Electronic Control Module (Generator Set)
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| Illustration 1 | g01045431 |
(1) Display screen (2) AC overview key (3) Engine overview key (4) Yellow warning lamp (5) Red shutdown lamp (6) Acknowledge key (7) Lamp test key (8) Run key (9) Auto key (10) Stop key (11) Up key (12) Escape key (13) Right key (14) Enter key (15) Down key (16) Left key | |
Navigation Keys
AC Overview (2) - The "AC OVERVIEW" key will navigate the display to the first screen of AC information. The "AC OVERVIEW" information contains various AC parameters that summarize the electrical operation of the generator set.
Engine Overview (3) - The "ENGINE OVERVIEW" key will navigate the display to the first screen of engine information. The "ENGINE OVERVIEW" information contains various engine parameters that summarize the operation of the generator set.
Acknowledge Key (6) - Pressing the "ACKNOWLEDGE" key will cause the horn relay to turn off. This will silence the horn. Pressing this key may also cause the red flashing light or yellow flashing light to turn off. Pressing this key may also cause the red flashing light or the yellow flashing lights to come on continuously. The "ACKNOWLEDGE" key may also be configured to send a global alarm silence signal on the J1939 Data Link which will silence the horns on the annunciators.
Lamp Test Key (7) - Pressing and holding the "LAMP TEST" key will cause each LED and the display screen pixels to turn on continuously until the key is released.
RUN Key (8) - Pressing the "RUN" key will start the engine.
AUTO Key (9) - Pressing the "AUTO" key will cause the engine to enter the "AUTO" mode. The engine will start if the module receives a start command from a remote source.
STOP Key (10) - Pressing the "STOP" key will stop the engine.
Up Key (11) - The "UP" key is used to navigate through the various menus and monitoring screens. The "UP" key is also used when a setpoint is entered. When numeric data is entered the "UP" key is used in order to increment the digits (0-9). If the setpoint requires selection from a list, the "UP" key is used to navigate UP through the list.
Escape Key (12) - The "ESCAPE" key is used in order to navigate through the menus. When the key is pressed, the user moves backward or the user moves upward through the menus. The "ESCAPE" key is also used to exit out of entering data when the user is programming the setpoints. If the "ESCAPE" key is pressed during setpoint adjustment, changes that are made on the screen will not be saved.
Right Key (13) - The "RIGHT" key is used during setpoint adjustment. The "RIGHT" key is used to select a digit that will be edited as numeric data is entered. The "RIGHT" key is also used to select a check box as setpoint adjustments are made. The "RIGHT" key is also used to unselect a check box as setpoint adjustments are made. If a check box has a check mark, the function has been enabled. Pressing the "RIGHT" key will disable the function. Pressing the "RIGHT" key will also cause the check mark to disappear. If the check box does not have a check mark, the function is disabled. Pressing the "RIGHT" key will enable the function. Pressing the "RIGHT" key will also cause a check mark to appear.
Enter Key (14) - The "ENTER" key is used in order to navigate through the menus. When the key is pressed, the user moves forward or the user moves downward through the menus. The "ENTER" key is also used to save any changes while the setpoints are being programmed. Pressing the "ENTER" key during programming the setpoints causes the changes to be saved to memory.
Down Key (15) - The "DOWN" key is used to navigate downward through the various menus or screens. The "DOWN" key is also used to program the setpoints. The "DOWN" key is used to decrease the digits as numeric data is entered. If the setpoint requires selection from a list, the "DOWN" key is used to navigate DOWN through the list.
Left Key (16) - The "LEFT" key is used during setpoint adjustment. The "LEFT" key is used to select the digit that is edited during the entry of numeric data. The "LEFT" key is also used during some of the setpoint adjustments to select a check box. The key is also used to unselect a check box. If a check box has a check mark, pressing the "LEFT" key will disable the function. Pressing the key will also remove the check mark. Pressing the "LEFT" key will also cause the check mark to disappear. If the check box does not have a check mark, pressing the "LEFT" key will enable the function. Pressing the "LEFT" key will also cause a check mark to appear.
Alarm Indicators
Yellow Warning Lamp (4) - A flashing yellow light indicates that there are active warnings that have not been acknowledged. A continuous yellow light indicates that there are acknowledged warnings that are active. If there are any active warnings, the yellow light will change from flashing yellow to continuous yellow after the "ACKNOWLEDGE" key is pressed. If there are no longer any active warnings, the yellow light will turn off after the "ACKNOWLEDGE" key is pressed.
Red Shutdown Lamp (5) - A flashing red light indicates that there are active shutdowns that have not been acknowledged. A continuous red light indicates that there are active shutdowns that have been acknowledged. If there are any active shutdowns the red light will change from flashing red to continuous red after the "ACKNOWLEDGE" key is pressed. Any condition that has caused a shutdown must be manually reset. If there are no longer any active shutdowns, the red light will turn off.
Digital Inputs
Note: There are 8 digital inputs on "EMCP 3.2" and "EMCP 3.3". There are 6 digital inputs on "EMCP 3.1".
Digital Input 1 - Digital Input 1 is used for the emergency stop. This input should be wired to GROUND through an Emergency Stop switch. The input can be set to activate on an active high (normally closed contact) or an active low (normally open contact). Activating the emergency stop input will cause the generator set to stop immediately. The emergency stop input will also prevent the generator set from starting. As Digital Input 1 is activated, the engine will not start until the event has been cleared. Refer to System Operation, Troubleshooting, Testing and Adjusting, RENR7902, "Digital Input Resetting".
