EMCP4.1/EMCP4.2 Caterpillar


Analog Input Programming

Usage:

C18 DTP
EMCP 4.1 and EMCP 4.2 support three 2-wire (plus shield) analog inputs. None of the analog inputs are dedicated to specific functions. The analog inputs are individually selectable as either "Voltage" or "Resistive Sender" inputs for interface to senders and customer signals. The modes of operation are described below:

  • 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 1g02271735

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:



    Illustration 2g02271737

  1. At the main menu, press the down key to select "VIEW". Press the "OK" key.

    A screen like Illustration 3 appears.



    Illustration 3g02271738

  2. Select "I/O STATUS". Press the "OK" key.

    A screen like Illustration 4 appears.



    Illustration 4g02271740

  3. Select "ANALOG INPUTS". Press the "OK" key.

    A screen like Illustration 5 appears.



    Illustration 5g02271741

  4. Choose the analog input to program. Press the "OK" key.

    A screen like Illustration 6 appears.



    Illustration 6g02271742

  5. The programmed data identification of the selected analog input is shown. Press the down key to view the remaining parameters for this input.

Configuring Analog Inputs for Resistive Mode

To configure an analog input for resistive mode, follow the Steps below:



    Illustration 7g02271833

  1. At the main menu, select "CONFIGURE". Press the "OK" key.

    A screen like Illustration 8 appears.



    Illustration 8g02271857

  2. Select "INPUTS & OUTPUTS". Press the "OK" key.

    A screen like Illustration 9 appears.



    Illustration 9g02271858

  3. Select "ANALOG INPUTS". Press the "OK" key.

    A screen like Illustration 10 appears.



    Illustration 10g02271859

  4. Select the analog input to program. Press the "OK" key.

    A screen like Illustration 11 appears.



    Illustration 11g02271919


    Illustration 12g02271920

  5. Press the "OK" key to highlight the current configuration. Select "RESISTIVE". Press the "OK" key.

    A screen like Illustration 13 appears.



    Illustration 13g02271953

  6. Press the down key to select "DATA IDENTIFICATION". Press the "OK" key to change the current data identification.

    A screen like Illustration 14 appears.



    Illustration 14g02271974

  7. Select the data identification to program. Press the "OK" key.

    A screen like Illustration 15 appears.



    Illustration 15g02271976

  8. 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.



    Illustration 16g02271977

  9. Select the "MAP SELECTION NUMBER" to program. Press the "OK" key.

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.

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:



    Illustration 17g02271833

  1. At the main menu, select "CONFIGURE". Press the "OK" key.

    A screen like Illustration 18 appears.



    Illustration 18g02271857

  2. Select "INPUTS & OUTPUTS". Press the "OK" key.

    A screen like Illustration 19 appears.



    Illustration 19g02271858

  3. Select "ANALOG INPUTS". Press the "OK" key.

    A screen like Illustration 20 appears.



    Illustration 20g02271859

  4. Select the analog input to program. Press the "OK" key.

    A screen like Illustration 21 appears.



    Illustration 21g02271919


    Illustration 22g02272293

  5. Select "VOLTAGE". Press the "OK" key.

    A screen like Illustration 23 appears.



    Illustration 23g02272333

  6. Select "SENSOR RANGE". Press the "OK" key to change the current sensor range.

    A screen like Illustration 24 appears.



    Illustration 24g02272334

  7. Select the "SENSOR RANGE" to program. Press the "OK" key.

    A screen like Illustration 25 appears.



    Illustration 25g02272335

  8. Select "DATA IDENTIFICATION". Press the "OK" key to change the current "DATA IDENTIFICATION".

    A screen like Illustration 26 appears.



    Illustration 26g02272513

  9. Select the status parameter to program. Press the "OK" key.

    A screen like Illustration 27 appears.



    Illustration 27g02272514

  10. Select "DATA RANGE MIN". Press the "OK" key to change the current data range minimum.

    A screen like Illustration 28 appears.



    Illustration 28g02272515

  11. 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.



    Illustration 29g02272517

  12. Select "DATA RANGE MAX". Press the "OK" key to change the current data range maximum.

    A screen like Illustration 30 appears.



    Illustration 30g02272518

  13. Select the "DATA RANGE MAX" to program. Press the "OK" key.

The data identification list is the same whether signal type is resistive or voltage.

Disabling Analog Inputs

To disable an analog input, follow the Steps below:



    Illustration 31g02271833

  1. At the main menu, select "CONFIGURE". Press the "OK" key.

    A screen like Illustration 32 appears.



    Illustration 32g02271857

  2. Select "INPUTS & OUTPUTS". Press the "OK" key.

    A screen like Illustration 33 appears.



    Illustration 33g02271858

  3. Select "ANALOG INPUTS". Press the "OK" key.

    A screen like Illustration 34 appears.



    Illustration 34g02271859

  4. Select the analog input to program. Press the "OK" key.

    A screen like Illustration 35 appears.



