + (ATB+). No further reduction of the input voltage is required.

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When the engine-generator, or any source to which the engine-generator is synchronized to, is operating, voltages up to 600V are present in the control panel. Do not short these terminal with line voltage to ground with any part of the body or any conductive material. Loss of life or injury could result from electrical shock or injury from molten metal.

Test Step 1. CHECK THE DISPLAY OF THE GSC+P FOR VOLTAGE READINGS

1. Start the genset.

2. Check the voltage readings on the display of the GSC+P.

Expected Result:

The voltage readings on the GSC+P should be accurate.

Results:

• OK - The voltage readings on the GSC+P are accurate. Proceed to Test Step 2.

• NOT OK - The voltage readings on the GSC+P are inaccurate. Proceed to Test Step 4.

Test Step 2. CHECK THE DISPLAY OF THE GSC+P FOR CURRENT READINGS

1. Check the current readings on the display of the GSC+P.

Expected Result:

The current readings on the GSC+P should be accurate.

Results:

• OK - The current readings on the GSC+P are accurate. Proceed to Test Step 3.

• NOT OK - The current readings on the GSC+P are inaccurate. Proceed to Test Step 8.

Test Step 3. CHECK THE DISPLAY OF THE GSC+P FOR POWER CONSUMPTION

1. Check the power consumption on the display of the GSC+P.

Expected Result:

The power consumption that is displayed on the GSC+P should be accurate.

Results:

• OK - The power consumption that is displayed on the GSC+P is accurate.

  Repair: There is no problem at this time. Keep monitoring the system for inaccurate readings.

  STOP

• NOT OK - The power consumption that is displayed on the GSC+P is NOT accurate. Proceed to Test Step 10.

Test Step 4. CHECK SETPOINT P020

1. Check the setpoint P020. See Testing and Adjusting, "Engine/Generator Setpoint Viewing OP2-0".

Expected Result:

P020 should be set to match the system's application. To find the correct setpoint, refer to Table 1 .

Results:

• OK - Setpoint P020 is set for the application. Proceed to Test Step 5.

• NOT OK - Setpoint P020 is NOT set for the application.

  Repair: Program P020 to match the system's application. See Testing and Adjusting, "Engine/Generator Setpoint Programming OP5-0".

  STOP

Test Step 5. CHECK THE JUMPER FOR CORRECT INSTALLATION

1. Check the setpoint P020. See Testing and Adjusting, "Engine/Generator Setpoint Viewing OP2-0".

2. Check the jumper on the relay module for correct AC voltage range. See System Operation, "AC Voltage Range - Adjust".

Expected Result:

The jumper should be installed correctly in order to match the value in setpoint P020.

Results:

• YES - The jumper is installed correctly in order to match the value in setpoint P020. Proceed to Test Step 6.

• NO - The jumper is NOT installed correctly in order to match the value in setpoint P020.

  Repair: Install the jumper in accordance to the procedure in System Operation, "AC Voltage Range - Adjust".

  STOP

Test Step 6. CHECK THE VALUES IN OP8

1. Turn the ECS to the STOP position in order to shut down the engine. Enter service mode and enter the password.OP4 is showing on the lower display of the GSC+P. For more information, see Systems Operation, "Service Mode"for more information. See the Systems Operation, "Password Entry OP3"for more information.

2. Press the "SCROLL UP" key five times. "OP 8" is showing on the lower display.

3. Press the "SCROLL UP" key five times. "OP 8" is showing on the lower display.

4. Press the "SELECT" key. "AC01" is showing. The value of the setpoint is also showing. The value will be between 0 to 255. Record the value.

5. Press the "SCROLL UP" key in order to retrieve the values for the setpoints AC02 through AC06. Record each value.

6. Press the "EXIT" key. "OP 1" is showing on the lower display.

7. Press the "EXIT" key. The display will return to the Normal Mode.

8. Compare the recorded values with the values that are written on the bar code sticker of the ATB+.

Expected Result:

The recorded values should match the values that are written on the bar code sticker of the ATB+.

Results:

• Yes - The values match. Proceed to Test Step 7.

• NO - The values do NOT match.