Digital Input 2 - Digital Input 2 is used for remotely starting and stopping the generator set. This input should be wired to GROUND through a switch that can be initiated remotely. The input can be set to activate on an active high (normally closed contact) or an active low (normally open contact). If the input is active and the engine is in AUTO, the engine will attempt to start. If the input is inactive, the engine will enter cooldown mode and the engine will stop.
The remainder of the inputs can be configured. The "DIGITAL" input adds additional monitoring of the engine and generator. The inputs can be configured by going to the "EVENT I/P FUNCTIONS" parameter under the "SETPOINTS" menu. The "DIGITAL INPUTS" parameter can only be set to "ACTIVE HIGH" or "ACTIVE LOW" in order to initiate a High Warning, Low Warning, High Shutdown, Low Shutdown, or Status.
The inputs can be programmed to monitor the following parameters or components. Refer to System Operation, Troubleshooting, Testing and Adjusting, RENR7902, "Digital Input Programming".
Pressures
- Air filter differential pressure
- Engine oil pressure
- Fire extinguishing system
- Fuel filter differential pressure
- Oil filter differential pressure
- Starting air pressure
Temperatures
- Ambient air temperature
- Engine coolant temperature
- Engine oil temperature
- Exhaust temperature
- Rear bearing temperature
- Right exhaust temperature
- Left exhaust temperature
Levels
- Engine coolant level
- Engine oil level
- Fuel level
- External fuel tank level
Other
- Closed air damper
- ATS in normal position
- ATS in emergency position
- Battery charger failure
- Closed breaker
- Closed utility breaker
- Detected fuel leak
- Custom event
For detailed information about the electronic control module, see Systems Operation, Troubleshooting, Testing and Adjusting, RENR7902, "EMCP3".
Control Panel
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| Illustration 2 | g01185966 |
(1) Auto/manual switch for starting aid (2) Panel light switch (3) Emergency stop push button (4) Voltage adjust potentiometer (5) Speed adjust potentiometer (6) Customer connection (7) Horn (8) Pump run switch (if equipped) (9) Pump stop switch (if equipped) | |
Auto/Manual Switch for starting aid (1) - The starting aid switch is optional. The starting aid switch is used to inject ether into the engine when you are starting the engine in cold weather conditions. When the starting aid switch is in the ON position, the switch energizes the starting aid solenoid valve and the switch meters a specific amount of ether into a holding chamber. When the starting aid switch is released, the solenoid releases the ether to the engine.
Panel Light Switch (2) - The panel lights switch turns on or the panel lights switch turns off the panel lights.
Emergency Stop Push Button (3) - The emergency stop push button (ESPB) is used to shut down the engine during an emergency situation. If equipped, the ESPB shuts off the fuel and the ESPB activates the optional air shutoff.
Voltage Adjust Potentiometer (4) - This switch can be used to raise the voltage. The switch can also be used to lower the voltage.
Speed Potentiometer (5) - The speed potentiometer is optional. The speed potentiometer can be used with the generator set that has an electronic governor.
Customer Connection (6) - The customer connection is a 9-pin connector for connecting the Caterpillar Electronic Technician.
Horn (7) - The horn provides an audible alarm.
Pump Run Switch (8) - Under normal circumstances, the fuel transfer system is automatic. In some instances, a manual operation may be required. Press the pump run switch once in order to manually start the pump.
Pump Stop Switch (9) - The pump stop switch is a push button switch that locks into position. The pump stop switch will stop the pump if the switch is locked into position. Releasing the switch will place the pump back into the run mode.
Annunciator Module
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| Illustration 3 | g01101388 |
General Information
The annunciator module is used to indicate various system events and conditions. The annunciator module uses indicator lights and an audible horn to give the operator information about the current status of the system. The annunciator module can be used to announce faults and/or status signals to the operator. The annunciator module allows the operator to silence the horn. The annunciator module also allows the operator to acknowledge faults to the system.
There are seventeen pair of LED indicators on the annunciator's front panel. Sixteen pair of LED indicators are used to announce events, diagnostics, and ready signals. The seventeenth pair of led indicators is used as a combined network operation and module information. The seventeenth pair of LED indicators can tell the operator if there is a problem with the J1939 data link connection.
Basic Operation
Each pair of LED indicators on the annunciator consists of two of the following three colors: green, yellow and red. For example, a pair of red and yellow LED indicators may be configured for engine oil pressure. If a low engine oil pressure condition is read over the data link, the annunciator will flash the yellow LED and the audible horn will sound. If the low oil pressure shutdown is read over the data link, the annunciator will flash the red LED and the audible horn will sound.
Press the "Alarm Acknowledge" key in order to acknowledge a shutdown condition. Press the "Alarm Acknowledge" keyin order to acknowledge an alarm condition. In order to silence the horn, press the "Alarm Acknowledge" key that is located near the middle of the annunciator.
Test the led indicators by pressing the "Lamp Test" key near the top of the annunciator. Test the horn when the data link is connected by holding in the "Lamp Test" key. Test the horn when the data link is disconnected by pressing the "Lamp Test" key that is located near the top of the annunciator.
Configuration
The annunciator module can be customized in order to signal many different conditions that are related to the system. Each pair of LED lights must be configured by using the appropriate service tool. Once the service tool has been connected to the annunciator, the user must enter the "Configuration" screen. Each pair of LED lights has four settings: SPN, Trigger Type, Trigger Severity Level and Failure Mode Identifier (FMI).
For detailed information about the annunciator module, see Systems Operation, Troubleshooting, Testing and Adjusting, RENR7902, "EMCP3".