- Voltage mode: 0-5 V with software-selectable sub ranges. The input impedance is a minimum of 10k ohms, and a maximum of 1M ohms. The analog input return signals must be tied to battery negative external to the controller.
- Resistive Sender (VDO type motor) Mode: 5-2000 Ohms with software-selectable nonlinear maps. Accuracy is 1% or 0.5 ohms accuracy, whichever is worse. The analog input return signals must be tied to battery negative external to the controller.
The analog inputs have a 5 VDC common non-isolated power supply capable of supplying up to 100 mA of current, with overload protection. This supply is to be used to provide power to sensors if required by the source power pin and analog input returns. The negative side of this supply is battery negative.
Analog inputs programmed to monitor pressures should be wired to sensors that read gauge, not absolute pressure, unless absolute pressure is desired.
For analog inputs, the data range can be positive or negative, but event thresholds are only positive. Therefore, to prevent nuisance alarms for low warnings, disable the "Event Response Configuration" if data is acceptable to be negative.
The first and second analog inputs are configured by default for non-electronic engines. The inputs are to monitor engine oil pressure and engine coolant temperature, respectively, and are protected by level 3 security. The third analog input by default is protected at level 2 security.
Alternately, Cat ET can be used to program these set points.
Note: If the analog inputs are set to "DISABLED", then any sensor faults or events will not be broadcast or annunciated on the network.
Note: If more than one analog input is configured for the same physical quantity (that is, the set point "Analog Input Data Identification" matches between two "Analog Inputs"), then the higher numbered "Analog Input" value will be displayed on the "Engine Overview" screen. The following is an example. If both "Analog Input #2" and "Analog Input #3" are configured for oil temperature, but the sensor is connected only to "Analog Input #2" (and "Analog Input #3" is left open), a display of "****" diagnostic will result. The "Engine Overview" screen will display the value from "Analog Input #3". Warnings and shutdowns will be monitored for both analog inputs. When troubleshooting inputs, always make sure to check for configuration conflicts.
The analog inputs are not used for electronic engines that use ADEM A3, A4, or newer, engine ECM. On the electronic engines, the engine oil pressure sensor and the engine coolant temperature sensors are wired to the engine ECM. On the electronic engines, the engine oil pressure sensor and the engine coolant temperature sensors are not wired to the generator set control.
Inorder to receive the sensor information from the data link instead of from sensors wired into the EMCP 4, the set points "Engine Oil Pressure Sensor Configuration" and "Engine Coolant Temperature Sensor Configuration" must be set to "Data Link". If the set points are not set correctly, the sensor values on the "Engine Overview" screen on the EMCP 4 display will show "****".
Note: Improper configuration of the inputs can cause a false event to be triggered or cause an event not to trigger when desired. If a user disables an input without including other external protection, or disables the annunciation of an enabled input, detection will not be available. If a spare input is enabled, but not wired to a sensor, a false event may occur.
The programming of the analog inputs starts by selecting a "Usage Type". The rest of the programming is dependent upon what "Usage Type" is selected. Illustration 1 summarizes the paths possible for programming an analog input.
Illustration 1 | g02271735 |
Programming Analog Inputs using the Display
The steps to configure the Analog Inputs for each of the Usage Types are described below. Level 3 security is required for Analog Inputs #1 and #2. Level 2 security is required for Analog Input #3.
Viewing the Current Analog Input Status
To view the status of an Analog Input, go through the following menu options:
- At the main menu, press the down key to select "VIEW". Press the "OK" key.
A screen like Illustration 3 appears.
Show/hide tableIllustration 3 g02271738 - Select "I/O STATUS". Press the "OK" key.
A screen like Illustration 4 appears.
Show/hide tableIllustration 4 g02271740 - Select "ANALOG INPUTS". Press the "OK" key.
A screen like Illustration 5 appears.
Show/hide tableIllustration 5 g02271741 - Choose the analog input to program. Press the "OK" key.
A screen like Illustration 6 appears.
Show/hide tableIllustration 6 g02271742 - The programmed data identification of the selected analog input is shown. Press the down key to view the remaining parameters for this input.