    Illustration 35g02272914

  5. Press the "OK" key to highlight the current configuration.

    A screen like Illustration 36 appears.



    Illustration 36g02272915

  6. Select "DISABLED". Press the "OK" key.

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:

  1. Connect the EMCP 4 to Cat ET.


    Illustration 37g02272933

  2. Select "Analog Inputs" on the left.

    Refer to Illustration 37.



    Illustration 38g02272934

  3. Determine which input to configure. For example, all of the set points for "Analog Input #1" have the text "#1" in the name.

  4. 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.



    Illustration 39g02272973

  1. 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.



    Illustration 40g02272974

  2. The "Analog Input #N Configuration Code" and "Data Identification" parameters will now be visible in the right pane.

    Refer to Illustration 40.



    Illustration 41g02272975

  3. 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.



    Illustration 42g02272935

  4. 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.



    Illustration 43g02273753

  5. 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.

    Table 2
    Failure Mode Identifier Valid Options 
    Suspect Parameter Number  High Shutdown  Low Shutdown  High Warning  Low Warning 
    Engine Oil Pressure     
    Engine Coolant Temperature   
    Engine Oil Temperature 
    Fuel Level 
    External Tank Fuel Level 
    Generator Volt Control         
    Custom Event 
    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.



    Illustration 44g02273775

  6. 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.

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.



    Illustration 45g02273796

  1. 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.



    Illustration 46g02273798

  2. 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.



    Illustration 47g02273799

  3. 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.



    Illustration 48g02273800

  4. 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.

  5. Based on whether the selected option supports events, the list of set points shown will adjust accordingly.


    Illustration 49g02273801

  6. 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.



    Illustration 50g02273802

  7. 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.



    Illustration 51g02273913

  8. 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.

Disabling Analog Inputs



    Illustration 52g02273975

  1. 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.

Analog Input Maps

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 53g02274076

Table 3
Analog Input Map #1 
Engine Oil Pressure Map #1 
Ohms  kPa 
5.1 
10.2 
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 54g02274077

Table 4
Analog Input Map #2 
Engine Oil Pressure 
Ohms  kPa 
45 
9.8  50 
97.5  1000 

Analog Input Map #3 Engine Coolant Temp Map #1



Illustration 55g02274078

Table 5
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 
1575.6 
2249.4  -5 

Analog Input Map #4 Engine Coolant Temp Map #2



Illustration 56g02274079

Table 6
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 
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 

Analog Input Map #5 Oil Temp



Illustration 57g02274080

Table 7
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 

Analog Input Map #6 Engine Coolant Temp Map #3



Illustration 58g02274081

Table 8
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 
916.6 
1318.5  -6 
2046.6  -14 

Analog Input Map #7 Fozmula Fuel Level



Illustration 59g02274082

Table 9
Analog Input Map #7 
Fozmula Fuel Level 
Ohms  % 
10.5 
35.6  25 
60.2  50 
85.2  75 
103.2  100 

Analog Input Map #8 Linear Level



Illustration 60g02274084

Table 10
Analog Input Map #8 
Linear Level 
Ohms  % 
2000  100 

Analog Input Map #9 Power Module Tank Level #1



Illustration 61g02274086

Table 11
Analog Input Map #9 
Power Module Tank Level #1 
Ohms  % 
10.5 
35.6  25 
60.2  50 
85.2  75 
103.2  100 

Analog Input Map #10 Power Module Tank Level #2



Illustration 62g02274089

Table 12
Analog Input Map #10 
Power Module Tank Level #2 
Ohms  % 
10  100 
135  100 
348.2 
500 

Analog Input Map #11



Illustration 63g03506581

Table 13
Fuel Level 
Ohms 
255 
240 
30  100 
15  100 

Analog Input Map #12



Illustration 64g03507185

Table 14
Temperature(1) 
Ohms  Degrees C 
2541.5 
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).

Voltage Senders

The EMCP 4.1 and EMCP 4.2 voltage senders can be configured within the ranges in Table 15.

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.

Warnings and Shutdowns

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 −30° C (−22° F) to 120° C (248° F), the only range that includes all of 0 to 3 VDC. The 0 to 5 VDC range should be used. The range between 3VDC and 5VDC will never be used. To make the data accurate, set the "Minimum Data Range" to −30° C (−22° F), and determine the "Maximum Data Range" mathematically. Refer to Illustration 65.



Illustration 65g02274673
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 66g02274694
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 −40° C (−40° F) to 500° C (932° F), the EMCP 4 will not support the analog voltages higher than 5 VDC. However, as long as the sensor will not exceed 5 VDC, the 0 VDC to 5 VDC range may be used. To make the data accurate, set the "Minimum Data Range" to −40° C (−40° F), and determine the "Maximum Data Range" mathematically. Refer to Illustration 67.



Illustration 67g02274695
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 68g02274733
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 69g02274734
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