  Repair: Program the setpoints in OP8 to match the values on the ATB+. See System Operation, "Voltmeter/Ammeter Programming OP8".

  STOP

Test Step 7. CHECK THE AC OFFSET ADJUSTMENT

1. Check the AC offset adjustment. See System Operation, "AC Offset Adjustment OP10".

Expected Result:

The offset values should be set to zero.

Results:

• YES - The offset values are set to zero.

  Repair: The GSC+ may have failed. It is unlikely that the GSC+ has failed. Exit this procedure and perform this entire procedure again. If the problem remains, replace the GSC+. See Testing And Adjusting, "EMCP Electronic Control (Generator Set) - Replace".

  STOP

• NO - The offset values are not set to zero.

  Repair: Reset the offset values to zero. See System Operation, "AC Offset Adjustment OP10". Verify that the voltage readings are accurate.

  STOP

Test Step 8. CHECK SETPOINT P021

1. Check the setpoint P021. See Testing and Adjusting, "Engine/Generator Setpoint Viewing OP2-0".

Expected Result:

P021 should be set to 600A.

Results:

• OK - P021 setpoint is set to 600A. Proceed to Test Step 9.

• NOT OK - P021 setpoint is NOT set to 600A.

  Repair: Program P021 to 600A. See Testing and Adjusting, "Engine/Generator Setpoint Programming OP5-0".

  STOP

Test Step 9. CHECK THE VALUES IN OP8

1. Turn the ECS to the STOP position in order to shut down the engine. Enter service mode and enter the password. OP4 is showing on the lower display. For more information, see Systems Operation, "Service Mode"for more information. See the Systems Operation, "Password Entry OP3"for more information.

2. Press the "SCROLL UP" key five times. "OP 8" is showing on the lower display.

3. Press the "SCROLL UP" key five times. "OP 8" is showing on the lower display.

4. Press the "SELECT" key. "AC01" is showing. The value of the setpoint is also showing. The value will be between 0 to 255. Record the value.

5. Press the "SCROLL UP" key in order to retrieve the values for setpoints AC02 through AC06. Record each value.

6. Press the "EXIT" key. "OP 1" is showing on the lower display.

7. Press the "EXIT" key. The display will return to the Normal Mode.

8. Compare the recorded values with the values that are written on the bar code sticker of the ATB+.

Expected Result:

The recorded values should match the values that are written on the bar code sticker of the ATB+.

Results:

• YES - The values match.

  Repair: The GSC+ may have failed. It is unlikely that the GSC+ has failed. Exit this procedure and perform this entire procedure again. If the problem remains, replace the GSC+. See Testing And Adjusting, "EMCP Electronic Control (Generator Set) - Replace".

  STOP

• NO - The values do NOT match.

  Repair: Program the setpoints in OP8 to match the values on the ATB+. See System Operation, "Voltmeter/Ammeter Programming OP8".

  STOP

Test Step 10. INACCURATE POWER CONSUMPTION IS DISPLAYED ON THE GSC+P.

1. Start the genset.

2. Check for inaccurate power factors for each individual phase by depressing the "Power Key" for more than 5 seconds.

Expected Result:

The power factors for each phase should be accurate.

Results:

• OK - The power factors for each phase are accurate.

  Repair: The GSC+ may have failed. It is unlikely that the GSC+ has failed. Exit this procedure and perform this entire procedure again. If the problem remains, replace the GSC+. See Testing And Adjusting, "EMCP Electronic Control (Generator Set) - Replace".

  STOP

• NOT OK - The power factors for each phase are inaccurate. Proceed to Test Step 11.

Test Step 11. CHECK THE POLARITY OF THE CURRENT TRANSFORMERS

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Illustration 4	g00607036

1. Turn the ECS to the STOP position in order to shut down the engine.

2. Check the polarity of the current transformers. Refer to Illustration 4.

Expected Result:

The polarity of the current transformers should be correct.

Results:

• OK - The polarity of the current transformers are correct.

  Repair: The ATB+ has failed. Replace the ATB+. See Testing and Adjusting, "EMCP Electronic Control (AC Transformer Box) - Replace".

  STOP

• NOT OK - The polarity of the current transformers are NOT correct.

  Repair: Install the current transformers to the correct polarity.

  STOP