Illustration 2 | g02271737 |
Configuring Analog Inputs for Resistive Mode
To configure an analog input for resistive mode, follow the Steps below:
- At the main menu, select "CONFIGURE". Press the "OK" key.
A screen like Illustration 8 appears.
Show/hide tableIllustration 8 g02271857 - Select "INPUTS & OUTPUTS". Press the "OK" key.
A screen like Illustration 9 appears.
Show/hide tableIllustration 9 g02271858 - Select "ANALOG INPUTS". Press the "OK" key.
A screen like Illustration 10 appears.
Show/hide tableIllustration 10 g02271859 - Select the analog input to program. Press the "OK" key.
A screen like Illustration 11 appears.
Show/hide tableIllustration 11 g02271919 Show/hide tableIllustration 12 g02271920 - Press the "OK" key to highlight the current configuration. Select "RESISTIVE". Press the "OK" key.
A screen like Illustration 13 appears.
Show/hide tableIllustration 13 g02271953 - Press the down key to select "DATA IDENTIFICATION". Press the "OK" key to change the current data identification.
A screen like Illustration 14 appears.
Show/hide tableIllustration 14 g02271974 - Select the data identification to program. Press the "OK" key.
A screen like Illustration 15 appears.
Show/hide tableIllustration 15 g02271976 - Press the down key to select "MAP SELECTION NUMBER". Press the "OK" key to change the current map selection number.
A screen like Illustration 16 appears.
Show/hide tableIllustration 16 g02271977 - Select the "MAP SELECTION NUMBER" to program. Press the "OK" key.
Illustration 7 | g02271833 |
The data identification will remain the same when switching between resistive or voltage.
Any analog input can be configured for any one of the data identification parameters in Table 1.
Data Identification Parameters | |
---|---|
Engine Oil Pressure | Custom Parameters |
Engine Coolant Temp | Data Link - SCADA (EMCP 4.2 only) |
Engine Oil Temp | Engine Speed Control |
Engine Fuel Level | Generator Voltage |
External Tank Fuel Level |
The sensor codes correspond to sensor maps as defined later in this manual.
Configuring Analog Inputs for Voltage Mode
To configure an analog input for voltage mode, follow the Steps below:
- At the main menu, select "CONFIGURE". Press the "OK" key.
A screen like Illustration 18 appears.
Show/hide tableIllustration 18 g02271857 - Select "INPUTS & OUTPUTS". Press the "OK" key.
A screen like Illustration 19 appears.
Show/hide tableIllustration 19 g02271858 - Select "ANALOG INPUTS". Press the "OK" key.
A screen like Illustration 20 appears.
Show/hide tableIllustration 20 g02271859 - Select the analog input to program. Press the "OK" key.
A screen like Illustration 21 appears.
Show/hide tableIllustration 21 g02271919 Show/hide tableIllustration 22 g02272293 - Select "VOLTAGE". Press the "OK" key.
A screen like Illustration 23 appears.
Show/hide tableIllustration 23 g02272333 - Select "SENSOR RANGE". Press the "OK" key to change the current sensor range.
A screen like Illustration 24 appears.
Show/hide tableIllustration 24 g02272334 - Select the "SENSOR RANGE" to program. Press the "OK" key.
A screen like Illustration 25 appears.
Show/hide tableIllustration 25 g02272335 - Select "DATA IDENTIFICATION". Press the "OK" key to change the current "DATA IDENTIFICATION".
A screen like Illustration 26 appears.
Show/hide tableIllustration 26 g02272513 - Select the status parameter to program. Press the "OK" key.
A screen like Illustration 27 appears.
Show/hide tableIllustration 27 g02272514 - Select "DATA RANGE MIN". Press the "OK" key to change the current data range minimum.
A screen like Illustration 28 appears.
Show/hide tableIllustration 28 g02272515 - Select the "DATA RANGE MIN" to program. Press the "OK" key.
A screen like Illustration 29 appears.
For analog inputs, the data range can be positive or negative, but event thresholds are only positive. Therefore, to prevent nuisance alarms for low warnings, disable the event response configuration if data is acceptable to be negative.
Show/hide tableIllustration 29 g02272517 - Select "DATA RANGE MAX". Press the "OK" key to change the current data range maximum.
A screen like Illustration 30 appears.
Show/hide tableIllustration 30 g02272518 - Select the "DATA RANGE MAX" to program. Press the "OK" key.
Illustration 17 | g02271833 |
The data identification list is the same whether signal type is resistive or voltage.
To disable an analog input, follow the Steps below:
- At the main menu, select "CONFIGURE". Press the "OK" key.
A screen like Illustration 32 appears.
Show/hide tableIllustration 32 g02271857 - Select "INPUTS & OUTPUTS". Press the "OK" key.
A screen like Illustration 33 appears.
Show/hide tableIllustration 33 g02271858 - Select "ANALOG INPUTS". Press the "OK" key.
A screen like Illustration 34 appears.
Show/hide tableIllustration 34 g02271859 - Select the analog input to program. Press the "OK" key.
A screen like Illustration 35 appears.
Show/hide tableIllustration 35 g02272914 - Press the "OK" key to highlight the current configuration.
A screen like Illustration 36 appears.
Show/hide tableIllustration 36 g02272915 - Select "DISABLED". Press the "OK" key.
Illustration 31 | g02271833 |
Programming Analog Inputs using Cat ET
The EMCP 4 analog inputs can be configured using Cat ET. Program the set points related to each input in order from top to bottom. To program an analog input, follow the Steps below:
- Connect the EMCP 4 to Cat ET.
Show/hide table
Illustration 37 g02272933 - Select "Analog Inputs" on the left.
Refer to Illustration 37.
Show/hide tableIllustration 38 g02272934 - Determine which input to configure. For example, all of the set points for "Analog Input #1" have the text "#1" in the name.
- Next follow the Steps below according to which usage type is desired.
Configuring Analog Inputs for Resistive Mode
The EMCP 4 supports resistive sender maps, which are nonlinear maps representing the transfer function of the resistive sender. Once an analog input is configured as a resistive input type, a map must be selected.
- Double-click the "Analog Input #N Usage Type" to change this value to "Resistive Sender" from the drop-down menu. Click the "OK" button to program.
Refer to Illustration 39.
Show/hide tableIllustration 40 g02272974 - The "Analog Input #N Configuration Code" and "Data Identification" parameters will now be visible in the right pane.
Refer to Illustration 40.
Show/hide tableIllustration 41 g02272975 - Double click the "Configuration Code" set point to change this value from the drop-down menu. Click the "OK" button to program.
Refer to Illustration 41.
Show/hide tableIllustration 42 g02272935 - Based on whether the selected option supports events, the list of set points shown will adjust accordingly. If the selected option does not support events, then the configuration is complete. If the selected option does support events, then continue and configure the event thresholds and delays. The "Analog Input #N Threshold" and "Delay Time" parameters will now be visible in the right pane.
Refer to Illustration 42.
Show/hide tableIllustration 43 g02273753 - Table 2 lists the options and which, if any, events are supported. Not all SPN and FMI combinations are valid. Table 2 indicates which FMIs are valid for which SPNs. If a combination other than one indicated with a "X" in the table above is configured, the event will not trigger any response by the EMCP 4. The EMCP 4 may not give the option of an invalid FMI for a given SPN. In Cat ET, there is no restriction on the SPN/FMI combination. An invalid combination in Cat ET will result in an "Out of Range" error.
Show/hide table
Table 2 Failure Mode Identifier Valid Options Suspect Parameter Number High Shutdown Low Shutdown High Warning Low Warning Engine Oil Pressure X X Engine Coolant Temperature X X X Engine Oil Temperature X X X X Fuel Level X X X X External Tank Fuel Level X X X X Generator Volt Control Custom Event X X X X Data Link Only Desired Engine Speed Command Note: For custom events, each input can only trigger the custom event number that matches the analog input number. Analog input #1 can only activate custom event #1 and so on.
Show/hide tableIllustration 44 g02273775 - Configure each of these set points by double clicking each one and typing a new value. Click the "OK" button to program.
Note: The units for the event thresholds are not shown. For pressures, the units are always kPa. Temperatures are always displayed in degrees Celsius. Levels are displayed in percent. Custom parameter types are unitless. The range for custom parameters is defined by the selected sensor map if programmed for resistive.
Illustration 39 | g02272973 |
Configuring Analog Inputs for Voltage Mode
The EMCP 4 supports linear voltage senders, which are senders whose output voltage varies linearly with the change in a physical measurement. Once the analog input is configured as a voltage input type, the linear mapping must be defined. The linear mapping is defined by entering the sensor voltage range and the corresponding minimum and maximum physical measurement range.
- Double click the "Analog Input #N Usage Type" to change this value to "Voltage" from the drop-down menu. Click the "OK" button to program.
Refer to Illustration 45.
Show/hide tableIllustration 46 g02273798 - The following parameters will now be visible on the right side of the dialog:
- Analog Input #N signal range
- Data identification
- Minimum data range
- Maximum data range
Refer to Illustration 46.
Show/hide tableIllustration 47 g02273799 - Double click the "Signal Range" set point to change the value from the drop-down menu to match the range supported by your sensor. If needed, select the next larger range. Click the "OK" button to program.
Refer to Illustration 47.
Show/hide tableIllustration 48 g02273800 - Double click the "Data Identification" set point to change this value from the drop-down menu. Click the "OK" button to program.
Refer to Illustration 48.
- Based on whether the selected option supports events, the list of set points shown will adjust accordingly.
Show/hide table
Illustration 49 g02273801 - Configure each of the "Minimum Data Range" and "Maximum Data Range" set points by double clicking each set point and typing a new value. Click the "OK" button to program.
For analog inputs, the data range can be positive or negative, but event thresholds are only positive. Therefore, to prevent nuisance alarms for low warnings, disable the "Event Response Configuration" if data is acceptable to be negative.
Refer to Illustration 49.
Show/hide tableIllustration 50 g02273802 - If the selected data identification does support events, then continue and configure the event thresholds and delays. The "Analog Input #N Threshold" and "Delay Time" parameters will be visible in the right pane.
Refer to Illustration 50.
Show/hide tableIllustration 51 g02273913 - Configure each of these set points by double clicking each one and typing a new value. Click to "OK" button to program.
Note: The units for the event thresholds are not shown. For pressures, the units are always kPa. Temperatures are always displayed in degrees Celsius. Levels are displayed in percent. Custom parameter types are unitless. The range for custom parameters is defined by the selected sensor map.
Refer to Illustration 51.
Illustration 45 | g02273796 |
- Double click the "Analog Input #N Usage Type" to change this value to "Disabled" from the drop-down menu. Click the "OK" button to program.
Refer to Illustration 52.
Illustration 52 | g02273975 |
Resistive senders can use nonlinear sensor maps. These maps are not available for Voltage or Current modes. Maps are predefined in the software flash file, and can be selected by the customer. Analog inputs can read a resistance from ~5 ohms up to 2000 ohms.
The following maps are predefined:
Analog Input Map #1 Engine Oil Pressure Map #1
Illustration 53 | g02274076 |
Analog Input Map #1 | |
Engine Oil Pressure Map #1 | |
Ohms | kPa |
5.1 | 0 |
10.2 | 0 |
20.9 | 50 |
31.3 | 100 |
41.6 | 150 |
51.6 | 200 |
61.3 | 250 |
70.9 | 300 |
80.4 | 350 |
89.5 | 400 |
98.6 | 450 |
107.3 | 500 |
115.9 | 550 |
124.3 | 600 |
132.5 | 650 |
140.5 | 700 |
148.2 | 750 |
155.8 | 800 |
163.1 | 850 |
170.2 | 900 |
177.2 | 950 |
183.9 | 1000 |
Analog Input Map #2 Engine Oil Pressure Map #2
Illustration 54 | g02274077 |
Analog Input Map #2 | |
Engine Oil Pressure | |
Ohms | kPa |
0 | 0 |
8 | 0 |
9 | 45 |
9.8 | 50 |
97.5 | 1000 |
Analog Input Map #3 Engine Coolant Temp Map #1
Illustration 55 | g02274078 |
Analog Input Map #3 | |
Engine Coolant Temperature Map #1 | |
Ohms | Degrees °C |
11.0 | 150 |
12.8 | 143 |
15.0 | 136 |
17.9 | 129 |
20.8 | 123 |
24.2 | 117 |
28.4 | 111 |
33.4 | 105 |
39.6 | 99 |
46.9 | 93 |
56.1 | 87 |
67.9 | 81 |
82.4 | 75 |
103.6 | 68 |
129.6 | 61 |
168.0 | 54 |
221.9 | 47 |
291.5 | 40 |
387.5 | 33 |
520.6 | 26 |
677.0 | 20 |
890.6 | 14 |
1182.9 | 8 |
1575.6 | 2 |
2249.4 | -5 |
Analog Input Map #4 Engine Coolant Temp Map #2
Illustration 56 | g02274079 |
Analog Input Map #4 | |
Engine Coolant Temperature Map #2 | |
Ohms | Degrees °C |
2442 | -48 |
1518 | -39 |
968.9 | -30 |
633.6 | -21 |
423.9 | -12 |
289.7 | -3 |
201.9 | 6 |
148.8 | 14 |
111.2 | 22 |
84.2 | 30 |
64.5 | 38 |
50 | 46 |
39.2 | 54 |
31 | 62 |
24.8 | 70 |
20 | 78 |
16.3 | 86 |
13.3 | 94 |
11.0 | 102 |
9.18 | 110 |
7.7 | 118 |
6.5 | 126 |
5.5 | 134 |
4.7 | 142 |
4.1 | 150 |
Illustration 57 | g02274080 |
Analog Input Map #5 | |
Oil Temp | |
Ohms | Degrees °C |
10.2 | 180 |
11.9 | 172 |
13.9 | 164 |
16.4 | 156 |
19.0 | 149 |
22.0 | 142 |
25.7 | 135 |
30.2 | 128 |
35.6 | 121 |
42.5 | 114 |
51.2 | 107 |
61.9 | 100 |
75.8 | 93 |
93.6 | 86 |
115.6 | 79 |
145.2 | 72 |
184.72 | 65 |
238.0 | 58 |
309.9 | 51 |
408.7 | 44 |
546.6 | 37 |
773.7 | 29 |
1114.9 | 21 |
1640.3 | 13 |
2473.6 | 5 |
Analog Input Map #6 Engine Coolant Temp Map #3
Illustration 58 | g02274081 |
Analog Input Map #6 | |
Engine Coolant Temp Map #3 | |
Ohms | Degrees °C |
6.9 | 150 |
8.2 | 142 |
9.8 | 134 |
11.6 | 127 |
13.8 | 120 |
16.3 | 113 |
19.6 | 106 |
23.7 | 99 |
28.8 | 92 |
35.4 | 85 |
43.7 | 78 |
54.5 | 71 |
68.5 | 64 |
87.1 | 57 |
111.8 | 50 |
145.1 | 43 |
190.5 | 36 |
253.4 | 29 |
341.5 | 22 |
467.0 | 15 |
648.8 | 8 |
916.6 | 1 |
1318.5 | -6 |
2046.6 | -14 |
Analog Input Map #7 Fozmula Fuel Level
Illustration 59 | g02274082 |
Analog Input Map #7 | |
Fozmula Fuel Level | |
Ohms | % |
10.5 | 0 |
35.6 | 25 |
60.2 | 50 |
85.2 | 75 |
103.2 | 100 |
Analog Input Map #8 Linear Level
Illustration 60 | g02274084 |
Analog Input Map #8 | |
Linear Level | |
Ohms | % |
0 | 0 |
2000 | 100 |
Analog Input Map #9 Power Module Tank Level #1
Illustration 61 | g02274086 |
Analog Input Map #9 | |
Power Module Tank Level #1 | |
Ohms | % |
10.5 | 0 |
35.6 | 25 |
60.2 | 50 |
85.2 | 75 |
103.2 | 100 |
Analog Input Map #10 Power Module Tank Level #2
Illustration 62 | g02274089 |
Analog Input Map #10 | |
Power Module Tank Level #2 | |
Ohms | % |
10 | 100 |
135 | 100 |
348.2 | 0 |
500 | 0 |
Illustration 63 | g03506581 |
Fuel Level | |
Ohms | % |
255 | 0 |
240 | 0 |
30 | 100 |
15 | 100 |
Illustration 64 | g03507185 |
Temperature(1) | |
Ohms | Degrees C |
2541.5 | 5 |
1991.4 | 10 |
1249.5 | 20 |
1000 | 25 |
805.5 | 30 |
652.8 | 35 |
532.3 | 40 |
436.6 | 45 |
360 | 50 |
298.4 | 55 |
248.7 | 60 |
208.2 | 65 |
175.2 | 70 |
148.1 | 75 |
125.7 | 80 |
107.2 | 85 |
91.7 | 90 |
78.8 | 95 |
68 | 100 |
58.9 | 105 |
51.2 | 110 |
44.6 | 115 |
39 | 120 |
30.1 | 130 |
23.6 | 140 |
18.6 | 150 |
(1) | Useful for temperatures based on CAT sensor. The EMCP only supports down to 10 degrees Centigrade). |
The EMCP 4.1 and EMCP 4.2 voltage senders can be configured within the ranges in Table 15.
Analog Input Ranges | |
Voltage Sender Ranges | 0V to 5V |
1V to 5V | |
0.5V to 4.5V |
Analog input data ranges can be defined with positive and negative values. Event thresholds are only programmable as positive values. To prevent nuisance alarms for low warnings when using negative numbers for data ranges, the "Event Response Configuration" can be disabled. The input data must be acceptable to be negative.
Each of the inputs can be configured to have "HIGH WARNINGS", "LOW WARNINGS", "HIGH SHUTDOWNS"and "LOW SHUTDOWNS". The inputs have thresholds that can be configured. Any value below the bottom point on the map or above the highest point on the map will raise a corresponding diagnostic event. Also, all of the events associated with the analog inputs have programmable time delays. "Low Idle Oil Pressure" set points are also available under the "Engine Oil Monitor" menu.
Unsupported Analog Input Sensor Ranges
There may be voltage sensors available that use ranges not explicitly supported by the EMCP 4. Depending on the situation, there may be different ways to handle the unsupported sensor ranges. The following sections give options on how to handle the situations.
Sensor Range is Smaller than Set Point Options
If the desired sensor range is smaller than one of the available set point options, then extrapolation may be used to support the desired sensor. For example, for a 0 to 3 VDC temperature sensor reads
Illustration 65 | g02274673 |
Mathematical Extrapolation of Maximum Data Range |
The maximum data range can be found graphically or algebraically. In the example, the maximum data range would be defined by the equation of the line after the slope is determined. Since the data rises by 50 degrees for every volt, increasing 2 V above the 3 V limit requires the maximum range to be 100 degrees above the sensor limit of 120 degrees. The total would be 220 degrees. Refer to Illustration 66.
Illustration 66 | g02274694 |
Example Calculation for Extrapolation of Maximum Data Range |
Sensor Range is Larger than Set Point Options, but Usable Range is not
If the desired sensor range is larger than one of the available set point options, but the useful range for the sensor is within the supported ranges, then interpolation may be used to support the desired sensor. For example, for a 0 to 6 VDC temperature sensor that reads
Illustration 67 | g02274695 |
Mathematical Interpolation of Maximum Data Range |
The maximum data range can be found graphically or algebraically. In this example, the maximum data range would be defined by the equation of the line after the slope is determined. Since the data rises by 90 degrees for every volt, decreasing 1 V below the 6 V limit requires the maximum range to be 90 degrees below the sensor limit of 500 degrees. The total will be 410 degrees. Refer to Illustration 68.
Illustration 68 | g02274733 |
Example Calculation for Interpolation of Maximum Data Range |
Sensor Range is Larger than Set Point Options, and Usable Range is Larger than Set Point Options
If the desired sensor range is larger than one of the available set point options, and the useful range for the sensor is outside of the supported ranges, a third-party device is required to convert the signal range into a supported range. Refer to Illustration 69.
Illustration 69 | g02274734 |